Manufacturing

Manufacturing Processes
Machine Tool
Classification of Machine Tool
Feed
DOC
Cutting Speed

Cutting Tool Geometry and Tool

Signature
Cutting Motions

Principle

Engine Lathe
Why?

 Functions of lathe

Cylindrical jobs
Used for operations such as turning, taper turning, facing
knurling, screw thread cutting, grinding, drilling, boring,
reaming etc.

Construction of lathe

Bed
Headstock
Tailstock
Carriage
Feed mechanism

Bed
Casting of iron (cast iron)
All the parts are mounted on bed. (headstock, tailstock, and
carriage)
Rigidity, alignment and accuracy
Rigid- so cutting forces can be withstand
Sufficient weight for vibration absorption
Should be lubricated to avoid rusting.

Headstock
It supports the main spindle in the bearings and aligns
it properly.
Transmission mechanism with speed changing levers
Gears or cone pulley can be used to change speed of
spindle (Belt driven HS, All- geared headstock)
Chuck, face plate are mounted on headstock.
Center line of the headstock is parallel to the guide
ways, in both horizontal and vertical planes.
Main Spindle:
Hollow cylindrical shaft

Tailstock
I.
II.

To support the other end of the work when being machined.

To hold a tool for performing operations like drilling, reaming,
tapping, etc.
It is also used for taper turning (tailstock set over method)

Carriage
It is located between headstock and tailstock
Fitted on bed and slides along the bed guide ways.
Can be locked at any position
It can be moved manually with a wheel or with power feed.
It provides three movements- longitudinal feed, cross feed,
angular feed.

It consists of 5 parts

Saddle
Cross slide
Compound rest
Tool post
The apron

Saddle
Movement across the bed (along
workpiece axis)
It is made up of H shaped casting.
It has v-guide and flat guide on side
for mounting it on lathe bed
guideways.

Cross slide
Moves cutting tool at right angles to
lathe bed
Cross to saddle movement.

Compound rest
It supports the tool post and cutting
tool.
Can rotate to any angle in horizontal
plane.
Helps in turning angles and boring
short tapers.

Tool post
It is used to hold various cutting tool
holders.
It is fixed on top slide of compound
rest.
Can adjust the height on some types

Apron
It is fastened to saddle and hangs over the front of the bed.
It houses gears, levers, handwheels and clutches to operate the
carriage by hand or automatic power feed.
Pinion to engage with the rack for saddle movement.
It contains the gears and clutches for transmitting motion from
feed rod to the carriage.

Feed shaft
Used to move the Carriage automatically

It converts rotary motion of the feed rode or the lead screw to a

translatory motion of carriage.

Lead screw
Used when screw cutting on the lathe

Split nut engages with the lead screw during cutting threads.

Feed gear box (feed

mechanism)
The position of levers on the quick change
gear box determine the ratio between the
headstock spindle speed and the speed of
the lead screw to the carriage.
End gears transmit power from lathe
spindle to the lead screw, through the feed
gear box.

Overload safety devices

Shear pin and slip clutches are used to prevent
damage by overloading.
Shear pin is designed to be of a particular torque.
When designed torque exceeded, shear pin
shears and machine stops.
Slip clutches used for disengage and engage feed
rod when force crosses max limit.

Shear pin in end gear

train prevents damage
to the gears in case
of an overload

Spring-ball clutch
will slip when too
much strain is
applied to feed rod

WORK HOLDING AND SUPPORTING DEVICES

LATHE CENTERS
CHUCK
COLLETS
CARRIERS AND CATCH PLATES
FACE-PLATE
MANDREL
STEADY REST
FOLLOWER

Lathe centers
Live center
Dead center

Chuck
Holds and rotates the job
Attached to headstock of lathe
spindle
I.
II.
III.
IV.
V.
VI.

Three jaw chuck

Four jaw chuck
Collet chuck
Pneumatic chuck
Magnetic chuck
Vaccum operated chuck

Three jaw chuck

Self centering chuck
Size of chuck is its outside diameter
Advantages:
Jobs can be held easily
A wide range of cylindrical and hexagonal jobs can be
held in chuck.

Limitations:
Only regular component can be held e.g. round and
hexagonal.
Accuracy decreases as chuck becomes worn.
Eccentrically holes cannot be made.
Run out cannot be corrected.

Four jaw chuck

Not Self centering chuck.
All jaws are independently adjusted.
Can grip rectangular and irregular shapes.
Advantages:
Jaws can be reversed for holding externally or internally on the
workpiece.
A wide range of regular and irregular jobs can be held in chuck.
Holes can be drilled concentrically or eccentrically.
High gripping power, heavy cuts can be made.
No loss of accuracy even if chuck wears out.

Limitations:
More time consumption.
Chuck is heavy and bulky.
Owing to high gripping power of chuck, fine work can be easily
damaged during setting.

Collet

Pneumatic chuck
Chucking automatic
For example- parting off the
component

Magnetic chuck
For ferrous material in lathe
Where distortion is not permitted

Vaccum
Used for non ferrous metals

Faceplate
A face plate is used to hold the work
which, due to its complicated shape
and size, cannot be held in chuck.

Catch plate

Carrier or Lathe dog

Steady rest and Follower

rest
mounted on bed, used for
long heavy jobs that deflect
centrally by self weight

mounted on carriage and moves with tool, used for long

thin jobs that deflect laterally by cutting force.

Mandrels

Setting the tool height

The cutting tool
on the lathe must
be set to the
exact centre of
the work-piece
We use the centre
of the tailstock to
guide us to the
correct height

Operations performed on lathe

Centering
Turning (plain, taper, step/shoulder turning, eccentric)
Facing
Parting
Chamfering
Grooving
Knurling
Threading
Spinning
Miscellaneous Filing, polishing, spring winding, drilling,
reaming, boring, counter-boring, counter- sinking,
tapping, taper boring, grinding etc.

Centering
Center drilling helps to hold the workpiece
between centers.
How ?

Turning
Tool is fed parallel to it, depth of cut is
perpendicular to it, thus producing a
straight cylindrical surface.
Diameter is effected but length is not
effected.

Turning

Turning
Producing a
Cylindrical Surface

Shoulder/step turning
Same as turning except that diameter is reduced
only up to certain length.

Taper turning
Taper Turning

Facing
The tool is moved
at right angles to
the work axis
using the cross
slide
Flat surfaces are
produced

Facing
Producing a Flat Surface

Knurling

A knurling tool is used to press a pattern onto a

round section.
The pattern is normally used as a grip for a handle.
This provide a grip for the round part
e.g. Screwdriver

Knurling Tool
Toolpost-type toolholder on which
pair of hardened-steel rolls
mounted
Knurling tool with
one set of rolls in
self-centering head
Knurling tool with
three sets of rolls
in revolving head
53-59

Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.

Parting off

to cut off the useful

part
hacksaw and a vice
can be used or use
the parting off tool on
the lathe.

Parting off

Parting Off / Under Cutting

Chamfering
Beveled edge at a specified angle
It removes burrs from the end of
workpiece and provide it a better
appearance.

Grooving
Done at end of
thread to permit full
travel of nut up to a
shoulder or at edge
of shoulder for
proper fit
Also called
recessing,
undercutting, or
necking
Rounded grooves

Square

Round
V-shaped

Threading
Lathes are also
used to cut
threads in round
bars
These threads
take up different
profiles e.g iso
(60) ACME etc.

Spinning
It is the operation of pressing and
forming cup shaped components
from sheet metal.

Miscelleneous

Turning