IPE 4821

MACHINE
TOOLS
Lecture 2: General
Purpose Machine Tools
( Lathe Machine )
Reference Books

ELEMENTS OF MACHINE MACHINING FUNDAMENTALS OF

TOOLS BY DR. M. TECHNOLOGY BY HELMI MACHINING AND MACHINE
ANWARUL AZIM A. YOUSSEF TOOLS BY GEOFFREY
BOOTHROYD AND WINSTON
A. KNIGHT
 Lathe Machine

• The lathe is used for production of

cylindrical work.

• The workpiece is rotated while the cutting

tool movement is controlled by the
machine.
 Classification of Lathe
(a) According to configuration
• Horizontal
-Most common
• Vertical
- Occupies less floor space, only some large lathes are of this type.
(b) According to purpose of use
• General purpose
- Very versatile where almost all possible types of operations are carried out on wide ranges
of size, shape and materials of jobs; example : center lathes
• Single purpose
- Only one (occasionally two) type of operation is done on limited ranges of size and material of
jobs; example – facing lathe, roll turning lathe etc.
• Special purpose
- Where a definite number and type of operations are done repeatedly over long time on a specific
type of blank; example: gear blank machining lathe etc.
Lathe Machine
Description of a lathe (Centre Lathe)
 Description of a lathe (Centre Lathe)

• The Centre Lathe is used to manufacture cylindrical shapes from a range of materials including;
steels. Many of the components that go together to make an engine work have been
manufactured using lathes. These may be lathes operated directly by people (manual lathes) or
computer-controlled lathes (CNC machines) that have been programmed to carry out a
particular task. A basic manual centre lathe is shown in previous slide. This type of lathe is
controlled by a person turning the various handles on the top slide and cross slide to make a
product / part.

• These machines consist of, at the least, a headstock, bed, carriage and tailstock. The better
machines are solidly constructed with broad bearing surfaces (slides or ways) for stability and
manufactured with great precision. However, there may be different varieties.
 Description of a lathe (Centre Lathe)

The Headstock :
The headstock houses the main spindle, speed change mechanism and change gears The headstock is
required to be made as robust as possible due to the cutting forces involved, which can distort a lightly
built housing, and induce harmonic vibrations that will transfer through to the work piece, reducing the
quality of the finished work piece. Levers on the front of the headstock allow various rotational speed to
be selected. In most cases, an electric motor mounted rear of the machine in the headstock for driving the
spindle and gears.
Bed :
The bed is a robust base that connects to the headstock and permits the carriage and tailstock to be
aligned parallel with the axis of the spindle. This is facilitated by hardened and ground ways which
restrain the carriage and tailstock in a set track. The carriage travels by means of a rack and pinion
system, lead screw of accurate pitch, or feed screw.
Types of beds include inverted "V" beds, flat beds, and combination "V" and flat beds. "V" and
combination beds are used for precision and light duty work, while flat beds are used for heavy duty
work.
 Description of a lathe (Centre Lathe)
Feed and lead screws :
The feed screw is a long driveshaft that allows a series of gears to drive the carriage mechanisms. These gears are in the
apron of the carriage. Both the feed screw and lead screw are driven by either the change gears (on the quadrant) or an
intermediate gearbox known as a quick-change gearbox or Norton gearbox. These intermediate gears allow the correct
ratio and direction to be set for cutting threads or worm gears. Tumbler gears are provided between the spindle and gear
train along with a quadrant plate that enables a gear train of the correct ratio and direction to be introduced. This
provides a constant relationship between the numbers of turns the spindle makes, to the number of turns the lead screw
makes. This ratio allows screw threads to be cut on the work piece without the aid of a die.

