Machining Process-II

Overview on lathe Machine

Mubashar Parvaiz

International Islamic University

Islamabad
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Machining
 A material removal process in which a sharp cutting tool is
used to mechanically cut away material so that the desired
part geometry remains
 Most common application: to shape metal parts
 Machining is the most versatile and accurate of all
manufacturing processes in its capability to produce a
diversity of part geometries and geometric features (e.g.
screw threads, gear teeth, flat surfaces)
 Casting can also produce a variety of shapes, but it lacks the
precision and accuracy of machining

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 Classification of Machined Parts
1. Rotational - cylindrical or disk-like shape. Achieved by
rotation motion of the workpart. Ex. turning and boring
2. Nonrotational (also called prismatic) - block-like or plate-like.
Achieved by linear motion of the workpart. Ex. Milling,
shaping, planing and sawing

Figure 22.1 - Machined parts are classified as: (a) rotational, or (b)
nonrotational, shown here by block and flat parts
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 Machining Operations and Part Geometry
Each machining operation produces a characteristic part geometry due to two
factors:
1. Relative motions between the tool and the workpart
• Generating – part geometry is determined by the feed trajectory of
the cutting tool. Feed motion creates shape. Ex. Straight turning,
taper turning, and profile milling
2. Shape of the cutting tool
• Forming – part geometry is created by the shape of the cutting
tool. Cutting edge has the reverse of the shape to be produced on
the part surface. Ex. Form turning, drilling and broaching
 Forming and generating are sometimes combined in one operation, such as
in thread cutting on a lathe and slot milling

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Figure 22.2 - Generating shape: (a) straight turning, (b) taper turning, (c) contour
turning, (d) plain milling, (e) profile milling

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Figure 22.3 - Forming to create shape: (a) form turning, (b) drilling, and (c)
broaching

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Figure 22.4 - Combination of forming and generating to create shape: (a) thread
cutting on a lathe, and (b) slot milling

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Turning
 A single point cutting tool removes material from a rotating
workpiece to generate a cylindrical shape
 The tool is fed linearly in a direction parallel to the axis of
rotation
 Performed on a machine tool called a lathe
 Variations of turning that are performed on a lathe:
 Facing
 Contour turning
 Chamfering
 Cutoff
 Threading

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N=v/Do Do – Df =2d MRR = vfd

Figure 22.5 -Turning operation

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Facing
Tool is fed
radially inward to
create a flat
surface

Figure 22.6 (a) facing

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 Contour Turning
Instead of feeding the tool parallel to the axis of rotation, tool
follows a contour that is other than straight, thus creating a
contoured form

Figure 22.6 (c) contour turning

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 Chamfering
Cutting edge cuts an angle on the corner of the cylinder,
forming a "chamfer"

Figure 22.6 (e) chamfering

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 Cutoff
Tool is fed radially into rotating work at some location to cut
off end of part (also called parting)

Figure 22.6 (f) cutoff

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 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

Figure 22.6 (g) threading

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 Machining Operation - Lathe

Contour Form
Facing Taper turning turning turning

Chamfering Cutoff Threading

Boring Drilling Knurling

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The Engine Lathe

Figure 22.7
Diagram of
an engine
lathe,
showing its
principal
components

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Page 17
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Lathe Machines
 Most lathe machines are horizontal but vertical lathe
machines are also used for jobs with large diameter relative
to the length and for heavy work
 The size of the lathe is designated by swing and maximum
distance between centers
 Swing is the maximum workpart diameter that can be
rotated in the spindle
 Maximum distance between centers indicate the maximum
length of a workpiece that can be mounted between
headstock and tailstock centers
 350 mm x 1.2 m lathe means a swing of 350 mm and
maximum distance between centers of 1.2 m

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Methods of Holding the Work in a
Lathe
There are four common methods used to hold workparts in
turning-to grasp the work, center and support it in position
along the spindle axis, and rotate it:
 Holding the work between centers
 Chuck
 Collet
 Face plate

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 Holding the Work Between Centers

• Figure 22.8 (a) mounting the work between centers using a "dog”
• Appropriate for parts with large length to diameter ratios
• The tailstock center can be either live or dead
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Chuck

• Figure 22.8 (b) three-jaw chuck

• Can also be four-jaw
• A self-centering chuck has a mechanism to move the jaws in or
out simultaneously thus centering the work at the spindle axis
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Collet

• Figure 22.8 (c) collet

• Collet is a tubular bushing with longitudinal slits running over
half its length and equally spaced around its circumference
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Face Plate

• Figure 22.8 (d) face plate for non-cylindrical workparts

• The face plates is equipped with custom-designed clamps
for the particular geometry of the part
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Other Lathes and Turning Machines
Other turning machines developed to satisfy particular
functions or to automate the turning process:
 Toolroom lathe
 Speed Lathe
 Turret Lathe
 Chucking Machine
 Automatic Screw Machine
 Numerically Controlled Lathe

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Turret Lathe
 A manually operated lathe in which the tailstock replaced by
“turret” that holds up to six tools
 Tools rapidly brought into action by indexing the turret
 Tool post replaced by four-sided turret to index four tools
 Applications: high production work that requires a sequence
of cuts on the part

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Turret Lathe

Figure 22.9
Schematic illustration
of the components of a
turret lathe. Note the
two turrets: square and
hexagonal (main).
Source: American
Machinist and
Automated
Manufacturing.

