Manufacturing Processes (Pr.

Muhammad Waqas Mustafa

Jr Lecturer
Mechanical Engineering Department
WEC, University of Wah
 Objective – Lab 06
To demonstrate the Lathe Machine and Lathe operations like facing,
threading, grooving, drilling, knurling, boring, turning, step-turning
and taper-turning on Lathe Machine.
Complete a job on Lathe Machine which involves 3-5 above mentioned
operations.
Lathe Machine
 A lathe is a machine tool
that rotates a workpiece
about an axis of rotation to
perform various operations.
 Such as cutting, knurling,
drilling, facing, and
turning, with tools that are
applied to the workpiece to
create an object with
symmetry about that axis.

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Parts of Lathe Machine
 Bed
 Tool post
 Chuck
 Head stock
 Tail stock
 Lead screw
 Legs
 Carriage
 Apron
 Chips pan
 Guide ways
 Speed controller
 Spindle

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Parts of Lathe Machine …
 Bed
 Tool post
 Chuck
 Head stock
 Tail stock
 Lead screw
 Legs
 Carriage
 Apron
 Chips pan
 Guide ways
 Speed controller
 Spindle

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Parts of Lathe Machine …
 Bed: It is the main body of the machine. All
main components are bolted on it. It is usually
made by cast iron due to its high compressive
strength and high lubrication quality. It is made
by casting process and bolted on floor space.
 Tool post: It is bolted on the carriage. It is used
to hold the tool at correct position. Tool holder
mounted on it.
 Chuck: Chuck is used to hold the workspace. It
is bolted on the spindle which rotates the chuck
and work piece. It is four jaw and three jaw
according to the requirement of machine.
 Head stock: Head stock is the main body parts
which are placed at left side of bed. It serves as
holding device for the gear chain, spindle,
driving pulley etc. It is also made by cast iron.

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Parts of Lathe Machine …
 Tail stock: Tail stock situated on bed. It is
placed at right hand side of the bed. The main
function of tail stock to support the job when
required. It is also used to perform drilling
operation.
 Lead screw: Lead screw is situated at the
bottom side of bed which is used to move the
carriage automatically during thread cutting.
 Legs: Legs are used to carry all the loads of the
machine. They are bolted on the floor which
prevents vibration.
 Carriage: It is situated between the head stock
and tail stock. It is used to hold and move the
tool post on the bed vertically and horizontally.
It slides on the guide ways. Carriage is made by
cast iron.

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Parts of Lathe Machine …
 Apron: It is situated on the carriage. It consist
all controlling and moving mechanism of
carriage.
 Chips pan: Chips pan is placed lower side of
bed. The main function of it to carries all chips
removed by the work piece.
 Guide ways: Guide ways take care of
movement of tail stock and carriage on bed.
 Speed controller: Speed controller switch is
situated on head stock which controls the speed
of spindle.
 Spindle: It is the main part of lathe which holds
and rotates the chuck.

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Parts of Lathe Machine …

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Lathe Machine Operation & Working
Lathe machine is used to cut the metal from
cylindrical work piece, and convert it into desire
shape. It turns the cylindrical work piece, and during
turning a sharp edge cutting tool introduce, which
cuts the metal. Its working can be described as
follow:
 Lathe machine is used to cut the metal from
cylindrical work piece, and convert it into desire
shape.
 A cylindrical work piece fixed to the chuck. A
chuck may have three jaw (cannot move
independently) or four jaw (can move
independently) according to the requirement. The
work piece is at the center or some eccentric
according to the process perform.

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Lathe Machine Operation & Working …
 The spindle starts to rotate and set it at desire speed. The spindle speed plays
a huge role during cutting. The spindle rotates the chuck and work piece.
 Now check the work piece is turning properly. If it not set the work piece
using dial gauge.
 Now set the tool at desire feed by moving the tool post and carriage. The
feed also play main role during cutting. Large feed may cause unwanted
temperature increase.
 After it, tool is introduced between moving work piece at desire feed rate.
It cut the metal from work piece. The feed rate is set at the cutting
condition.
 Now all unwanted metal is removed by moving the carriage horizontally
and vertically as desire according to the job requirement. After completing
all necessary process we would get a well finished job as desired.
 Lathe can perform turning, boring, chamfering, shaping, facing,
drilling, knurling & grooving as shown in figure.

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Lathe Machine Operation
(Facing, Turning, Grooving & Knurling)

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Types of Lathe Machine
There are many types of lathes, but they
are broadly classified into seven types as
under:
 Speed lathes
 Engine lathes
 Bench lathes
 Tool room lathes
 Capstan and turret lathes
 Special purpose lathes
 Automatic lathes Speed lathe.
This lathe is simplest of all
the lathes and is easily understandable
to everyone.

