Material Removal Processes

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Turning and Related
Operations

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 Material Removal
Processes
• The starting material is solid metal

• Excess material is removed from the starting metal so

that the resulting part has the desired geometry

• Most common in this category are machining operations

such as turning, drilling and milling, accomplished using
cutting tools that are harder and stronger than the
work metal

• In grinding abrasive grinding wheel is used to remove

material

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 What is a Machine
Tool?
• A machine tool is a non-portable, power operated
device or system of devices in which energy is
expended to produce jobs of desired size, shape and
surface finish by removing excess material from the
preformed blanks in the form of chips with the help of
cutting tools moved past the work surface(s).

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 What is Common in Machine
Tools?
• Electric Motor • Different Levers,
• Transmission Handwheels &
Mechanism Gauges
• Spindle • Workpiece
• Base or Bed holding device
• Slides or Ways • Accessories
• Cutting Tool • Cutting Speed
• Mechanisms for • Feed Rate
different movements
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 The
Lathe
• The forerunner or mother of all machine tools

• The work is held and rotated on its axis while

the cutting tool is advanced along the lines of a
desired cut

 The main purpose of a lathe is to machine

round work

• The engine lathe is the most common lathe found in

a machine shop
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 Parts of the
• Lathe
The main parts of the lathe are
–The bed (and ways)
–Headstock
–Quick-change gear box
–Carriage
–Tailstoc
k Bed:
• The bed is a heavy casting made to support
the working parts of the lathe

• On its top section are machined ways that guide and

align the major parts of the lathe
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 Parts of the
Headstock:
Lathe…
• The headstock is clamped on the left-hand side of the
bed

• The headstock spindle, a hollow cylindrical shaft

provides a drive through gears from motor to work-
holding devices

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 Parts of the
Lathe…
Quick-change Gearbox:
• The quick-change gearbox, containing a number of
different-size gears, provides the feed rod and lead
screw with various speeds for turning and thread
cutting operations

• The feed rod advances the carriage for turning

operations when the automatic feed lever is
engaged
• The lead screw advances the carriage for thread
cutting when the split-nut lever is engaged
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 Parts of the
Lathe…
Carriage:
• Used to move the cutting tool along the lathe bed

• The saddle, an H-shaped casting mounted on the

top of the lathe ways, provides a means of
mounting the cross-slide and the apron

• The cross-slide, mounted on the top of the saddle,

provides a manual or an automatic cross movement
for the cutting tool

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 Parts of the
Lathe…
• The compound rest, fitted on top of the cross-
slide, is used to support the cutting tool

• It can be swiveled to any angle for taper-turning

operations

• The apron handwheel can be turned manually

to move the carriage along the bed

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 Parts of the
Lathe…
Tailstock:
• The tailstock can be adjusted for taper or parallel
turning by two screws set in the base
• The tailstock spindle has an internal taper to receive the
dead center, which provides support for the right-hand
end of the work
• Other standard tapered-shank tools, such as reamers
and drills, can be held in the tailstock spindle

• The tailstock handwheel moves the tailstock spindle

in or out of the tailstock casting

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Schematic view of a center lathe

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General view of a typical lathe, showing various components

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General view of a typical lathe, showing various components

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Movement of different parts of Lathe in different
axes

The Carriage
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Numerical Control Lathe and
Turret

(a) A computer numerical-control lathe. Note the two turrets on this machine. These
machines have higher power and spindle speed than other lathes in order to take
advantage of new cutting tools with enhanced properties. (b) A typical turret equipped
with ten tools, some of which are powered.
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 Lathe Workholding
Devices
Lathe Centers:
• Most turning operations can be performed between centers
on a lathe
• Work to be turned between centers must have a center
hole drilled in each end to provide a bearing surface
• A lathe dog, fitted into a driving plate, provides a drive for
the work
• The lathe dog has an opening to receive the work and a
setscrew to fasten the dog to the work
• The tail of the dog fits into a slot on the driveplate
and provides a drive to the workpiece

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Lathe centers and lathe dogs
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Lathe centers and lathe dogs
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 Lathe Workholding
Devices
Chucks:
The most common are three-jaw universal, four-
jaw independent, and collet chuck
The three-jaw universal chuck:
• Holds round and hexagonal work
• Three jaws move simultaneously when adjusted
by the chuck wrench
• Usually provided with two sets of jaws, one for
outside chucking and the other for inside
chucking
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Three-jaw universal chuck
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 Lathe Workholding
Devices
Four-jaw Independent Chucks:
• 4-jaw chucks are usually non-self-centering
• Each jaw can be moved independently
• Ideal for gripping round, square, hexagonal
and irregularly shaped workpieces
• The jaws can be reversed to hold work by
inside diameter
• Multi-jaw chucks (6 or 8 jaws) for special
purpose and high standards of accuracy

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Four-jaw and six-jaw chucks
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 Lathe Workholding
Devices
Magnetic Chuck:
• It has the advantage of holding iron or steel parts
• The parts that are too thin or that may be
damaged if held in a conventional chuck
• Suitable only for light operations
• A magnetic chuck consists of an accurately
centered permanent magnet face

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Magnetic chuck
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 Lathe Workholding
Devices
Faceplates:
• Circular metal plate fixed to the end of spindle
• Used to hold work that is too large or of such a
shape that it cannot be held in a chuck or between
centers
• It has slots or threaded holes
• W.piece is clamped using T-bolts in the slots
or threaded holes

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Faceplate and T-bolts
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 Lathe Workholding
Devices
Collet Chucks:
• Used for small parts that cannot be held in a
jaw- chuck

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 Lathe Workholding
Devices
Collet
Chucks:

Workpiece held in collet chuck

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 Lathe Workholding
Devices
Steadyrest:
• Used to support long or slender work held in a chuck or
between lathe centers
• It is located on, and aligned by, the ways of the lathe

• It may be positioned at any point along the lathe bed,

provided it clears the carriage travel
• Itsthree jaws my be adjusted to support any
work diameter within the steadyrest capacity
• It also supports the center of long work to
prevent springing when the work is machined
between centers
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Steadyrest

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 Lathe Workholding
Devices
Follower Rest:
• Often used to support a long, slender workpiece
during machining

• Mounted on the saddle, travels with the carriage to

prevent work from springing up and away from the
cutting tool

• The cutting tool is generally positioned just ahead of

the follower rest to provide a smooth bearing
surface for the two jaws of the follower rest

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Follower Rest

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 Lathe
Cutting
Operations
Miscellaneous cutting operations
that can be performed on a lathe.
Note that all parts are circular –
a property known as
axisymmetry.

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2
 Brief Review on
Lathe
Intro to Lathe Operations
Video

Lathe Workholding

Video Lathe Cutting

Tools Video Lathe

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 Center Lathe
Specifications
• Maximum diameter and length of job that can
be accommodated

• Power of the main drive (motor)

• Range of spindle speeds

• Range of feeds

• Space occupied by the machine

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 Referenc
es
• Technology of Machine Tools, 6th Ed. by S. F. Krar, A. R. Gill, P.
Smid; McGraw Hill Higher Education

• Degarmo’s Materials And Processes In Manufacturing, 10th Ed.

By J.T Black, R. A. Kohser; John Wiley And Sons

• Manufacturing Engineering And Technology, 5th

Ed. By S. Kalpakjian, S. R. Schmid;
Pearson Education

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