COMMAN OPERATIONS ON

LATHE MACHINE
DR. D. N. RAUT
SY (PROD) 2020, COVID BATCH
 Operations on Lathes
•Turning

 Part is rotated while it is being machined.

 Axisymmetric jobs are produced

 Starting material is generally a workpiece made

by other processes, such as casting, forging,
extrusion, drawing, or powder metallurgy.
 Principle of Working
 Workpiece hold between two rigid and strong
supports called centers or in a chuck or face plate
which revolves
 The cutting tool is rigidly held and supported in a tool
post which is fed against the revolving work.
 Cutting tool removes metal in the form of chips by
shear action.
 The normal cutting operations are performed with the
cutting tool fed either parallel or at right angles to the
axis of the work. The cutting tool may also be fed at an
angle relative to the axis of work for machining tapers
and angles.
 LETHE OPERATIONS
1. Job is held and driven by chuck with the
other end supported on the tail stock centre.
2. Job is held between centers and driven by
carriers and catch plates.
3. Job is held on a mandrel, which is
supported between centers and driven by
carriers and catch plates.
4. Job is held and driven by a chuck or a
faceplate or an angle plate.
 HOLDING THE WORKPIECE
BETWEEN CENTERS / A CHUCK
• 1. Straight turning • 8. Forming

• 2. Shoulder turning • 9. Filing

• 3. Taper turning • 10. Polishing

• 4. Chamfering • 11. Grooving

• 5. Eccentric turning • 12. Knurling

• 6. Thread cutting • 13. Spinning

• 7. Facing • 14.Spring winding

WORKPIECE BETWEEN CENTERS
TURNING OPERATIONS
Facing Operation
HOLDING WORK: CHUCK/ FACEPLATE/ANGLE PLATE

•1. Undercutting •5. Reaming

•Parting-off •6. Boring

3. Internal thread •7. Counter boring

cutting
•8. Taper boring
4. Drilling
•9. Tapping
LATHE OPERATIONS
LATHE OPERATIONS
LETHES OPERATINS
 OPERATIONS WHICH ARE
PERFORMED BY USING SPECIAL
LATHE ATTACHMENTS ARE:

• Milling • Grinding

• Taper Turning • Knurling

• Threading
OPERATIONS ON SPECIAL Attachments
 TURNING
• .
 Turning
 Turning: to produce straight, conical,
curved, or grooved work pieces
• such as shafts, spindles, and pins.
 In this process the tool is fed along the
axis of the spindle. Turning is the
removal of metal from the outer
diameter of a rotating cylindrical work
piece.
 Turning Operations
•Facing: to produce a flat surface at the end of the part and
perpendicular to its axis , useful for parts that are
assembled with other components. Face grooving
produces grooves for applications such as O-ring seats
 Turning Operation
•Facing:Facing is the process of making flat surfaces on a
lathe.
 The job is held on a faceplate or chuck and the tool is fed
at right angles to the bed to obtain flat surfaces.
 using a 4- jaw chuck you can face rectangular or odd-
shaped work to form cubes and other non-cylindrical
shapes.
 Operation on Lathes
Straight turning: The work is turned straight when it is
made to rotate about the lathe axis and the tool is fed
parallel to the lathe axis. The straight turning produces a
cylindrical surface by removing excess metal from the
workpieces
 Operation on Lathes
Shoulder turning/Step Turning:
 Process of turning different surfaces having
different diameters.
 Thework is held between centres and the tool is
moved parallel to the axis of the lathe.
 Also called shoulder turning.
 Turning Operation
Forming: A forming tool having cutting edges conforming to
the shape required is fed straight into the work for turning a
convex, concave or any irregular shape
 Turning Operation
Filing:finishing operation that remove
burrs, sharp corners and feed marks from
the workpiece.
•Polishing: After filing, the surface quality
is improved by the polishing operation with
the help of emery cloth of fine grades.
 Turning Operation
•Grooving/Recessing/Necking:
 cutting a narrow groove on the cylindrical surface
 often done at the end of thread or adjacent to a
shoulder to leave a margin.
 The groove may be square, radial or beveled in shape.
 Turning
• Cutting with form • .
tools: to produce
various axisymmetric
shapes for functional
or aesthetic purposes
 Turning
• Boring: to enlarge a • .
hole or cylindrical
cavity made by a
previous process or to
produce circular
internal grooves
 Turning
• Drilling: to produce a .
hole , which may be
followed by boring to
improve its
dimensional accuracy
and surface finish.
 Turning Operation
• Parting: also called .
cutting off, to cut a
piece from the end of
a part, as is done in
the production of
slugs or blanks for
additional processing
into discrete products
 Operations on Lathe
• Threading: .
To produce external or
internal threads
 Operations on Lathe
• Knurling: .
• to produce a
• regularly shaped
roughness on
cylindrical surfaces, as
in making knobs and
handles
•Knurling:Process of embossing a diamond shaped pattern
on the surface of a work piece by making a series of
indentations or depressions
 The knurling tool holder has one or two hardened steel
rollers with edges of required pattern.
 The tool holder is pressed against the rotating work. The
rollers emboss the required pattern.
 Knurls are available in coarse, medium and fine pitches.
The patterns may be straight, inclined or diamond
shaped to provide an effective gripping surface, better
appearance, to slightly increase the diameter of the work
Spinning :
 also known as spin forming or spinning or metal turning
 a disc or tube of metal is rotated at high speed and formed into an
axially symmetric part.
 This process is covered in detail in sheet metal forming processes.
Spring winding:
 Method of springs winding performed on lathe. Not in our scope to
discuss here.
Undercutting:
 Done at the end of a hole
 Near the shoulder of stepped cylindrical surfaces
 At the end of the threaded portion in bolts
 Enlarging the diameter if done internally
and reducing the diameter if done
externally over a short length.
 Mainly to make fits perfect. Boring tools
and parting tools are used
 Operations on Lathe
Parting-off: The parting or cutting off is the operation of cutting away a desired
length of the workpiece, i.e., dividing the workpiece in two or more parts
 Operations on Lathe
Drilling
 Making holes generally in the centre of the workpiece with the help
of drills.
 The drill is held in the tailstock and the drilling operation is carried out by
advancing the drill in the workpiece by rotating the handle of the tail stock.
 First face the end, then drill hole using a center drill and
then
perform drilling.
 Hole become oversized and misaligned without use of centre drill.
Operations on Lathe
 Operations on Lathe
 Reaming: process of enlarging holes to accurate
sizes. always carried out after drilling.
 similar to drilling -reamer is held in tailstock
 Two broad categories:Hand reamers and Machine
reamers.
 Operations on Lathe
•Boring:Enlarging a hole produced by drilling, casting,
punching or forging with the help of a single point tool.
 Boring cannot originate a hole.
 Job is held in a chuck or face plate and a boring tool held
on the tool post are fed into it.
 The operation is similar to external turning in that the
feed and depth of cut are given by the longitudinal
and cross motions of the tool respectively.
 Operations on Lathe
•Counter .
boring:Process of
boring a hole to more
than one diameter on
the same axis
 Needed for
receiving the head
of a socket head
cap screw.
 Carried out with a
boring tool.
Operations on Lathe
•Taper boring:
Process of making
angular or tapered
bores
•Tapping: Process of
making internal
threads by using a
tool called Tap
 Operations on Lathe
•Milling
 Operation of removing material from a work piece with multi point
rotating cutter generally on milling machines
 In absence of milling machine, can be performed on lathe by
milling attachment
 On a lathe, the milling cutter is
held in the headstock and the
work piece is clamped in
movable vice.
 cutter revolving against the
• work piece.
 used for milling small work
pieces only, where a milling
machine cannot be used
 Operations on Lathe
•Grinding : Removing material by means of rotating
abrasive wheel for finishing operations.
 work piece is held between the centres and the grinding
operation is carried out by mounting the tool post
grinder on the compound slide.
 Carried out after rough turning, to provide an accurate
finish by removing a small amount of material.
 TAPERS AND TAPER TURNING
• A taper is defined as a uniform increase or decrease in diameter of a
piece of work measured along its length.
• In a lathe machine, taper turning means to produce a conical surface by
gradual reduction in diameter from a cylindrical job.
• Taper in the British System is expressed in taper per foot or taper per
inch.
• Taper per inch = (D – d)/l
• Where,
• D = is the diameter of the large end of cylindrical job,
• d = is the diameter of the small end of cylindrical job, and
• l = is the length of the taper of cylindrical job, all
expressed in inches,
 TAPERS AND TAPER TURNING
1.By swiveling the compound rest,
2.By setting over the tailstock centre,
3.By a broad nose form tool,
4.By a taper turning attachment,
5.By combining longitudinal and cross feed in a
special lathe and
6.By using numerical control lathe
• Some of the important taper turning methods are
discussed as under
Taper Turning by Swivelling the Compound Rest
Taper Turning by Swivelling the Compound Rest
Taper Turning Attachment Method
 Taper Turning with Tailstock set over Method