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Types of Lathe Machine & Operations …

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Lathe Operations
 Facing
 Thread cutting
 Grooving
 Drilling
 Knurling operation
 Boring
 Turning

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Lathe Operations …
Facing
 It is an operation of reducing the length of the
workpiece by feeding the perpendicular to the
lathe axis. This operation of reducing a flat surface
on the end of the workpiece. For this operation,
regular turning tool or facing tool may use. The
cutting edge of the tool should set to the same
height as the centre of the workpiece.
 Facing consist of 2 operations:
 Roughing: Here the depth of cut is 1.3mm
 Finishing:  Here the depth of cut is 0.2-
0.1mm.

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Lathe Operations …
Thread Cutting
 It is the important operation in the lathe to obtain the
continuous “helical grooves” or “threads”.
 When the threads or helical grooves are formed on the out
surface of the workpiece is called external thread cutting.
When the threads or helical grooves are formed on the inner
surface of the workpiece is called internal thread cutting.
The workpiece is rotating between the two centres i.e. live
centre and dead centre on the lathe.
 Here the tool is moved longitudinally to obtain the required
type of the thread. When the tool is moved from right to the
left; we get the left-hand thread. Similarly, when the tool is
moved from left to the right; we get the right-hand thread.
 Here the motion of the carriage is provided by the lead screw.
A pair of gears drives the lead screw and by rotating the
handle the depth of cut can be controlled.

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Lathe Operations …
Grooving
 It is the process of reducing the
diameter of a workpiece over a very
narrow surface.
 It is done by a groove tool. A grooving
tool is similar to the parting-off tool.
 It is often done at the end of a thread or
adjacent to a shoulder to leave a small
margin.

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Lathe Operations …
Drilling
 Drilling is the operation of producing a
cylindrical hole in a workpiece. It is done by
a rotating tool, the rotating side of the cutter,
known as drilling drill. In this operation,
The workpiece is revolving in a chuck or a
faceplate and the drill is held in the tailstock
drill holder or drill chuck.
 The feeding is adopted is affected by the
movement of the tailstock spindle. This
method is adopted for the drilling regular
shaped workpiece.

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Lathe Operations …
Knurling
 It is an operation of obtaining a diamond shape
on the workpiece for the gripping purpose.
This is done to provide a better gripping
surface when operated by hands. It is done
using a knurling tool. The tool consists of a
set of hardened steel roller, and it is held
rigidly on the tool-post.
 Knurling is done at the lowest speed available
on a lathe. It is done on the handles and also in
case of ends of gauges. The feed varies from 1
to 2 mm per revolution. Two or three cuts may
be necessary to give the full impression.

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Lathe Operations …
Boring
 Boring is the operation of enlarging the hole
which is already drilled, punched or forged. It
cannot produce a hole. Boring is similar to the
external turning operation and can be performed
in a lathe. In this operation, the workpiece is
revolved in a chuck or a faceplate and the tools
which are fitted to the tool post is fed into the
work.
 It consists of a boring bar having a single-point
cutting tool which enlarges the hole. It also
corrects out of roundness of a hole. This method
adopted for boring small-sized works only. The
speed of this process is slow.

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Lathe Operations (Boring) …

Boring …
 Counterboring
 Taper Boring
 Tapping
 Undercutting

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Lathe Operations (Boring) …
Counterboring
 Counterboring is the operation of enlarging the end of
the hole through a certain distance. It is similar to a
shoulder work in external turning. Tapping
 Tapping is the operation of cutting internal threads of small
 The operation is similar to boring and plain boring tools
or a counterbore may be used. The tool is used called a diameter using a multipoint cutting tool called the tap. In a lathe,
counterbore. The speed is slightly less than drilling. the work is mounted on a chuck or on a faceplate and revolved at
a very slow speed. A tap of required size held on a special fixture
Taper Boring is mounted on the tailstock spindle.
 The principle of turning a tapered hole is similar to the Undercutting
external taper turning operation and is completed by
rotating the work on a chuck or a faceplate. The feeding
 Undercutting is similar to grooving operation when performed
tool is at an angle to the axis of rotation of the inside a hole. It is the process of boring a groove or a large hole at
workpiece. a fixed distance from the end of a hole.
 A boring tool is mounted on the tool post and by
 This is similar to the boring operation, except that a square
swiveling the compound slide to the desired angle, a nose parting is used. Undercutting is done at the end of an
short taper hole is machined by hand feeding. internal thread or a counterbore to provide clearance for the tool
or any part.
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Lathe Operations …
Turning
 It is the most common type of operation in all
lathe machine operations. Turning is the
operation of removing the excess material from
the workpiece to produce a cylindrical surface
to the desired length.
 The job held between the centre or a chuck and
rotating at a required speed. The tool moves in
a longitudinal direction to give the feed towards
the headstock with proper depth of cut. The
surface finish is very good.