Carriage :
In its simplest form the carriage holds the tool bit and moves it longitudinally (turning) or perpendicularly (facing) under
the control of the operator. The carriage is driven along the bed ( lateral z) by lead screw(for screw cutting) or a rack and
pinion gear and feed rod(for turning). Both the lead screw and feed rod are connected to the main spindle through a train
of gears. Alternatively, the carriage can remain stationary on the bed, and the gear train can be used to drive the
toolholder across the carriage (longitudinal motion X) using a lead screw in the cross slide.
 Description of a lathe (Centre Lathe)

Cross-slide :
The cross-slide stands atop the carriage and has a feed screw that travels perpendicular to the main spindle
axis. This permits facing operations to be performed, and the depth of cut to be adjusted. This feed screw
can be engaged, through a gear train, to the feed shaft (mentioned previously) to provide automated 'power
feed' movement to the cross-slide. On most lathes, only one direction can be engaged at a time as an
interlock mechanism will shut out the second gear train.

Compound rest :
The compound rest (or top slide) is the part of the machine where the tool post is mounted. It provides a
smaller amount of movement along its axis via another feed screw. The compound rest axis can be adjusted
independently of the carriage or cross-slide. It is utilized when turning tapers, to control depth of cut when
screw is cutting or precision facing, or to obtain finer feeds (under manual control) than the feed shaft
permits.
 Description of a lathe (Centre Lathe)
Tool post :
The single point cutting tool is held in a tool holder or tool post, which is mounted on a cross slide, which in turn
mounted on the carriage. The tool bit is mounted in the tool post which may be of the American lantern style, traditional
4-sided square styles, or in a quick-change style. The advantage of a quick-change set-up is to allow an unlimited
number of tools to be used (up to the number of holders available) rather than being limited to 1 tool with the lantern
style, or 3 to 4 tools with the 4-sided type. Interchangeable tool holders allow the all the tools to be preset to a center
height that will not change, even if the holder is removed from the machine.

Tailstock :
The tailstock is a tool holder directly mounted on the spindle axis, opposite the headstock. The spindle does not rotate
but does travel longitudinally under the action of a lead screw and hand wheel. The spindle includes a taper to hold drill
bits, centers and other tooling. The tailstock can be positioned along the bed and clamped in position as required. There
is also provision to offset the tailstock from the spindle's axis, this is useful for turning small tapers.

The workpiece is usually gripped at one end by a chuck mounted at the end of the main spindle and supported at the
other end by a center mounted in the tailstock.
 Lathe Description

Tailstock: part of job holding system

Drive: comes from electric motor
 Lathe-different parts
• Bed: Usually made of cast iron. Provides a heavy rigid frame on which all the main components are
mounted.
• Ways: Inner and outer guide rails that are precision machined parallel to assure accuracy of movement.
• Headstock: mounted in a fixed position on the inner ways, usually at the left end. Using a chuck, it rotates
the work.
• Gearbox: inside the headstock, providing multiple speeds with a geometric ratio by moving levers.
• Spindle: Hole through the headstock to which bar stock can be fed, which allows shafts that are up to 2
times the length between lathe centers to be worked on one end at a time.
• Chuck: 3-jaw (self centering) or 4-jaw (independent) to clamp part being machined. Chuck allows the
mounting of difficult workpieces that are not round, square or triangular.
• Tailstock: Fits on the inner ways of the bed and can slide towards any position the headstock to fit the
length of the work piece. An optional taper turning attachment would be mounted to it.
 Lathe-different parts

• Tailstock Quill: Has a Morse taper to hold a lathe center, drill bit or other tool.
• Carriage: Moves on the outer ways. Used for mounting and moving most the cutting tools.
• Cross Slide: Mounted on the traverse slide of the carriage and uses a handwheel to feed tools into the
workpiece.
• Tool Post: To mount tool holders in which the cutting bits are clamped.
• Compound Rest: Mounted to the cross slide, it pivots around the tool post.
• Apron: Attached to the front of the carriage, it has the mechanism and controls for moving the carriage
and cross slide.
• Feed Rod: Has a keyway, with two reversing pinion gears, either of which can be meshed with the mating
bevel gear to forward or reverse the carriage using a clutch.
• Lead Screw: For cutting threads.
• Split Nut: When closed around the lead screw, the carriage is driven along by direct drive without using a
clutch.
• Quick Change Gearbox: Controls the movement of the carriage using levers.
• Steady Rest: Clamped to the lathe ways, it uses adjustable fingers to contact the workpiece and align it.
Can be used in place of tailstock or in the middle to support long or unstable parts being machined.
• Follow Rest: Bolted to the lathe carriage, it uses adjustable fingers to bear against the workpiece.
 General-Purpose Machine Tools

