Cutting Tool Materials

During machining, part of the cutting tool

remains in physical contact with the workpiece
and thus experiences severe cutting temperature
and insistent rubbing. The material of the cutting
tool must have the capability to sustain such
high cutting temperature as well as cutting force.
Every tool material must possess certain
properties such as high hardness, high hot
hardness, high strength, higher melting point
and chemically inert even at high cutting
temperature.

As a thumb rule, the hardness of the tool material

should be at least 1.5 times of the hardness of the
workpiece for smooth cutting action.

Suitable coating can also be applied on the tool to

improve various desired properties. However, a
coated tool does not allow easy re-sharpening by
grinding when the edges are worn out after
prolonged use.
Now-a-days, insert based tools are available
where small interchangeable inserts can be
attached or clamped on large shank. These
inserts perform cutting action and thus worn out
gradually. When wear exceeds the tolerable limit,
the inserts can be replaced by a new one, while
the shank can be used repeatedly.

Some of the tool materials commonly available

in todays’ market are enlisted below.

Cutting Tool Material Properties

 • Hardness ( Cutting tool material must
be 1.5 times harder than the material it is
being used to machine).
• Capable of maintaining a red hardness
during machining operation ( Red
hardness: ability of cutting tool to
maintain sharp cutting edge , Also
referred to as hot hardness or hot
strength)
• Wear Resistance ( Able to maintain
sharpened edge throughout the cutting
operation , Same as abrasive resistance )
• Shock Resistance ( Able to take the cutting
loads and forces )
• Shape and Configuration ( Must be
available for use in different sizes and
shapes).
Cutting Tool Materials
1. High-Speed Steel • May contain
combinations of tungsten, chromium,
vanadium, molybdenum, cobalt • Can take
heavy cuts, withstand shock and maintain
sharp cutting edge under red heat •
Generally two types (general purpose) •
 Molybdenum-base (Group M) • Tungsten-
base (Group T) • Cobalt added if more red
hardness desired.
18-4-1 High speed steel: This steel contains 18 per cent tungsten, 4 per cent chromium and 1 per
cent vanadium.

 It is considered to be one of the best of all purpose tool steels.

 It is widely used for drills, lathe, planer and shaper tools, milling cutters, reamers, broaches,
threading dies, punches,

2. Cast Alloy • Usually contain 25% to 35%

chromium, 4% to 25% tungsten and 1% to
3% carbon • Remainder cobalt • Qualities •
High hardness • High resistance to wear •
Excellent red-hardness • