 INTRODUCTION:

 What Is Lathe?

A lathe is a machine tool which rotates the workpiece on its axis to

perform various operations such as cutting, sanding, knurling, drilling, or
deformation with tools that are applied to the workpiece to create an object
which has symmetry about an axis of rotation.

 Development of Lathes:

Turret and capstan lathes are the natural development of the engine lathe,
where the tailstock is replaced by an indexable multistation tool head, called the
capstan or the turret. This head carries a selection of standard tool holders and
special attachments. A square turret is mounted on the cross slide in place of the
usual compound rest in engine lathe. Sometimes a fixed tool holder is also
mounted on the back end of the cross slide. Dimensional control is affected by
means of longitudinal (for lengths) and traversal (for diameters) adjustable stops.

Therefore, capstan and turret lathes bridge the gap between manual engine lathes
and automated lathes and are most practical for batch and short-run production.
In comparison with manual lathes, the chief distinguishing feature of capstan and
turret lathes is the multiple tool holders that enable the setting up of all the tools
necessary to produce a certain job. Except for sharpening, the tools need no
further handling. Considerable skill is required to set and adjust the tools on such
machines properly. But once the machines are set, they can be operated by
semiskilled operators. Eliminating the setup time between operations reduces the
production time considerably. The development of this group of lathes has been
enhanced to provide the level of accuracy required for interchangeable
production.

A capstan lathe or a turret lathe is a production lathe used to manufacture any

number of identical pieces in the minimum time. These lathes are development of
engine lathes. The capstan lathe was first developed in the United States of
America by Pratt and Whitney sometimes in 1860.

Special characteristics of a capstan or turret lathe enable it to perform a series of

operations such as drilling, turning, boring, thread cutting, reaming, chamfering,
cutting- off and many other operations in a regular sequence to produce a large
number of identical pieces in a minimum time.
  Construction of Turret Lathe:

Turret Lathe

A – Headstock F - Cross slide K - Star Handle for Turret Operation

B – Spindle G -Intermediate saddle L - Turret Apron
C - Pilot Bar H - Turret M - Turret saddle
D - Tool post I - Turret Clamp Lever N - Intermediate saddle Apron
E - Rear Tool post J - Saddle Looking Lever O - Feed Gearbox
  Construction of Capstan Lathe:

A - Turret Locking Handle C - Capstan Slide E - Capstan Slide Block

B – Turret D - Capstan Rest F - Sliding Bridge
 Scope of Work:
The main purpose of these types of lathes is to
eliminate the setup time between operations which reduces the
production time considerably.

As mentioned before, Turret and Capstan Lathes are mainly used in

Mass/Batch Production to produce products such as:

 Collets.
 Collets sleeves.
 Drill collets.
 Drill collets holder.

 And many other products as shown:

 Differences between a Capstan Lathe, and a
Turret Lathe:

The first picture shows a Capstan lathe turret, and this description is
the cause of the confusion. The turret is the toolholding and rotating
part which is carried on a fixed but movable saddle. The turret itself
moves on the saddle.
 The second picture shows a turret off a Turret lathe, and the
turret itself moves with the saddle at all times. This moving
saddle on the turret lathe is what makes it different in operation
from the Capstan machine.

 The headstock of a turret lathe is similar to that of an engine lathe in

construction but possesses wider range of speeds, and is of heavier in
construction.

Similar sizes of capstan and turret lathe and engine lathe, when an engine lathe
will require a motor of 3h.p. to drive its spindle and other parts, a capstan and
turret lathe will demand power as high as 15h.p. for high rate of production.

In a turret lathe, the tailstock of an engine lathe is replaced by a turret. This is a

six sided block (or more), each of which may carry one or more tools. These tools
may be indexed one after the other to perform different operations in a regular
order. This is a decisive advantage in mass production.