Machine tools are factory equipment used for producing machines, instruments, tools, and
all kinds of spare parts. Therefore, the size of a country’s stock of machine tools, and their
technical quality and condition, characterize its industrial and technical potential fairly
well. Metal cutting machine tools are mainly grouped into the following categories:
• General-purpose machine tools. These are multipurpose machines used for a wide range
of work.
• Special-purpose machine tools. These are machines used for making one type of part of
a special configuration, such as screw thread and gear cutting machines.
• Capstan, turret, and automated lathes.
• Numerical and computer numerical controlled machine tools.
 LATHE MACHINES AND OPERATIONS
Lathes are generally considered to be the oldest machine tools still used in industry. About one-third of the machine
tools operating in engineering plants are lathe machines. Lathes are employed for turning external cylindrical, tapered,
and contour surfaces; boring cylindrical and tapered holes, machining face surfaces, cutting external and internal
threads, knurling, centering, drilling, counterboring, countersinking, spot facing and reaming of holes, cutting off, and
other operations. Lathes are used in both job and mass production.

TURNING OPERATIONS
In operations performed on lathes (turning operations), the primary cutting motion v (rotary) is imparted to the
workpiece (WP), and the feed motion f (in most cases straight along the axis of the WP) is imparted to a single-point
tool. The tool feed rate f is usually very much smaller than the surface speed v of the WP. Figure 3.1 visualizes the basic
machining parameters in turning that include:
LATHE MACHINES AND OPERATIONS
Lathe Operations and Relevant Tools
Lathe Operations and Relevant Tools
 METAL CUTTING LATHES
Every engine lathe provides a means for traversing
the cutting tool along the axis of revolution of the
WP and at right angles to it. Beyond this similarity,
the lathe may embody other characteristics common
to several classifications according to fields of
application that ranges from manual to fully
automatic machining. Metal cutting lathes may
differ in size and construction. Among these are the
general-purpose machines that include universal
engine lathes, plain turning lathes, facing lathes,
and vertical turning and boring mills.
Universal Engine Lathes
The bed (2) carries the headstock (1), which contains the speed gearbox. The bed also
Universal engine lathes are widely employed in job
mounts the tailstock (6) whose spindle usually carries the dead center. The work may be
and lot production, as well as for repair work. Parts held between centers, clamped in a chuck, or held in a fixture mounted on a faceplate. If a
of very versatile forms may be machined by this long shaft (5) is to be machined, it will be insufficient to clamp one end in a chuck;
lathe. Its size varies from small bench lathes to therefore, it is necessary to support the other end by the tailstock center. In many cases
heavy-duty lathes for machining parts weighing when the length of the shaft exceeds 10 times its diameter (ℓ > 10 D), a steady rest or
many tons. follower rest is used to support these long shafts. Single-point tools are clamped in a
Figure 3.2 illustrates a typical universal engine square turret (4) mounted on the carriage (3). Tools such as drills, core drills, and reamers
are inserted in the tailstock spindle after removing the center. The carriage (3), to which
lathe.
the apron (10) is secured, may traverse along the guideways either manually or powered.
The cross slide can also be either manually or power traversed in the cross direction.
 Universal Engine Lathes
Surfaces of revolution are turned by longitudinal traverse of the carriage. The cross slide feeds the tool in the cross direction to perform
facing, recessing, forming, and knurling operations. Power traverse of the carriage or cross slide is obtained through the feed
mechanism. Rotation is transmitted from the spindle through change gears and the quick-change feed gearbox (11) to either the lead
screw (8) or feed rod (9). From either of these, motion is transmitted to the carriage. Powered motion of the lead screw is used only for
cutting threads using a threading tool. In all other cases, the carriage is traversed by hand or powered from the feed rod. Carriage feed
is obtained by a pinion and rack (7) fastened to the bed. The pinion may be actuated manually or powered from the feed rod. The cross
slide is powered by the feed rod through a gearing system in the apron (10). Figure 3.3 shows an isometric view of the apron
mechanism. During thread cutting, the half nuts (9) are closed by the lever (10) over the lead screw (1).