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 Examples of Turrets
(b)

Figure 22.11 (a) A turret with six different tools for

inside-diameter and outside-diameter cutting and
threading operations. (b) A turret with eight different
cutting tools. Source: Monarch Machine Tool Company. Page 28
Chucking Machine
 Uses chuck in its spindle to hold workpart
 No tailstock, so parts cannot be mounted between centers
 Cutting tool actions controlled automatically
 Operator’s job: to load and unload parts
 Applications: short, light-weight parts

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Bar Machine
 Similar to chucking machine except collet replaces chuck,
permitting long bar stock to be fed through headstock
 At the end of the machining cycle, a cutoff operation
separates the new part
 Highly automated (the term automatic bar machine is often
used)
 Applications: high production of rotational parts.

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Automatic Screw Machine
 Same as automatic bar machine but smaller
 Applications: high production of screws and similar small
hardware items; hence, its name

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Multiple Spindle Bar Machines
 More than one spindle, so multiple parts machined
simultaneously by multiple tools
 Example: six spindle automatic bar machine works on six parts
at a time
 After each machining cycle, spindles (including collets and
workbars) are indexed (rotated) to next position

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Figure 22.9 - (a) Part produced on a six-spindle automatic bar machine; and (b)
sequence of operations to produce the part: (1) feed stock to stop, (2) turn
main diameter, (3) form second diameter and spotface, (4) drill, (5) chamfer,
and (6) cutoff

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Computer Numerical Control
Lathe

Figure 22.10 A computer numerical control lathe.

Note the two turrets on this machine. Source: Jones
& Lamson, Textron, Inc.
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Boring
 Boring is similar to turning. It uses a single-point tool against a
rotating workpart
 Difference between boring and turning:
 Boring is performed on the inside diameter of an existing hole
 Turning is performed on the outside diameter of an existing
cylinder
 In effect, boring is an internal turning operation
 Machine tools used to perform boring operations are called boring
machines
 Boring machines
 Horizontal or vertical - refers to the orientation of the axis of
rotation of machine spindle

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Horizontal Boring

Boring bar on tool post Boring bar between centres

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Vertical Boring Mill

• Figure 22.12 - A vertical boring mill –for large, heavy workparts

• Usually the workpart diameter is greater than its length
• Typical boring machine can position and feed several cutting tools
simultaneously Page 37
 Drilling
 Machining operation used to
create a round hole in a
workpart
 Contrasts with boring which
can only enlarge an existing
hole
 Cutting tool called a drill or
drill bit-a rotating cylindrical
tool which has two cutting
edges on its working end
Figure 21.3 (b) drilling
 Customarily performed on a
drill press
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 Cutting Conditions in Drilling

N=v/D MRR = D2fr / 4 where fr=Nf

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 Through Holes vs. Blind Holes
Through-holes - drill exits the opposite side of work
Blind-holes – drill does not exit work on opposite side

Figure 22.13 - Two hole types: (a) through-hole, and (b) blind hole

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Operations Related to Drilling
 Most of these operations follow drilling; a hole must be made
first by drilling, and then the hole is modified by one or the
other operations
 Reaming
 Tapping
 Counterboring
 Countersinking
 Centering
 Spotfacing

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 Reaming
 Used to slightly enlarge
a hole, provide better
tolerance on diameter,
and improve surface
finish
 The tool called reamer
has straight flutes

Figure 22.14 -
Machining operations
related to drilling:
(a) reaming Page 42
 Tapping
 Used to provide
internal screw
threads on an
existing hole
 Tool called a tap

Figure 22.14 (b) tapping

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 Counterboring
 Provides a stepped hole,
in which a larger
diameter follows a
smaller diameter
partially into the hole
 Used to seat boltheads
into a hole

Figure 22.14 (c) counterboring

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Countersinking Centre drilling Spot facing

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 Drill Presses: The Machine Tools for Drilling

Upright Drill
Stands on the floor

Bench Drill
Similar but smaller
and mounted on a
table or bench

Figure 22.15 - Upright drill press

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 Radial Drill
 Large drill press designed
for large parts
 Head can be positioned at
significant distance from
the column to
accommodate large work

Figure 22.16 - Radial drill press (Willis Machinery and Tools)

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GANG DRILL

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MULTIPLE SPINDLES

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 CNC Turret Drilling Machine

Figure 22.29 A three-axis

computer numerical control
drilling machine. The turret
holds as much as eight different
tools, such as drills, taps, and
reamers.

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End of Lecture

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