MACHINING TIME AND POWER ESTIMATION

• Machining time
cutting speed =
Time for single pass given by
•The number of roughing passes (Pr) is given by

The number of finishing passes (Pf) is given by

 Power estimation
Power required (WC) = FC x V
FC = Force in the direction of cutting tool

Due to shear and friction, the total power is

divided into two components. They are;
1. Power due to shear.
2. Power due to friction.
So,
Total power = Power due to shear + Power due to friction
WC = Ws + Wf = [Fs x Vs] + [Ff x Vf]
where,
Fs – Force due to shear.
Vs – Velocity of shear.
Ff – Force due to friction.
Vf – Velocity of friction.
 SPECIAL PURPOSE LATHES
The main limitations of centre lathes are:
• The setting time for the job in terms of holding the job is
large.
• Only one tool can be used in the normal course. Sometimes
the conventional tool post can be replaced by a square tool
post with four tools.
• The idle times involved in the setting and movement of
tools between the cuts is large.
• Precise movement of the tools to destined places is difficult
to achieve if proper care is not takenby the operator.
 The centre lathe is thus modified to improve
the production rate. The various modified lathes
are capstan and turret lathes, semi automatics
and automatics. Improvements are achieved
basically in the following areas:
Work holding methods.
Multiple tool availability.
Automatic feeding of the tools.
Automatic stopping of tools at precise locations.
Automatic control of the proper sequence of
operations.
 CAPSTAN AND TURRET LATHES
Capstan and turret lathes are production
lathes used to manufacture any number of
identical pieces in the minimum time.
These lathes are development of centre
lathes.
The capstan lathe was first developed in the
year 1860 by Pratt and Whitney of USA.
Capstan and turret lathes are very similar in
construction, working, application and specification.
CAPSTAN LATHE
TURRET LATHE
Bar feeding mechanism
Turret indexing mechanism
Comparison of capstan and turret lathe
Specifications of capstan and turret lathes
• Maximum diameter of the work piece that can be
machined.
• Swing over cross slide.
• Swing over bed.
• Power of the main drive motor.
• Range of spindle speeds.
• Range of feeds for the carriage.
• Range of feeds for the turret or saddle.
• Total weight of the machine.
• Floor space required.
 Process Planning And Tool Layout
For Machining a Product In
Semi-Automatic And Automatic Lathes.
Step to be followed in production of
job by machining in semi-automatic and automatic general purpose machine
Example tool layout
Tool Layout
 Draw a tool layout for the component shown
in Fig. Also determine the machining time for all
the operations, the manipulation times and the
overall machining time for producing the
component on a turret lathe.
 SEMI AUTOMATICS
The characteristic features of semi-automatic lathes are:
• Some major auxiliary motions and handling operations
like bar feeding, speed change, tool change etc. are
done quickly and consistently with lesser human
involvement.
• The operators need lesser skill and putting lesser
effort and attention.
• Suitable for batch or small lot production.
• Costlier than centre lathes of same capacity.
 Classification of semi automatics
Single spindle semi automatics
Centre type: In this type, the workpiece is
held between centres
Chucking type:In this type, the workpiece is
held in a chuck.
Multi spindle semi automatics
The machine may also be built in two designs:
Centre type.
Chucking type.
These multi spindle semi automatics are
classified as:
Parallel action or single station type.
Progressive action or multi station type.
 AUTOMATIC LATHE
These are machine tools in which the
components are machined automatically. The
working cycle is fully automatic that is repeated
to produce identical parts without participation
of the operator.
All the working and idle operations are
performed in a definite sequence by the control
system adopted in the automats which is set up
to suit a given work.
 Classification of Automats
The automats can be classified as follows:
According to the type of work materials used:
 Bar stock machine.
 Chucking machine.
According to the number of spindles:
 Single spindle machine.
 Multi spindle machine.
According to the position of spindles:
 Horizontal spindle type.
 Vertical spindle type.
According to the use:
 General purpose machine.
 Single purpose machine.
According to the feed control:
 Single cam shaft rotating at constant speed.
 Single cam shaft with two speeds.
 Two cam shafts.
 Advantages of automats over conventional
lathes
• Mass production of identical parts.
• High accuracy is maintained.
• Time of production is minimized.
• Less floor space is required.
• Unskilled labor is enough. It minimizes the labor cost.
• Constant flow of production.
• One operator can be utilized to operate more than one
machine.
• The bar stock is fed automatically.
• Scrap loss is reduced by eliminating operator error.
 Comparison of automats and
semiautomatics
S.No Automatics Semi-automatics
1 Loading and unloading of work piece are Loading and unloading are done
done automatically by the machine. manually.
2 Feeding of bar stock and bringing the tools These are done manually.
to correct machining positions are done
automatically.
3 A single operator can attend a number of An operator can attend to only
machines when they are arranged one or two machines at a line.
together as a group.
4 Production time and cost less. Comparatively high
5 Suitable for production of small size Suitable for large size components
components.
6 Initial cost of machine is high. Initial cost is lower than that of
automatic lathe.
 SINGLE SPINDLE AUTOMATS
• These machines have only one spindle. So,
one component can be machined at a time.
• These are modified form of turret lathe. These
machines have maximum of 4 cross slides in
addition to a 6 station or 8 station turret.
• These cross slides are operated by disc cams
which draws the power from the main spindle
through cycle time change gears.
SINGLE SPINDLE AUTOMATIC CUTTING OFF
MACHINE
This machine produces large quantities of
work pieces of smaller diameter and shorter
lengths. Components with simple form are
produced in this machine by means of cross
sliding tools.
SWISS TYPE AUTOMATIC SCREW MACHINE

• This machine was designed and developed in

Switzerland. So it is often called as Swiss auto
lathe.
• This machine is also known as ‘Sliding head
screw machine’, or ‘Movable headstock
machine’, because the head stock is movable and
the tools are fixed.
• This machine is used for machining long accurate
parts of small diameter (2 mm to 25 mm).
Advantages
 It is used to precision turning of small parts.
 Wide range of speeds is available.
 It is rigid in construction.
 Micrometer tool setting is possible.
 Interchangeability of cams is possible.
 Tolerance of 0.005 mm to 0.0125 mm is
obtained.
 SINGLE SPINDLE AUTOMATIC SCREW TYPE
MACHINE
• This is essentially wholly automatic bar type turret
lathe. This is very similar to capstan and turret lathes
with reference to tool layout, but all the tool
movements are cam controlled, such that full
automation in manufacturing is achieved.
• This is designed for machining complex external and
internal surfaces on parts made of bar stock or of
separate blanks. These machines are made in
several sizes for bar work from 12.7 mm to 60 mm
diameter.
 MULTI SPINDLE AUTOMATS
• The multi spindle automats are the fastest
type of production machines and are made in
a variety of models with 2, 4, 5, 6 or 8
spindles. Each of the spindles is provided with
its own set of tools for operation.
• As a result, more than one work piece can be
machined simultaneously in these machines
Classification of multi spindle automats
The multi spindle automats can be classified as follows:
According to the type of stock used:
 Bar stock machine.
 Chucking type machine.
According to the position of spindles:
 Horizontal spindle type.
 Vertical spindle type.
According to the principle of operation:
 Parallel action type.
 Progressive action type.
PARALLEL ACTION MULTI SPINDLE
AUTOMAT
PROGRESSIVE ACTION MULTI SPINDLE
AUTOMAT