Specifications of an Engine Lathe

Figure 3.4 shows the main dimensions that indicate the capacity of an engine
lathe. These are:
• Maximum diameter D of work accommodated over the bed (swing over
bed). According to most of national standards, D varies from 100 to 6300
mm, arranged in geometric progression φ = 1.26.
• Maximum diameter D1 of work accommodated over the carriage. Distance
between centers, which determines the maximum work length. It is
measured with the tailstock shifted to its extreme right-hand position
without overhanging.
• Maximum bore diameter of spindle, which determines the bar capacity
(maximum bar stock).
 Specifications of an Engine Lathe

In addition to these dimensions, other important

specifications are:
• Number of spindle speeds and speed range
• Number of feeds and feed range
• Motor power and speed
• Overall dimensions and net weight
 Other Types of General-Purpose Metal Cutting Lathes
These include plain turning lathes, facing lathes, and vertical turning and boring mills. Facing lathes, vertical turning
and boring mills, and heavy-duty plain turning lathes are generally used for heavy work. They are characterized by low
speeds, large feeds, and high cutting torques.
1. Plain turning lathes. Plain turning lathes differ from engine lathes in that they do not have a lead screw. They
perform all types of lathe work except threading and chasing. The absence of the lead screw substantially simplifies the
kinematic features and the construction of the feed gear trains. Their dimensional data are similar to those of engine
lathes. Plain turning lathes are available in three different size ranges: small, medium, and heavy duty. Heavy-duty plain
turning lathes have several common carriages that are powered either from a common feed rod, linked kinematically to
the lathe spindle, or powered from a variable speed dc motor mounted on each carriage. The tailstock traverses along
the guideway by a separate drive.
2. Facing lathes. These are used to machine work of large diameter and short length in single-piece production and for
repair jobs. These machines are generally used for turning external, internal, and taper surfaces, facing, boring, and so
on. Facing lathes have relatively small length and large diameter of faceplates (up to 4 m). Sometimes, they are
equipped with a tailstock. Its construction differs, to some extent, from the center lathe. It consists of the base plate (1),
headstock (4) with faceplate (5), bed (2), carriage (3), and tailstock (6) (Figure 3.14). The work is clamped on the
faceplate using jaws, or clamps, and T-slot bolts. It may be additionally supported by the tailstock center. The feed gear
train is powered from a separate motor to provide the longitudinal and transverse feeds. Facing lathes have been almost
superseded by vertical turning and boring mills; however, because of their simple construction and low cost, they are
still employed.
 Other Types of General-Purpose Metal Cutting Lathes
3.Vertical turning and boring mills. These machines are employed in machining heavy pieces of large diameters and
relatively small lengths. They are used for turning and boring of cylindrical and tapered surfaces, facing, drilling,
countersinking, counterboring, and reaming. In vertical turning and boring mills, the heavy work can be mounted on
rotating tables more conveniently and safely as compared to facing lathes. The horizontal surface of the worktable
excludes completely the overhanging load on the spindle of the facing lathes. This facilitates the application of high-
velocity machining and, at the same time, enables high accuracy to be attained. These small machines are called vertical
turret lathes. As their name implies, they are equipped with turret heads, which increase their productivity.
 Difference – Turret and Conventional lathe

What is the difference between turret lathe(=capstan lathe) and conventional

lathe(lathe)?

