UNIT-II

Basic Machine Tools - I

LATHE MACHINE
By
S Z PATHAN
Lecturer
Mechanical Engineering Department,
Govt. Polytechnic Jamnagar
 Lathe
Definition
Lathe is a machine, which removes the metal from a piece of work to the required
shape and size.

 Lathe is one of the most important machine tools in the metal working
industry. A
lathe operates on the principle of a rotating workpiece and a fixed cutting tool.

 The cutting tool is feed into the workpiece, which rotates about its own axis,
causing the workpiece to be formed to the desired shape.

 Lathe machine is also known as “the mother/father of the entire tool family”.
 INVENTOR OF CENTRE LATHE

 Henry Maudsley was born on an

isolated farm near Gigghleswick in

North Yorkshire and educated at
University Collage London. He was
an outstandingly student, collecting
ten Gold Medals and graduating with
an
M.D. degree in 1857.
Function of lathe
Lathe is to remove excess material in the form of chips
by rotating the work piece against a stationary cutting
tool
 Industrial revolution demanded
 More production

 More Precision

 Changes in Manufacturing process

 Lead to the Development of High speed

 Special purpose lathes

 MAIN PARTS

Lathe Machine is also known as “Centre Lathe”,

because it has two centres between which the
job can be held and rotated.
The main parts of centre lathe are:
 Bed,
 Head stock,
 Tail stock,
 Carriage,etc
Lathe
 Lathes

 Lathes are the oldest machine tools

 Lathe Components

Bed: supports all major components

Carriage: slides along the ways and consists of the cross-

slide, tool post, apron

Headstock – Holds the jaws for the work piece, supplies

power to the jaws and has various drive speeds

 Tailstock – supports the other end of the workpiece

 Feed Rod and Lead Screw – Feed rod is powered by a set of

gears from the headstock

Working principle of
lathe
 Working principle of
lathe
 If the tool moves parallel

to work piece cylindrical

surface is formed
 Working principle of lathe

 If the tool moves

inclined to the axis it

produces a taper
surface and is
called taper turning.
 Working principle of
lathe
 It holds the work between two supports called centers.
 Chuck or Face plate is also used for holding the work.

 Chuck or face plate is mounted on machine spindle

 Cutting tool is held and supported on a tool post.

 Movement of the job is rotation about spindle axis

 Tool is fed against the revolving work

 Movement of the tool is either parallel to or at any inclination to the

work axis
 Specifications of Lathe
1) a) Height of centers
b) type of bed(straight , semi gap, or gap)
c) center distance
2. a)swing over bed
b)swing over cross slide
c) swing in gap
d) gap in front of face
place
3. a) spindle speeds range
b) spindle nose
c) spindle bore
d) taper nose
 Specifications of
Lathe
4) a)Metric thread piches
b)lead screw pitch
c)longitudinal feeds
d)cross feeds
5) a) cross slide travel
b)top slide travel
c) tool section
6) a)tailstock sleeve travel
b)taper in sleeve bore
7) Motor horsepower and
RPM
8) shipping dimensions
 TYPES OF
LATHES
 Engine Lathe or center lathe

 It is most common type of lathe and is widely used in workshop.

 The speed of the spindle can be widely varied as desired which is not

possible in a speed lathe.

 Bench Lathe

 Small lathe which can mounted on the work bench

 It is used to make small precision and light jobs.

 Speed lathe

 It is named because of the very high speed of the head stock spindle.

 Consists head stock, a tail stock and tool post. it has no gear box.

 Applicable in wood turning, metal spinning and operations.

 TYPES OF
LATHES
 Tool room lathe :
• It is similar to an engine lathe, designed for obtaining accuracy.
• It is used for manufacturing precision components, dies, tools,
jigs etc. and hence it is called as tool room lathe.
 Special purpose lathes :
 Gap lathe
 Instrument lathe
 Facing lathe
 Flow turning lathe
 Heavy duty lathe
 Automatic Lathe

 A lathe in which the work piece is automatically fed and removed

without use of an operator.
 It requires very less attention after the setup has been made and
the machine loaded.
 Turret Lathe

 Turret lathe is the adaptation of the engine lathe where the tail stock is

replaced by a turret slide(cylindrical or hexagonal).

