Theory of Lathe Machines

Manufacturing Process: - A manufacturing process is the activity

(or combination of activities) of transforming a given material in to a
product of different forms and sizes with and without changing the
physical and mechanical properties of the product of material.
The word “process” means the engineering methods or techniques
for performing technological transformation.
Manufacturing is a sub-system of production wherein unprocessed
material brought as input is technologically transformed into useful
and desired product. During this process the raw material may be
modified physically or geometrically.
Thus the term “Manufacturing” therefore describes the entire
sequence of events from the time the raw material is brought into
the production system until it is changed into desired
characteristics of product.
Different Manufacturing Process:-
 Casting
 Welding
 Machining
 Fitting
 Bending
 Rolling
 Heat Treatment
Machining Process:-
A special class of manufacturing process is the ‘machining system’
where a ‘work piece’ (W) with aid of a ‘machine tool’ (M) and ‘Cutting
tool’ (T) is transformed into a product (P). Both the work piece and
cutting tool need fixtures (F) for proper holding, guidance in order that
proper size and shape obtainable.

M
(machine)
W (Work Transfo P(Finished
Piece) rmation Product)
T (Cutting Process
FTools)
(Fixtures)
In overall perspectives of production system , the accelerated
technological build –up is now epitomized in the machining system
comprising of ‘Machine Tools’, ‘Cutting Tools ‘ and ‘product Design’.
Thus entire activities in machining system can be understood by
following flow chart.
Product Design Raw Material Inspection Forming
Stage-
Inspection Final Inspection Dispatch
As it now stands Machining system is vital base that helps to increase
the production of various commodities, ensures mass production,
improves accuracy and becomes backbone of nation’s industrial
progress.
The effectiveness of any product is measured by productivity (P),
which is defined as P=R (output) ÷R (input)
Where, the operator P is the rupee equivalent for inputs and outputs.

Types of Machining Process:-

a) Conventional Machining Process- Removal of material from the work
piece in the form of chips by a sharp cutting tool.
b) Un- Conventional Machining: - An unconventional machining
process is that in which, there is no direct contact of cutting tool with
work piece. In this process a form of energy is used to remove unwanted
material from the work piece.
Machine Tools are required for Conventional Machine Shop-

 Lathe Machine
 Milling Machine
 Shaper Machine
 Grinding Machine
 Slotting Machine
 Drilling Machine
 Planer Machine
 Sawing Machine etc...

Lathe Machine
Lathe is a machine tool, which removes the metal from a work
piece in form of chips to the required shape & size.
Usually circular parts are produced by lathe machines. The
typical lathe provides a variety of rotating speeds and a means
to manually and automatically move the cutting tool into the
work piece.

Types of Lathe
 Engine Lathe or Centre Lathe- It is the most important
machine tool in lathe family and by far most widely used. Its
name is derived from the fact that early machine tools were
driven by separate engine or from a central engine with
overhead belts and shafts. The cutting tools are controlled
either by hand or by power.
 Speed Lathe:-It is the simplest form of lathe machine and
consists of a simple headstock, a tailstock and a tool post. It
has no gear box, lead screw and carriage. Cone pulley is the
only source provided for the spindle speed variation. This
machine is intended for wood turning, metal spinning and
polishing operations.
 Turret or Capstan Lathe: - More than one operation can be
carried out simultaneously by this machine. In it, several
tools are set on a revolving turret or capstan to facilitate
doing of large number of operations on a job with minimum
wastage of time.
 Tool room Lathe: - It is the modern engineering lathe
equipped with all necessary arrangements for tool room
work. It is a geared head driven machine with considerable
range in spindle speeds.
 Bench Lathe: - It is a small lathe which is usually mounted
on a work bench meant for small and light jobs.
 Computer Controlled Lathe: - A highly automated lathe,
where both cutting, loading, tool changing, and part
unloading are automatically controlled by computer coding.
 Main Parts of Lathe Machine