Tail stock set over = Taper length × Sine of half of taper angle (D –
d) / 2 = l × sin (a/2)
D = is the diameter of the large end of cylindrical job,
d = is the diameter of the small end of cylindrical job, and
l = is the length of the taper of cylindrical job, all expressed in inches,
a = taper angle
When a part length of the job is to be given taper then
tail stock set= ((D – d)/2)) × (total length of the cylindrical job/length of
taper) = l × sin (a/2) × (total length of the cylindrical job/length of taper)
 Form Tool Method& Taper Turning with Double Feeds

Form Tool method in which a taper form is used to obtain tapers. It is limitedto
short external tapers. The edge tool must be exactly straight for accurate
work.

Taper turning can also be cut by combining the two feeds shows this
arrangement of taper turning, which is good method of taper turning. In certain
lathes both longitudinal and cross feeds may be engaged simultaneously causing
the tool to follow a diagonal point which is the resultant of the magnitude of the
two feeds. The direction of resultant feed may be changed by varying the rate of
feeds by change gears provided inside the apron of the lathe.
 Thread Cutting on Lathe
• Byvarious cutting tools made of HSS or often
cemented carbide tools.
• Centre lathes to single spindle automats are used
• Special purpose lathes and CNC lathes including
turning centers used
• Threads are produced in centre lathes by various
methods
• By single point cutting tool
• By thread chasing (covered later)
• By attachments of die threading and
tapping (covered later)
Thread Cutting
 Cutting with Single Point Tool on Lathe
• A single-point cutting tool is used to produce a thread form
on a cylinder or cone.
• The tool moves linearly while the precise rotation of the
workpiece determines the lead of the thread.
• The process can be done to create external or internal
threads (male or female).
• In external thread cutting, the piece can either be held in a
chuck or mounted between two centers.
• With internal thread cutting, the piece is held in a chuck.
The tool moves across the piece linearly, taking chips off
the workpiece with each pass.
 Cutting with Single Point Tool on Lathe
a) Operator should be fully conversant with different terms,
types, starts and shape of threads.
b) External or internal threads may be cut on lathe either with
the help of a
• die or tap respectively or a thread cutting tool may be used.
c) A certain relation is needed between job revolutions and
revolutions of lead screw to control the linear movement of
the tool, parallel to the job length when half nut is engaged
with lead screw.
d) The tool should be ground to the proper shape and profile of
the thread to be cut.
 Cutting with Single Point Tool on Lathe
e)Many lathes are provided with quick-change
gearbox in which different ratios of spindle and
lead screw revolutions can be readily obtained
by simply shifting the gear change lever. In other
lathes, for cutting different pitches of threads,
every time gears are changed.
f) For cutting threads on a lathe, headstock spindle
is connected with the lead screw through gears
in such a way that positive carriage feed is
obtained and the lead screw is driven at a
predetermined speed in relation to the spindle
speed.
Cutting with Single Point Tool on Lathe
 Cutting with Single Point Tool
When cutting a screw thread, the tool is moved along the bed and is driven
by a nut engaging with the lead screw. The lead screw is driven by a train of
gears from the machine spindle. The gear train may be arranged in one of
the following ways
A. Simple gear train