In a turret lathe, combination of cuts can be taken. Two or more tools may be
mounted on the same face of the turret, making it possible to machine more than
one surface at a time. This feature reduces total operational time.

A semiskilled operator can operate a capstan or turret lathe after the machine has
been set up by a skilled machinist. A skilled machinist may be requisitioned for
setting up only for a large number of machines, where as actual production may
be given by a semiskilled operator.

Capstan and turret lathe is fundamentally a production machine, capable of

producing large number of identical pieces in a minimum time. The centre lathe is
suitable for odd jobs having different shapes and sizes.

 The essential components and operating principles of capstan and turret

lathes are illustrated schematically

In the shown figure. Capstan lathes are mainly used for bar work, whereas turret
lathes are applicable for large work in the form of castings and forgings.
In a capstan or ram-type lathe, the hexagon turret is mounted on a slide that
moves longitudinally in a stationary saddle (Shown Figure a). During setup of the
machine, the saddle is positioned along the bed to give the shortest possible
stroke for the job. The advantage of the capstan lathe is that the operator has less
mass to move, resulting in easier and faster handling. The disadvantage is that the
hexagonal turret slide is fed forward such that the overhang is increased,
resulting in the deflection of the ram slide, especially at the extreme of its
position, which produces taper and reduces accuracy.

In the turret- or saddle-type lathe, the turret is mounted directly upon a movable
saddle, furnished with both hand and power longitudinal feed (Shown Figure b).
This machine is designed for machining chuck work, in addition to bar work.
Owing to the volume of the swarf produced, the guide ways of the machine bed
are flame-hardened and provided with covers that protect the sliding surfaces.
The bed must be designed to allow free and rapid escape of swarf and coolant.
FIGURE 6.1 Essential
components and operating
principles of capstan and
turret lathes.
 Differences between (Capstan Lathe and
Turret Lathe) versus Conventional Lathe:

Centre lathe Capstan/Turret Lathe

(Conventional)

1 It is a manually operated lathe It is a semi automatic lathe

2 It has only one tool post tool Front and rear tool posts are
changing time is more available. Tool changing time is
less

3 It has tail stock It has turret head instead of tail

stock

4 Only one tool can be fitted in Six different tools can be fitted in
the tail stock the turret head

5 Number of speeds is less Number of speeds is more

6 Tool changing time is more Tool changing time is less

7 The machine should be Tool can be changed without

stopped for changing tool stopping the machine

8 It is not suitable for mass The tools are controlled by feed

production stops

9 The tool is centered manually The tool is centered automatically

after changing the tool

10 Only one operation is done at More than one operation can be

a time done at a time
  Tools:

Tools of capstan lathe machine:

Tool Geometry: For cutting tools, geometry depends mainly on the properties of the tool
material and the work material. The standard terminology is shown in the following figure.
For single point tools, the most important angles are the rake angles and the end and side
relief angles.

 The back rake angle affects the ability of the tool to shear the work material and form the
chip. It can be positive or negative. Positive rake angles reduce the cutting forces resulting
in smaller deflections of the work piece, tool holder, and machine. If the back rake angle is
too large, the strength of the tool is reduced as well as its capacity to conduct heat. In
machining hard work materials, the back rake angle must be small, even negative for
carbide and diamond tools. The higher the hardness, the smaller the back rake angle. For
high-speed steels, back rake angle is normally chosen in the positive range.

 Most lathe operations are done with relatively simple, single-point cutting tools. On right-
hand and left-hand turning and facing tools, the cutting takes place on the side of the tool;
therefore the side rake angle is of primary importance and deep cuts can be made. On the
round-nose turning tools, cutoff tools, finishing tools, and some threading tools, cutting takes
place on or near the end of the tool, and the back rake is therefore of importance. Such
tools are used with relatively light depths of cut. Because tool materials are expensive, it is
desirable to use as little as possible.