Head Stock- The headstock is normally mounted rigidly to the bed and
holds all the mechanisms, including various kinds and combinations of
pulleys or gears, so that the spindle can be made to turn at different
speeds.
Tail Stock- The unit is arranged to slide along the bed and can be locked
to it at any convenient point; the upper portion of the unit is fitted with
what is variously called a ‘barrel’, ‘spindle’, ‘ram’ or ‘shoot’ that can be
moved in and out of the main casting by hand, lever or screw feed and
carries a "Dead Centre" that supports the other end of work held (by
various means) in the headstock. 
Bed- The bed of the lathe provides the foundation for the whole machine
and holds the headstock, tailstock and carriage in alignment. The
surfaces of the bed that are finely machined - and upon which the
carriage and tailstock slide - are known as "ways".
Spindle-The spindle is made from high tensile steel and is well
machined and grounded .It is hollow type and has screwed nose to
receive the chuck.
Carriage- The whole assembly of Saddle, Apron, Top and Cross Slide
is known as the "Carriage".
 Saddle
The casting that fits onto the top of the bed and slides along it is
known, almost universally, as the "Saddle" - a self-explanatory
and very suitable term. 
 Apron
The vertical, often flat and rectangular "plate" fastened to the front
of the "Saddle" is known as the "Apron" and carries a selection of
gears and controls that allow the carriage to be driven (by hand or
power) up and down the bed. The mechanism inside can also
engage the screw cutting feed and various powered tool feeds,
should they be fitted. The lead screw, and sometimes a power shaft
as well, are often arranged to pass through the apron and provide it
with a drive for the various functions. The sophistication of the
apron-mounted controls, and their ease of use, is a reliable indicator
of the quality of a lathe. Virtually all screw-cutting lathes have what
is commonly-called a "half-nut" lever that closes down one and
sometimes two halves of a split nut to grasp the lead screw and
provide a drive for screw cutting.
 COMPOUND SLIDE consisting of the CROSS SLIDE and
TOP SLIDE 
Sitting on top of the "Saddle" is the "Cross Slide" - that, as its
name implies, moves across the bed - and on top of that there is
often a "Top Slide" or "Tool Post Slide" that is invariably arranged
so that it can be swiveled and locked in a new position. . The top
 and cross slide together should be referred to as "the
compound rest.

Specification of Lathe Machine:

A lathe is generally specified by;

1. Its swing, the maximum diameter of the work piece that can be
machined.
2. The maximum distance between the headstock and tailstock centers
i.e. distance between live centre to dead centre.
3. The length of the bed.
4. Total length of the machine.

Different Lathe Operations:

  Facing: to produce a flat surface at the end of the part or
for making face grooves.
 Turning: produce straight, conical, curved, or grooved
work pieces
 Boring: to enlarge a hole or cylindrical cavity made by a
previous process or to produce circular internal grooves.
 Drilling: to produce a hole by fixing a drill in the
tailstock
 Threading: to produce external or internal threads
 Knurling: to produce a regularly shaped roughness on
cylindrical surfaces
Taper Turning on the Job:
A job which decreases in diameter gradually, so that it assumes a conical
shape, is said to be tapered.
Taper angle is the angle, included between the tapering sides of the job
when extended to meet at a point.
Tangent of the taper angle (Ø) =
Large Diameter (D) - Small Diameter/2xTaper Length (L)
Different Methods of Taper Turning
Common methods of taper turning are
1. Compound rest method
2. Tail stock set over method
3. Taper attachment method
4. Forming tool method

Compound rest method:

This method is useful for turning steep and short tapers. There is circular
base graduated in degrees which can be swiveled at any angle from the
centre line of the lathe centers.
While turning a taper, the base of the compound rest is swiveled
through the angle equal to the taper angle. In this case, feed of the tool is
given with the compound rest feed handle/ with tool post slide.

Lathe Accessories:
Work holding and supporting is important aspects for manufacturing
people. A good method of holding helps in achieving economy and
efficient manufacturing. Standard work holding devices used in lathe
works are
1. Chuck 2.Centres 3. Face plates 4. Mandrels etc.
 Three jaw chuck: Four Jaw Chuck

Cullet Chuck Magnetic Chuck

Working Principle of lathe:

Lathe removes undesired material from the work piece with the help of a
tool which can be fed deep in the work. The tool which is fixed in the
tool post of the carriage mechanism may be given linear motion in any
direction.
An electric motor is fixed in the rear part of the head stock unit, plays as
the main power source to operate the machine.
Coolant- This Liquid is a mixture of water and cutting oil (synthetic or
mineral oil). For general turning works recommended ratio to be 20:1
respectively. Coolant pump and pipe with nozzle arrangement are
provided in the machine for cooling work piece and cutting tool.
Job Fabrication
1. Job to be Fabricated:-“Multiple Lathe Operations”
2. Raw Material Required _ 80x25mm Mild Steel Round Bar.
3. Process Plan:- Write in your own words.
4. Safety Adherence:- Write in your own words
5. Observation Table:-
Sl. Part to Measurin Least Drawin Toleranc Actua Remark
# Measur g Coun g Size e l Size s
e Instrumen t (in mm) (in mm) (in mm)

t Required (in mm)

1. A- Vernier 0.2 +_0.2

Length Caliper
_