 Tool post of the engine lathe is replaced by a cross slide which can
hold number of tools.
 Capstan lathe

• These are similar to turrent lathe with the difference that turret is not
fixed but moves on an auxiliary slide. these are used for fast production
of small parts.
 Computer Controlled Lathe


 Operating
Conditions
Cutting speed
Workpiece
Depth
N
of cut Machined
(d) surface
Chuck Feed (f ) Chip
Tool Depth of cut
 LATHE OPERATIONS
 Turning: to remove material from the outside diameter of a workpiece to

obtain a finished surface.

 Facing: to produce a flat surface at the end of the workpiece or for
making face grooves.
 Boring: to enlarge a hole or cylindrical cavity made by a previous
process or to produce circular internal grooves.
 Drilling: to produce a hole on the work piece.

 Reaming: to finishing the drilled hole.

 Threading: to produce external or internal threads on the work piece.

 Knurling: to produce a regularly shaped roughness on the workpiece.

LATHE OPERATIONS
 Turning ..
Cylindrical job
Operations on Lathe ..

Workpiece
Cutting
speed Depth of cut (d)
N
Machined
surface
Chuck Feed Chip
Tool
Depth of cut
 Turning ..
Operations on Lathe ..

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

Work is held in either chuck or

between centers.
Longitudinal feed is given to the tool either by

hand or power.
 Facin
g
Flat Surface/Reduce length
Operations on Lathe ..

Chuck Workpiece
d
Machined
Face
Cutting
speed Depth of
cut
Tool Feed
 Facing ..
 machine end of job  Flat surface or to Reduce Length
Operations on Lathe ..

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

 Knurlin
g
Operations on Lathe ..

Produce rough textured surface

For Decorative and/or Functional Purpose

Knurling Tool

 A Forming Process

 MRR~0
 Knurlin
g
Operations on Lathe ..

Knurled surface
Cutting
speed
Feed M ovement
Knurling tool for depth
Tool post
 Grooving
Operations on Lathe ..

 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
Operations on Lathe ..

produced by Groov
form tool e

Feed or Groovin
Form depth of g tool
tool cut
 Parting
Operations on Lathe ..

Cutting workpiece into Two

Similar to grooving
Parting Tool
Tool rides over – at slow feed
Coolant use
 Parting ..
Operations on Lathe ..

Feed
Parting tool
 Chamfering
Chamfer
Operations on Lathe ..

Feed
Chamfering tool
 Chamferin
g
Operations on Lathe ..

 Beveling sharp machined

edges
 Similar to form turning
 Chamfering tool – 45°
 To
 Avoid Sharp Edges
 Make Assembly Easier
 Improve Aesthetics
 Drillin
g in TS – feed from TS
Drill – cutting tool – held
Operations on Lathe ..

Quill
Drill clam movin
p g quill
Tail stock
Feed
Tail stock clamp
 Taper Turning

D1  D2
Operations on Lathe ..

tan   2
L

90°
D1  D2
B  C

A L
 Taper Turning..
Operations on Lathe ..

Methods
 Form Tool
 Swiveling Compound Rest
 Taper Turning Attachment
 Simultaneous
Longitudinal and Cross Feeds
 Taper Turning ..
by form tool
Operations on Lathe ..

Workpiece Taper


Form Direction
Straight of feed
cutting tool
 Taper Turning ,,
by compound rest
Dog
Operations on Lathe ..