 It is essential, at the same, that the cutting tool be supported in a strong, rigid manner to
minimize deflection and possible vibration. Consequently, lathe tools are supported in
various types of heavy, forged steel tool holders, as shown in the figure.
 The tool bit should be clamped in the tool holder with minimum overhang. Otherwise, tool
chatter and a poor surface finish may result. In the use of carbide, ceramic, or coated
carbides for mass production work, throwaway inserts are used; these can be purchased in
great variety of shapes, geometrics (nose radius, tool angle, and groove geometry), and
sizes.
Tools of turret lathe machine:

Boring Tool:

Face Tool:

Tapping Tools:
And many other tools:
  Operations:

1. Form tools:

For the machining of complex shapes, it is common to use form tools. This contrasts with
the cutting that is performed on an engine lathe where the cutting tool is usually a single-
point tool. A form tool has the form or contour of the final part but in reverse, so it cuts the
material leaving the desired component shape. This contrasts to a single-point tool, which
cuts on one point at a time and the shape of the component is dictated by the motion of the
tool rather than its shape.

2. Rotary broaching:

Rotary broaching is another common operation. The broach holder is mounted stationary
while its internal live spindle and end cutting broach tool are driven by the workpiece. As the
broach is fed into or around the workpiece, the broach's contact points are constantly
changing, easily creating the desired form. The most common form made this way is a
hexagonal socket in the end of a cap screw.

3. Boring:
The process of using a single-point tool to enlarge a preexisting hole.

4. Center drilling:
A process in which a rigid drill precisely locates a hole in the center of a work piece. The
purpose of center drilling is to establish a true centerline diameter.

5. Drilling:
A process in which the work piece is held stationary, while a rotating cutter (the drill) makes
a round hole into the work piece to a certain depth.
 6. Facing:
An operation performed on a lathe that feeds a single-point tool into the end of a cylindrical
work piece to create a flat surface.

7. Parting:
Also called cutoff, a shearing operation that separates a finished part from bar stock.

8. Reaming:
The process of using a cutting tool with straight cutting edges to enlarge or smooth holes
that have been previously drilled.

9. Tapping:
The process of cutting internal threads in a work piece with a multi-point tool.

10. Threading:
The process used to machine a long, spiraling ridge down the outer or inner surface of a
work piece.

11. Turning:
An operation performed on a lathe that feeds a cutting tool along the length of a cylindrical
part to reduce its diameter.
  Features:
I. Bar feeding mechanism of capstan lathe:
Fig. 4.7.9 typically shows the kinematic arrangement of feeding and clamping of bar
stock in capstan lathes.
The bar stock is held and tightly clamped in the push type spring collets which is
pushed by a push tube with the help of a pair of bell-crank levers actuated by a taper
ring as shown in Fig. 4.7.9. Bar feeding is accomplished by four elementary
operations;
 unclamping of the job – by opening the collets
 bar feed by pushing it forward
 clamping of the bar by closing the collets
 free return of the bar-pushing element

After a job is complete and part off, the collets are opened by moving the lever
manually rightward to withdraw the push force on the collets. Further moving of the
lever in the same direction causes forward push of the bar with the help of the
ratchet – paul system shown. After the projection of the bar from the collets face to
the desired length controlled by a pre-set stop – stock generally held in one face of
the turret or in a separate swing stop, the lever is moved leftward resulting closing of
the collets by clamping of the barstock. Just before clamping of the collets, the
leftward movement of the lever pushes the bar feeder (ratchet) back freely against
the paul.

Fig. 4.7.9 Typical bar feeding mechanism in capstan lathe

II. Turret indexing mechanism in capstan and turret lathes:
Turret indexing mechanism of capstan and single spindle turret lathe is typically
shown schematically in Fig. 4.7.10.
The turret (generally hexagonal) holding the axially moving cutting tools have the
following motions to be controlled mechanically and manually;
 Forward axial traverse comprising;
- Quick approach: manually done by rotating the pinion as shown
- Slow working feed: automatically by engaging the clutch
- Stop at preset position depending upon the desired length of travel of the
individual tools
 Quick return: manually done by disengaging the clutch and moving the turret
back
o
 Indexing of the turret by 60 (or multiple of it): done manually by further moving
the turret slide back.