A turret lathe has six-usual tools arranged in the order of use on a rotating turret which is
cycled by a large wheel or (Turnstile) like contrivance- in fact some lathe makers called
them Turnstile lathes. the British prefer the term Capstan lathes, the Capstan being that old
extended bar device ( somewhat resembling a turnstile) used by seamen to manually raise
the anchor- in old Pirate films, etc. The Capstan or Turnstile is oriented vertically, like a
steering wheel. they usually have six stops on a hexagon turret. For this reason, several
automobile makers had hexagonal trademarks such as Essex and Packard- a mark of
homage to the machines used to make the parts!- the Turret Lathe
 Turret Lathes
Turret Lathes. In a turret lathe, a longitudinally feedable, usually hexagon turret replaces
the tailstock. The turret, on which more than one tool (e.g. if hexagon, six tools) can be
mounted, can be rotated about a vertical axis to bring each tool into operating position, and
the entire unit can be moved longitudinally, either annually or by power, to provide feed
for the tools.
Advantage of Turret Lathes
• A single product requires several machining operations which in turn would require
several different kinds of tools to carry out these operations. If an operator were to
manually adjust each tool after every single operation, this would certainly consume a
lot of time and unnecessary efforts.
• Keeping the above limitations in mind the engineers came up with the idea of a typical
lathe machine where everything could be fitted and configured in one go literally
speaking. Such a metal working lathe which has got a turret and can perform several
functions in an automated fashion is known as a turret lathe.
• So no need for the operator to perform setup tasks in between, such as installing or
uninstalling tools.
 Turret and capstan lathes
Turret and capstan lathes are the natural development of the engine lathe, where the tailstock is replaced by an indexable
multistation tool head, called the capstan or the turret. This head carries a selection of standard tool holders and special
attachments. A square turret is mounted on the cross slide in place of the usual compound rest in engine lathe.
Sometimes a fixed tool holder is also mounted on the back end of the cross slide. Dimensional control is affected by
means of longitudinal (for lengths) and traversal (for diameters) adjustable stops.

Therefore, capstan and turret lathes bridge the gap between manual engine lathes and automated lathes and are most
practical for batch and short-run production. In comparison with manual lathes, the chief distinguishing feature of
capstan and turret lathes is the multiple tool holders that enable the setting up of all the tools necessary to produce a
certain job. Except for sharpening, the tools need no further handling. Considerable skill is required to set and adjust the
tools on such machines properly. But once the machines are set, they can be operated by semiskilled operators.
Eliminating the setup time between operations reduces the production time considerably. The development of this group
of lathes has been enhanced to provide the level of accuracy required for interchangeable production.

The main advantages of turret and capstan lathes include the following:
1. Less-skilled operators are needed, as compared with center lathes
2. No need to change tooling or move the work to another machine, as many operations can be performed without the
need to change tooling layout
 DIFFERENCE BETWEEN CAPSTAN AND TURRET LATHES
The essential components and operating principles of capstan and turret lathes are illustrated schematically in Figure
6.1. Capstan lathes are mainly used for bar work, whereas turret lathes are applicable for large work in the form of
castings and forgings.

In a capstan or ram-type lathe, the hexagon turret is mounted on a slide that moves longitudinally in a stationary saddle
(Figure 6.2a). During setup of the machine, the saddle is positioned along the bed to give the shortest possible stroke for
the job. The advantage of the capstan lathe is that the operator has less mass to move, resulting in easier and faster
handling. The disadvantage is that the hexagonal turret slide is fed forward such that the overhang is increased, resulting
in the deflection of the ram slide, especially at the extreme of its position, which produces taper and reduces accuracy.

In the turret- or saddle-type lathe, the turret is mounted directly upon a movable saddle, furnished with both hand and
power longitudinal feed (Figure 6.2b). This machine is designed for machining chuck work, in addition to bar work.
Owing to the volume of the swarf produced, the guideways of the machine bed are flame-hardened and provided with
covers that protect the sliding surfaces. The bed must be designed to allow free and rapid escape of swarf and coolant.
DIFFERENCE BETWEEN CAPSTAN AND TURRET LATHES
DIFFERENCE BETWEEN CAPSTAN AND TURRET LATHES
DIFFERENCE BETWEEN CAPSTAN AND TURRET LATHES

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