Manufacturing Processes lab I

Running a lathe machine

 Machining
Machining – material removal by a sharp cutting tool,
e.g., turning, milling, drilling

Cutting action involves shear deformation of work material to form

a chip. (As chip is removed, new surface is exposed)
 Turning
Turning refers to cutting as shown in this figure.
Single point cutting tool removes material from a rotating
workpiece to form a cylindrical shape.
Cutting Conditions for Turning

Speed, feed, and depth of cut in turning.

Schematic diagram of the lathe machine
 Turning: Engine Lathe
Turning is another of the
basic machining processes.

Turning is performed on a
machine called a lathe in
which the tool is stationary
and the part is rotated.
 Turning: Engine Lathe
The figure illustrates an engine
lathe.

Lathes are designed solely for

turning operations, so that
precise control of the cutting
results in tight tolerances.

The work piece is mounted on

the chuck, which rotates
relative to the stationary tool.
Engine Lathe Detail
 Engine Lathe Carriage
The figure below illustrates the carriage of an engine lathe. The
carriage allows cross-feed and diagonal movements in addition to
axial movement.
 Chucks
The chuck is integral to a lathe's
functioning because it fixtures the
part to the spindle axis of the
machine. Below is shown a three-jaw
chuck with jaws that are all driven
by the same chuck key. This
arrangement provides convenience in
that parts can be mounted and
dismounted quickly.

3 and 4-jaws chuck: It is easier to

align the work piece axis with the
lathe axis which has 4 jaws chuck.
Engine Lathe Tail Stock
 Engine Lathe Tail Stock
The tail stock of an engine lathe is
used to provide a fixture at the
end of the part opposite from the
chuck.

The tail stock can be used to

support a long, thin part so that
more radial cutting force can be
applied and higher rotational
speeds can be attained without a
"whipping" instability effect.
 Engine Lathe Tail Stock
Drill bits can be fixtured in the tail stock to cut axial holes in a
turned part.
These central holes are more accurate than a drill press or mill
could provide since the lathe is dedicated to operations in which
an axially-symmetric part is rotated about its central axis.
The fixturing is more accurate since all fixturing is based upon
surfaces of revolution about the central axis, and the machining
is more rigidly supported for the same reason.
 Tool post
The cutting tool is fixed on the
tool post, which sits atop the
carriage assembly.
As mentioned, the carriage can
move the tool post along the axis
of part rotation, perpendicular to
the axial direction, and on a
diagonal.

Since the tool is stationary on a

lathe, there is great flexibility
for mounting the tool to best
advantage.
The tool post and carriage of a
lathe provide several ways of
positioning and feeding the tool.
 Tool
The tool inserted in the tool holder is shown below:
 Tool post

The tool post can pivot the tool

about a vertical axis and the
cutting tool can be moved in and
out along its long axis.

The cutting tool is held in by

the vertical screws, the heads
of which can be seen above the
cutting tool groove.
 Turret tool post
This tool post can hold many tool bits at the same time.
Each cutting tool can quickly be swiveled into cutting position and
clamped into place using a quick clamping handle.
 Parting Tool
This figure shows how a parting
tool is fixed and used.
Parting is important at the end of
a turning process in order to
separate the part from the raw
material.
Parting must be carried out slowly
and carefully since the tool is
quite long and is prone to
vibrating.
Parting is not very accurate, and a
finishing cut must often be
undertaken after parting if the
parted surface is to be accurate.
 Facing
The term "facing" is used to describe
removal of material from the flat end of
a cylindrical part, as shown below.

Facing is often used to improve the finish

of surfaces that have been parted.

Tool is fed
radially inward
 Threading
Pointed form tool is fed linearly across surface of rotating
workpart parallel to axis of rotation at a large feed
rate, thus creating threads
 Reaming
Used to slightly enlarge a hole,
provide better tolerance on
diameter, and improve surface
finish
 Knurling
Knurling is an operation used to produce a texture on a turned
machine part. Handles are often knurled in order to provide a
gripping surface. The two wheel inserts shown on the tool below
contact the work piece, and with pressure, cold-form a pattern
into the surface of the part.
Knurling
 Boring
The boring tool is fixed in the tail
stock.
Boring can be accomplished on a mill or
even a drill press, but is most accurate
on a lathe, because the fixturing is
relative to the central spindle axis

Boring is rather well named... its, urm, quite boring. Essentially you
have to drill a hole into the job with your biggest drill bit - Then
you have to mount the boring tool on the tool post so that it is
parallel to the ways. Then you use the tools to slowly increase the
inside diameter of the job to the size you require. The most you
can take off in each pass is about 0.5mm - so it can take a long time
to make a 2 inch bore hole!
Boring

The length of the boring

bar is of critical
importance because of its
tendency to bend.
 Turning categories
Below are illustrated some of the many types of machining that can be
accomplished on a lathe.
Turning categories
 Single-Point Cutting Tool Variety
Single-Point Cutting Tool Variety
There are many types of cutting tools for different operations.
Below is shown a few of the variety, here shown with a tool
holder adapter that fits into a larger tool post fixture.
 Single-Point Cutting Tool Variety
Below is shown how single-point lathe tools can be used.
 Test yourself!
Turning is performed on a machine called a lathe in
which the part is stationary and the tool is rotated.
– True
– False

You mount your work piece inside the chuck not a tail
stock.
– True
– False
 Test yourself!
Which part of lathe machine is this?

Chuck
 Test yourself!
Which operation is shown here:

Boring
 Test yourself!
Which operation is this?

Facing

Tool is fed
radially inward
 Test yourself!
What is the name of this operation:

knurling
 Test yourself!
Name different operations
shown here:

parting

Boring

Facing