Mandrel Tail stock quill

Tail stock

Face plate Direction of feed

Tool post Compound rest
& Tool Slide
holder Compound rest
Cross slide  Hand crank
TAPER TURNING ATTACHMENT
 Tape
r
I. A bed bracket attachesattotathcehlmatheenbted and keeps the angle
plate from moving to the left or the right.
II. carriage bracket moves angle plate in a dovetail and keeps the angle
plate from moving in or out on the bed bracket.
III. Taper to be cut is set by placing the guide bar, which clamps to the
angle plate, at an angle to the ways of the lathe bed.
IV. sliding block which rides on a dovetail on the upper surface of the
guide bar is secured during the machining operation to the cross
slide bar of the carriage, with the cross feed screw of the carriage
being disconnected.
V. carriage is traversed during the feeding operation, the cross slide bar
follows the guide bar, moving at the predetermined angle from the
ways of the bed to cut the taper.
VI. It is not necessary to remove the taper attachment when straight
 Thread cutting attachment
 On the lathe internal and external threads are cut either

with the help of a thread tool or with the help of tap and
die respectively.
 There should be a certain relation between job
revolutions and the revolutions of the lead screw to
control linear movement of the tool parallel to the job
when the half nut is engaged with the lead screw.
 The tool should be ground to the proper shape or profile

of the thread to be cut.

 In modern lathes quick change gear box is provided in
which different ratios of the spindle and lead screw
 Lathe
 Divided into two categories
Accessories
 Work-holding, -supporting, and –driving devices

 Lathe centers, chucks, faceplates

 Mandrels, steady and follower rests

 Lathe dogs, drive plates

 Cutting-tool-holding devices

 Straight and offset toolholders

 Threading toolholders, boring bars

 Turret-type toolposts
 Work holding

Devices
Various work holding attachments such as three jaw chucks, collets, and centers
can be held in the spindle.
 Work is held in the lathe with a number of methods,
 Between two centres. The work piece is driven by a device called a dog; this method
is suitable for parts with high length-to-diameter ratio.
 A 3 jaw self-centering chuck is used for most operations on cylindrical work-parts. For
parts with high length-to-diameter ratio the part is supported by center on the other
end.
 Collet consists of tubular bushing with longitudinal slits. Collets are used to grasp and
hold bar stock. A collet of exact diameter is required to match any bar stock
diameter.
 A face plate is a device used to grasp parts with irregular shapes.
 Mandrels

Fig : Various types of mandrels to hold work pieces for turning. These mandrels are
usually mounted between centers on a lathe. Note that in (a) both the cylindrical
and the end faces of the workpiece can be machined, whereas in (b) and (c) only
the cylindrical surfaces can be machined.
 Lathe
Centers
Work to be turned between centers must have

center hole drilled in each end

Provides bearing surface

Support during cutting

Most common have

solid Morse taper shank

60º centers, steel with
carbide tips
Care to adjust and
 Chuck
s
Used extensively for holding work for

machining operations
Work large or unusual shape

Most commonly used lathe chucks

Three-jaw universal

Four-jaw independent

Collet chuck
 Three-jaw Universal
Chuck
 Holds round and hexagonal work

 Grasps work quickly and accurate within few

thousandths/inch
 Three jaws move simultaneously when by
adjusted
chuck wrench
Caused by scroll plate into which all three
jaws fit
 Usually has three jaws which move in
unison as an
adjusting pinion is rotated.
Four Jaw Independent
Chuck
Used to hold round, square, hexagonal,
and irregularly shaped workpieces
Has four jaws
Each can be adjusted independently by
chuck
wrench
Jaws can be reversed to hold work by
inside diameter
TYPES OF
CHUCK
Three jaw
chuck
-

F
o
r
h
o
l
d
i
n
g

c
y
l
 Collet
Chuck

Collet chuck is
 Thin jobs can be held by means of
used to hold small
magnetic chucks. workpieces

Magnetic Chuck

Thin jobs can be

held by means of
magnetic
chucks.
 Work holding Devices
Chucks
usually equipped with 3
or 4 jaws
3 jaw chucks
generally
are self centering.
Used for round work
pieces.
Can be centered within
.025mm
independently
.
4 jaw chucks are for
square, rectangular,
or odd-shaped work
pieces
 Can be power
actuated
(a) and (b) Schematic illustrations of a draw-in-type collets. The workpiece is
placed in the collet hole, and the conical surfaces of the collet are forced inward by
pulling it with a draw bar into the sleeve. (c) A push-out type collet. (d)
Workholding of a part on a face plate.
 Headstock
Spindles
Universal and independent chuck fitted to three
types of headstock spindles
1. Threaded spindle nose
 Screws on in a
clockwise direction
2. Tapered spindle
nose
 Held by lock nut
that tightens on
chuck
46-50
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
 Headstock
Spindles
3. Cam-lock spindle nose
• Held by tightening cam-locks using T-wrench
• Chuck aligned by taper
on spindle nose

Registration lines on spindle nose

Registration lines on cam-lock

Cam-locks
Cam-lock mating stud on
chuck
or faceplate 46-51
 Collet
Chuck
Most accurate chuck
Used for high-precision work
Spring collets available to hold round, square,
or hexagon-shaped work pieces
Each collet has range of only few thousandths
of an inch over or under size stamped on collet
 Collet
Chuck

Special adapter fitted into taper of headstock spindle, and hollow draw bar
having internal thread inserted in opposite end of headstock spindle. It draws
collet into tapered adapter causing collet to tighten on workpiece.
 Types of Lathe
Dogs
Standard bent-tail lathe dog

Most commonly used for

round workpieces
Available with square-head
setscrews
of headless setscrews
• Straight-tail lathe dog

– Driven by stud in drive plate

– Used in precision turning

46-54
Copyright © The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
 Types of Lathe
Dogs
Safety clamp lathe dog
Used to hold variety of
work
Wide range of adjustment

• Clamp lathe dog

– Wider range
than others
– Used on all
shapes
 Left-Hand Offset
Toolholder
Offset to the right
Designed for machining work close to chuck
or faceplate and cutting right to left
Designated by letter L
Right-Hand Offset
Toolholder
Offset to the left
Designed for machining work close to the
tailstock and cutting left to right
Also for facing operations
Designated by letter R
 Straight Toolholder

General-purpose type
Used for taking cuts in either direction and for
general machining operations
Designated by letter S
 Straight Tool holder

General-purpose type
Used for taking cuts in either direction and for
general machining operations
Designated by letter S
 Semi automatic
lathes
 Semi automatic lathes are production lathes with human involvement for

certain operations
 Semi automatic lathes are production lathes with human involvement for

certain operations
 Capstan and turret lathes with additional attachments become
semi automatic lathes
 Also called retrofitting

 Vide range of jobs can be accommodated

 Higher production rates

 Semi Automatic
Lathes
 Designed for short continuous runs

 Turret or ram in place of tailstock

 Indexable square tool post on cross slide

 Suitable for Drilling, countersinking, reaming, tapping like

operations

 Turret and Capstan lathes are examples

 In Turret lathe Turret moves along with saddle

 In Capstan lathe turret slides over the ram

 Turret Lathe

Capable of performing multiple

cutting operations on the same
workpiece
 Turning
 Boring
 Drilling
 Thread cutting
 Facing

Turret lathes are very versatile

Types of turret lathes

 Ram-type: ram slides in a
separate base on the saddle
 Saddle type:
 more heavily
constructed
 Used to machine large
workpeiceces
Turret lathe
Capston
Lathe
 Turret Lathe
 These machines are capable of
carrying out multiple cutting
operations on the same
workpiece.
 Several cutting tools are
mounted on a tetra, penta, or
hexagonal turret, which
replaces the tailstock.
 These tools can be rapidly
brought into action
against the workpiece one by
one by indexing the turret.
 Comparision of turret & engine lathe
Turret lathe Capstan lathe
 Turret lathes are relatively more
robust and heavy duty machines  Capstan lathes generally deal
.work on chucking type jobs held in with short or long rod type blanks
the quick acting chucks held in collet,
 The heavy turret being mounted on
the saddle which directly slides with  In capstan lathe, the turret travels
larger stroke length on the main with limited stroke length within a
bed saddle type guide block, called
 One additional guide rod or pilot bar auxiliary bed, which is clamped
is provided on the headstock of the on the main bed
turret lathes to ensure rigid axial
travel of the turret head  External screw threads are cut in
 whereas in turret lathes external capstan lathe, if required, using a
threads are generally cut, if self opening die being mounted in
required, by a single point or one face of the turret,
multipoint chasing tool being
mounted on the front slide and
moved by a short leadscrew and a
AUTOMATIC LATHES
 AUTOMATIC LATHES

 Machine tools in which components are machined automatically.

 The working cycle is fully automatic that is repeated to produce duplicate parts with

out participation of operator.

 All movements of cutting tools, their sequence of operations, applications, feeding of

raw material, parting off, un loading of finished parts all are done on machine.
 All working & idle operations are performed in definite sequence by control system

adopted in automatic which is set up to suit a given work.

 Only operation reqd to be performed manually is loading of bar stock/ individual

casting/ forged blanks.

 These machines are used when production requirements are too high for turret lathes

to produce economically.
 Automatic
Lathes
 Manual machine controls replaced by various
mechanisms

 Parts are fed and removed automatically

 May have single or multiple spindles

 Automatic lathes uses servo motor

 Automatic lathes Limited ranges of variety and sizes

 Automatic Lathe
Features
 Minimum man power utilized

 Meant for mass production

 Manual machine controls replaced by various

mechanisms
 To eliminate the amount of skilled labour.

 Mechanisms enable to follow certain prescribed frequency

 Parts are fed and removed automatically

 Minimizing the loading and unloading time

 May have single or multiple spindles

 Tool set up may be permanent

 May have horizontal or vertical spindles

 More accuracy can be obtained

 Advantages

 Greater production over a given period.

 More economy in floor space.

 Improvement in accuracy.

 Floor space maintenance and inventory requirements are reduced.

 More consistently accurate work than turrets.

 More constant flow of production.

 Scrap loss is reduced by reducing operator error.

 During machine operation operator is free to operate another machine/

can
inspect completed parts.
 CLASSIFICATION OF AUTOMATIC
LATHES
 Depending up on type of work machined these machines are classified as:

1. Magazine loaded Automatics:

 Machines used for producing components from separate blanks.

 Also called as automatic checking machines.

2. Automatic Bar Machines:

 designed for machining components from bar/ pipe stock.

 M/c’s are used for manufacture of high quality fasteners (screws, nuts),
bushings, shafts, rings, rollers, handles which are usually made of bar / pipe
stock.
 Depending upon number of work spindles, automatic lathes are classified
as:

1. Single Spindle Automatics.

2. Multi Spindle Automatics.

 Depending upon purpose & arrangement of spindle also automatics

are classified as:

1. Purpose General & single purpose m/c.

2. Arrangement of spindle Horizontal & vertical

 I) Type of Single Spindle
Automatics:
a) Automatic Cutting Off
Machine:
 These machines produce short w/p’s of simple form by means of cross sliding

tools. Machines are simple in design.

 Head stock with spindle is mounted on bed.

 2 cross slides are located on bed at front end of spindle.

CAMS on cam shaft actuate movements of cross slide through system of levers.

Operation:
 The reqd length of work(stock) is fed out with a cam mechanism, up to stock

stop which is automatically advanced in line with spindle axis at each end of
cycle.
 Stock is held in collet chuck of rotating spindle.

 Machining is done by tolls that are held in slides operating only in cross wise

direction.
 Typical simple parts (3 to 20 mm dia) machined on such a machine is shown in

fig.
b) Single spindle Automatic Screw
m/c:
 Used for producing small screws(12.7 to 60 mm dia) generally, but also in

production of all sorts of small turned parts.

 These are completely automatic bar type turret lathes, designed for machining

complex internal & external surfaces on parts made of bar stock/separate

blanks.
 Up to 10 different cutting tools can be employed at one time in tooling of this

kind of screw machine.

 2 cross slides(front & rear) are employed for cross feeding tools.

 Vertical tool slides for parting off operation may also be provided .

 Head stock is stationary & houses the spindle.

 Bar stock is held in collet chuck & advanced after each piece is finished & cut
off.
 All movements of machine units are actuated by cams mounted on cam shaft.
 Bar stock is pushed through stock tube in a bracket & its leading end is

clamped in rotating spindle by means of collet chuck.

 By stock feeding mechanism bar is fed out for next part.