It includes only three gears driver,

driven and some suitable intermediate
gear. The intermediate gear has no
effect on the ratio. It simply acts as a
connection that is used to fill up the
distance gap between the driver, and
the driven gear and makes the lead
screw rotate in the same direction of
the machine spindle.
 Cutting with Single Point Tool
.B Compound gear train. Sometimes driver and driven gear ratio becomes
so typical that the selection of gears to arrange in a simple train becomes
difficult. For example Dr and Dn ratio is 4/26, and then a set of gears, which
can give this ratio in the simple train, may become difficult. In such cases the
solution is obtained with the use of compound wheel train, the gear ratio
become

Gears supplied with lathes, generally, range from 20 to 120 teeth in steps of 5
teeth with two 40s or two 60s. The lead screw on lathes is always single-
threaded and of a pitch varying from 5 to 10 mm depending on the size of the
machine. For English lathes, the most common screw threads have 2, 4, or 6
tpi.
Calculate suitable gear trains for the
following cases
a. 2.5 mm pitch on a 6 mm lead screw
b. 11 tpi on a 4 tpi lead screw
c. 7 threads in 10 mm on 6 mm lead screw
d. 7/22 in. pitch, 3 start on a lathe with 2 tpi
e. 2.5 mm pitch on a 4 tpi lead screw
f. 12 tpi on a lathe having 6 mm pitch lead screw
 Cutting with Single Point Tool on Lathe
Thread Catching
 Required depth of a thread cannot be obtained in a single
cut of tool and several successive cuts are needed.
 In the first cut, tool travels up to the job length, and then it is
to be taken to the starting position for giving the second cut.
 Now if tool is not fed exactly in the previous groove, it may
form a new groove thus wastage of the job.
 Modern machines are provided with facilities to reverse the
rotation of job, which will bring the tool to original position
without disengaging the half-nut.
 But few machines are not equipped with such facilities. In
those machines tool is to be brought back by some other
means.
 Cutting with Single Point Tool on Lathe
Thread Catching
The process of setting the tool repeatedly in the previously formed
groove is called thread catching or thread chasing. Few methods of
thread chasing are given below
(a)At the end of each travel of the tool, take it back from the job surface
and stop the machine. Disengage half-nut from lead screw and return it
by hand to the starting point of the cut. By trial method, set the tool in
right groove, start the machine to have the fresh cut after giving a certain
feed to the tool.
(b)Do not disengage half-nut from lead screw at the end of each cut. By
reversing the direction of lead screw, bring the carriage to the starting
position of the cut. A mark may be given on the bed by the side of the
carriage; this will help in setting the carriage immediately. This method is
useful for cutting threads on short lengths or in blind holes or for threads
of odd pitches, which are difficult to cut even with the help of chasing dial
method.
 Cutting with Single Point Tool on Lathe
Procedure for External Threads
 Hold the job between the lathe centres or in chuck as required and turn it to the
size of the major diameter of thread to be cut.
 Select suitable change gear set for cutting required pitch of thread and
arrange them. At the end of job, which will be starting end for every cut
while threading, turn a very small step of diameter equal to the minor
diameter to be cut i.e. recessing.
 Set the tool properly, swivel and clamp the compound rest at an angle if
required as discussed already. Adjust the spindle speed for threading.
 Bring the tool at the starting point, take a certain depth of cut and
engage the half nut with lead screw. This will move the tool along the job
length forming a thread groove.
 Have few successive cuts to obtain the required depth of thread. That
small step turned at the job and will guide you to feed the tool up to a
required depth.
 When threading is complete, stop the lathe and measure the depth of
the threads with a thread pitch gauge.
 Cutting with Single Point Tool on Lathe
Procedure for Internal Threads
 Hold the job in a chuck. Make a hole equal to the minor diameter of the
thread. A common practice is to make the hole slightly larger than minor
diameter of thread for providing a clearance between the mating parts.
 Turn a small groove at the end of the thread length equal to the major
diameter of the thread to guide the operator for maintaining the correct
depth of thread.
 Rest of the procedure is the same as for cutting external threads.