Just before indexing at the end of the return stroke, the locking pin is withdrawn by
the lever which is lifted at its other end by gradually riding against the hinged wedge
as indicated in Fig. 4.7.10 (a). Further backward travel of the turret slide causes
rotation of the free head by the indexing pin and lever as indicated in Fig. 4.7.10 (b).
Rotation of the turret head by exact angle is accomplished by insertion of the locking
pin in the next hole of the six equispaced holes. After indexing and locking, the turret
head is moved forward with the next cutting tool at its front face when the roller of the
lever returns through the wider slot of the wedge without disturbing the locking pin as
indicated in the figure. The forward motion of the turret head is automatically stopped
when the set-screw corresponding to the working tool is arrested by the mechanical
stop. The end position and hence length of travel of the tool is governed by
presetting the screw. There are six such screws, each one corresponds with
particular face or tool of the turret. The drum holding those equispaced six screw
with different projection length is rotated along with the indexing (rotation) of the
turret head by a pair of bevel gears (1:1) as indicated in Fig. 4.7.10 (a). The bottom
most screw, which corresponds with the tool on the front face of the turret, when hits
or touches the stop, the turret movement is stopped either manually by feeling or
automatically by disengaging the clutch between the feed rod and the turret slide.
 (a) sectional view

(b) top (inner) view

Fig.4.7.10 Turret indexing in capstan and turret lathe.
III. WORK HOLDING DEVICES:
The standard practice of holding work between two centers in an engine lathe finds
no place in a capstan or turret lathe as there is dead centre to support the work at
the other end. Work is, therefore supported at the spindle end by the help of chucks
and fixtures. The usual methods of holding work in a capstan or turret lathe are:

1. Jaw chucks:
• Self centering chuck. • Independent chuck.

• Combination chuck. • Air operated chuck.

2. Collet chucks:

• Push out type. • Draw in type. • Dead length type.

The collet chucks: The collet chucks are used for gripping bars introduced through the
head stick spindle of a capstan or turret lathe and is one of the most common method
of holding work.
Different sizes of spring collets having square, hexagonal, round or any other shaped
bore are fitted in the chuck body for holding different sizes of bar having different
sections.
PUSH OUT TYPE: To grip the work, the tapped portion of the spring collet is pushed
in to the mating taper of the chuck. There is a tendency of the bar to be pushed slightly
outward when the collet is pushed in to the chuck body for gripping. If the bar is fed
against a stop bar fitted on the turret head, this slight outward movement of the bar
ensures accurate setting of the length for machining.
DRAW IN TYPE: To grip the work, the tapered portion of the spring collet is pulled
back in to the mating taper of the chuck which causes the split end of the collet to
close in and grip the bar. The machining length of the bar in this type of chuck cannot
be accurately set as the collet while closing will draw the bar slightly outward towards
the spindle.
DEAD LENGTH TYPE: For accurate positioning of the bar, both the push out and
draw in type collet present some error due to the movement of the bar along with the
collet while gripping. This difficulty is removed by using a stationary collet on the bar.
A sliding sleeve closes up on the tapered collet which is prevented from any end
movement by the shoulder stop.
  Fixtures:

A fixture may be described as a special chuck built for the purpose of

holding, locating and machining a large number of identical pieces which
cannot be easily held by conventional gripping devices. Fixtures also
serve the purpose of accurately locating the machining surface. The main
functions of a fixture are as follows:

1. They accurately locate the work.

2. They grip the work properly, preventing it from bending or slipping
during machining operations.
3. They permit rapid loading and unloading of work pieces.

 Holding Workpiece in a Lathe: