Unit5Lesson1-LATHE
Unit5Lesson1-LATHE
LESSON 1 LATHE
STRUCTURE
Machining – material removal by a sharp cutting tool, e.g., turning, milling, drilling
Nontraditional processes - various energy forms other than sharp cutting tool to
remove material, e.g., electrochemical processes, chemical machining.
1.1 Machining
Machining is the process of removing excess material from a work piece by shearing
in the form of chips by cutting tools. If the work piece is metal, the process is often
called metal cutting. Majority of manufactured products require machining at some
stage in their production, ranging from relatively rough or non-precision work, such as
cleanup of castings or forgings, to high-precision work and high-quality finishes. Thus
machining undoubtedly is the most important of the basic manufacturing processes.
Initial over size work Final shape sought Excess material to be removed from the
piece initial work piece in order to achieve
final shape / product.
Figure 1: Machining is a material removal process; shape is obtained by removing
material from over size work piece
The essential basic requirements for machining work are schematically illustrated in
Figure below. The blank (work piece) and the cutting tool are properly mounted (in
fixtures/chuck/jaw) and moved in a powerful device called machine tool (lathe /
drilling / milling machines) enabling gradual removal of layer of material from the
work surface resulting in its desired dimensions and surface finish. Additionally some
environment called cutting fluid is generally used to ease machining by cooling and
lubrication.
Machine Tools produce geometrical surfaces like flat, cylindrical or any contour
on the preformed blanks by machining work with the help of cutting tools.
The process of metal cutting is complex because it has such a wide variety of inputs.
The variables are:
1. The machine tool selected to perform the process
2. The cutting tool selected (geometry and material)
3. The properties and parameters of the workpiece
4. The cutting parameters selected (speed, feed, depth of cut)
5. The workpiece holding devices or fixtures or jigs
There are seven basic material removal processes (see Figure below): turning,
milling, drilling, sawing, broaching, shaping (planing), and grinding (also called
abrasive machining).
Broaching Cutting
Figure 3: Seven basic machining (material removal) processes.
MEM 103 Unit 5, Lesson 1
1.2 Lathe
Lathe is known as mother of machine tools. The lathe machine tool is used for
producing components that have one or more cylindrical surface, which may be
internal or external. With special attachments, it can also be used for producing flat
surfaces, other types of surfaces, cutting threads, cutting grooves and holes.
Figure below shows some typical products that are made using a lathe.
1.3.6 Carriage assembly - The main function of the carriage is to hold the cutting
tool and move it to give longitudinal and/or cross feed. The carriage includes the
apron, saddle, compound rest, cross slide, tool post, and the cutting tool. This
provides the motion along the Z axis.
The saddle carries the cross slide and the compound rest.
The cross slide is mounted on the dovetail ways on the top of the saddle and moves
radially back and forth (X axis) at 90° to the axis of the lathe by the cross slide lead
screw. Thus controlling the radial position of the cutting tool
The compound rest is mounted on the cross slide and has circular base graduated
in degrees. It can be swiveled and clamped at any angle in a horizontal plane. It is
used for obtaining angular cuts and short tapers. The cutting tool and tool holder are
secured in the tool post, which is mounted directly to the compound rest.
The apron attached to the front of the carriage contains the gears and feed clutches
which transmit motion from the feed rod or lead screw to the carriage and cross slide.
It is equipped with mechanisms for both manual and mechanized movements.
A split nut in the apron is used to engage the lead screw with the carriage.
A feed reversing lever, located on the carriage, is used to cause the carriage and
the cross slide to reverse the direction of travel.
1.3.7 Feed rod - The feed rod is powered by a set of gears from the headstock. It
rotates during operation of the lathe and provides mechanized movement to the
carriage or the cross-slide by means of gears, a friction clutch, and a keyway along
the length of the feed rod.
1.3.8 Lead screw - The lead screw is also powered by the gears from the headstock
and is used for providing specific accurate mechanized movement to the carriage for
cutting threads on the workpiece. The lead screw has a definite pitch. Similarly, a
lathe not meant for thread cutting will not have a lead screw.