 Machining of central hole is done by tools that are mounted on turret

slide.
 Parting off/ Cutting off, form tools are mounted on cross slide.

 At end of each cut turret slide is with drawn automatically & indexed to

bring next tool to position.

c) Swiss type automatic screw/Sliding head
screw:
 As name implies in this m/c head stock is movable & tools are fixed.

 These machines are used for machining long accurate parts of small diameter.(2

to 25mm).
 Bar stock is held in rotating collet in head stock & all longitudinal feeds are

obtained by cam which moves entire head stock as unit.

 Rotating bar stock is fed through hard bushing in centre of tool head.

 Tool head consists of 5 single point tools is placed radially around bushing.

 Mostly diameter turning is done by 2 horizontal slides, other 3 slides used

for operations such as knurling, chamfering, cutoff.

 Tools are controlled & positioned by cams that bring tool in as needed to
turn,
face, form, cutoff w/p from bar as it emerges from bushing. Close tolerances
0.005 to 0.00125 mm are obtained.
 II) Multi Spindle
 These are fastest type ofAutomatics:
production machines and are made in a variety of
models with 2,4,5,6,8 spindles.
 In contrast with single spindle m/c where one turret face at a time is

working on one spindle, in multi spindle m/c all turret faces works on all
spindles at same time.
 Production capacity is higher, machining accuracy is lower compared to

single spindle.
 Because of longer set up time, increased tooling cost this machines are

less economical than other on short runs, more economical for longer
runs.
a) Parallel Action Automatics/ Multiple Flow
m/c:
 In this type of machine same operation is performed on each spindle, w/p is

finished in each spindle in one working cycle.

 It means that No. of components being machined== No. of spindles in machine.

 Rate of production is high & machine can be used to machine simple parts only

since all the machining processes are done at one position.

 These machines are usually automatic cutting off bar type machines, used to

perform same work as single spindle automatic cut off machines.

 Machine consists of frame with head stock at right end.

 Horizontal work spindles that are arranged one above the another are housed in

this head stock.

 Cross slides are located at right & left hand sides of spindles & carry cross

feeding tools. All working & auxiliary motions of machine unit are obtained
from CAM mounted on cam shaft.
b) Six Spindle Progressive Action Multi
Spindle:
 In this design of machine, the w/p is machined in states & progressively in station

after station.
 Head stock is mounted on left end of base of machine.

 It carries spindle carrier which rotates about a horizontal axis through centre of

machine.
 Working spindles are mounted on this spindle carriers.

 Spindles carry collets & bars from which w/p’s are machined.

 Bar stock is fed through each spindle from rear side.

 On face of spindle carrier support are mounted cross slides which carry tools for

operations such as cutoff, turning, facing, forming, chamfering.

 No. of slides === No. of spindles.

 Main tool slide (end tool slide) extends from middle of this support.

 Fed of each tool, both cross slide & end tool slides is controlled by its own

individual cams.
 In this diagram spindle carrier indexes on its own axis by 60° at each cutting

tool retraction.
 As spindle carrier indexes, it carries work from one station to another station

where different tolls operate on work.

 Stock moves round the circle in counter clock wise direction & returns to

station no. 6 for cutting off.

Tool layout
 Tool layout

schematically showing the type and configuration of A

typical tool layout for a particular job being machined in a
single spindle automatic lathe is schematically shown in Fig.
 Tool layout and cam
 design
Pre determined plan for order and method off machining
operations necessary to produce it . Following steps
are recommended for lay out for an automatic lathe.
 Machining Calculations:
Turning
 Spindle Speed - N (rpm)
v
 v = cutting speed N
 Do = outer diameter
π o
D
 Feed Rate - fr (mm/min -or-
fr  N
in/min)
f
 f = feed per rev
 Df
 Depth of Cut - d Do (mm/rev -or-
d 2
in/rev)
 Do = outer
diameter Tm  L
 Df = final
fr
(min)
diameter
MRR  v f
 Machining Time
d
 -Mat’l
Tm
Removal Rate - MRR (mm3/min -or- in3/min)
 L = length of