Special care is needed while threading a blind hole

• By moving carriage, bring the tool to the job front and let it go inside the
hole till it reaches the point at, which the last thread will terminate.
• At this position, make a line on the bed to guide the operator that he is
not to allow the carriage to come towards the left ahead of this mark
 Cutting Right hand & Left Hand Threads
Cutting Right Hand Threads
 Direction of rotation of job and lead screw should be
same
i.e. towards the operator (counter clock wise).
 For threading on job, start the cut from tail stock side.
 After engaging half nut, see that the tool moves from
the tail stock side to headstock side.

Cutting Left Hand Threads

 Reverse the direction of rotation of lead screw
with the direction reversing mechanism lever.
 Start the cut on job from headstock side so that when
half nut is engaged tool should move from headstock to
tail stock side.
 Cutting Multistart Threads
 Cutting procedure of multi start threads is similar to that of cutting
single start threads.
 In multi start thread, circumference of the job should be divided in to as
many parts as the starts of the threads and thus every part of the
divisions of the circumference of job becomes the starting point for the
new start.
 Several methods are given below to divide the job circumference
to take cuts for different starts
(a) Faceplate of lathe may be divided and marked in as many parts as the
starts are to be had on the job. Every mark will give the starting
position for new start of the thread.
(b) Indexing faceplate of typical construction for cutting multi start threads
are usually available. On the plate, means are provided to rotate the job
through
 Cutting Multistart Threads
c) Compound rest is also used for adjusting the tool to have
the correct spacing while cutting multi start threads. Set the
compound rest parallel to work axis. When one start of the
thread is cut, then the tool is moved a distance equal to the
pitch to be cut. This method is mostly used for cutting internal
threads. Make sure that there is no backlash in the compound
rest screw.

The rest of the procedure is to get the lines of different starts

inscribed on the job surface along the length with a thread
cutting tool, cut rough profiles of different starts. For finishing
the threads, finish first start completely and then one after the
other.
 Tapered Threads
• The only precaution used for cutting
threads on a tapered surface is that the
threading tool is set perpendicular to the
lathe axis and not to the tapered surface.
Rests of the procedure is same. Only
taper turning attachment is employed for
taper turning and thread cutting

•
Operations On Lathe
 Speed
• CUTTING SPEED : Cutting speed for lathe work may
be defined as the rate in meters per minute at
whichthe surface of the job moves past the cutting
too
• Cutting speed is highly important for good tool life
and efficient cutting.
• Too slow cutting speeds reduceproductivity and
increase manufacturing costs whereas too high
cutting speeds result inoverheating of the tool and
premature failure of the cutting edge of the tool.
 Factors affect the cutting speed
• (i) Kind of material being cut,
• (ii) Cutting tool material,
• (iii) Shape of cutting tool,
• (iv) Rigidity of machine tool and the job piece a
• (v) Type of cutting fluid being used.
• Calculation of cutting speed Cs, in meters per
minuteCs = ((22/7) × D × N)) /1000
• Where
• D is diameter of job in mm. N is in RPM
 Feed
• Feed is defined as the distance that a tool
advances into the work during one revolution
of the headstock spindle.
• It is usually given as a linear movement per
revolution of the spindle or job.
• During turning a job on the center lathe, the
saddle and the tool post move along the bed
of the lathe for a particular feed for cutting
along the length of the rotating job.