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Lathe Operations (Turning) …
Turning …
 Straight Turning
 Rough Turning
 Shoulder Turning
 Eccentric turning
 Taper Turning
 Form tool method
 Combined feeds method
 Compound rest swivel method
 Taper turning attachment method
 Tailstock set over method

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Lathe Operations (Turning) …

Straight Turning Shoulder Turning

 The workpiece is held on the chuck and it is made to  When a workpiece has different diameters and is to be turned,
rotate about the axis, and the tool is fed parallel to the the surface forming steps from one diameter to the other is
lathe axis. The straight turning produces a cylindrical called the shoulder and machining this part of the workpiece is
surface by removing excess metal from the workpiece. 
called shoulder turning.
Rough Turning
Eccentric Turning
 It is the process of removal of excess material from the  When a cylindrical surface two separate axis of rotation, with
workpiece in minimum time by applying high rate feed
and heavy depth of cut. in rough turning the average the first axis, is offset to the other axis then such a workpiece
depth of cut 2mm to 4mm can be given and feed is from is machined by the operation called eccentric turning. Here
0.3 to 1.5mm per revolution of the work. three sets of centre holes are drilled.
 By holding the workpiece at these three centres the machining
operation for each of the surface can be completed.

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Lathe Operations (Turning) …
Taper Turning
 A “taper” is the uniform increase or decrease in the  In the case of a lathe, the taper on a given workpiece is obtained
diameter of the workpiece and measured along with its by tuning the job and feeding the tool at an angle to produce a
gradual increase or decrease in the diameter of the workpiece.
length.
 The two important types of tapers are:
 Taper turning means to produce a conical shape by a  More Taper here, the angle is very small and varies from
gradual reduction in diameter from a cylindrical
1.4 to 1.5°.
workpiece.
 Metric Taper is available in seven standard sizes with
 The amount of taper in the workpiece is usually standard taper angles.
specified on the basis of the difference in diameter of the  Methods of Taper Turning:
taper to its length. It is known as a cone and it is
indicated by the letter K.  Form tool method
 Combined feeds method
 It has the formula K = D-d / L to produce the taper on
the workpiece. Where, D = Larger diameter of taper & d  Compound rest method or swiveling compound rest method
= Small diameter of taper.  Tailstock set over method
 Taper turning attachment method
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Lathe Operations (Methods of Taper Turning) …
Form tool method
 Here the taper length obtain is equal to the width of the form tool. To obtain
the required size of the taper the form tool is fed slowly straight into the
workpiece by operating the cross slide perpendicular to the lathe axis.
 This is the simplest method of taper turning. It is limited to obtain small
taper length such as chamfering the side of the workpiece. The method is
done at a faster rate.
Combined feeds method
 The combined feed is made with the movement of a tool in longitudinal and
lateral direction simultaneously while moving the workpiece.

 The taper, which we are going to obtain, is equal to the resultant to the
magnitude of the longitudinal and lateral feeds. Changing the feeds rates in
both directions can change the direction and the taper angle.

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Lathe Operations (Methods of Taper Turning) …
Compound rest swivel method
 Here the workpiece rotates and the tool is fed at an angle by swiveled compound rest. The base of
the compound rest is graduated in degrees.
 The taper angle is the angle at which the compound rest to be rotated is calculated by using the
formula tanα = D-d / 2L, where, D= bigger diameter, d = smaller diameter, L = length of the
workpiece.
 Compound rest can be swiveled to the required angle α. Once the compound rest is set to
a particular angle then the tool is moved by compound rest and wheel.
Tailstock set over method
 Here the workpiece on the job is tilted at the required taper angle. The tool is fed parallel to the axis.
 The tilting of the workpiece or the job to the required taper angle is achieved by the movement of
the tailstock with the help of tailstock set over the screw. This method is useful for small tapers.

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Lathe Operations (Methods of Taper Turning) …
Advantages of taper turning attachment:
Taper turning attachment method  Internal tapers can be obtained accurately.
 This method is similar to the compound rest method.  Large size tapers can be easily obtained.
 Here the job or workpiece rotates and the tool is fed at  Once the attachment is set the taper turning
the taper angle α. operation can do at a faster rate.
 In this, arrangement, which has guide block graduated in  By setting the taper angle to ‘zero’ we can carry
degrees, with the help of this the block can be required out plain turning. 
taper angle to the lathe axis.
Disadvantages of taper turning attachment:
 The taper angle is calculated similarly to  It requires additional mounting facilities.
the compound rest method using the formula: tanα = D-d
/ 2L.  Fitting and removing attachment consume more
time.
 The attachment has to take large forces.
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Task

 Submit a report comprises of the basic introduction of topic, topic

details, operation procedure (with examples, figures / suitable
schematic diagrams), deduce valid conclusions / comments.

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Related Topics

 22 Different Types of Lathe Machine Operations

Video Link: https://www.theengineerspost.com/lathe-machine-operations/

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 Thank You.

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Department of Mechanical Engineering, WEC, University of Wah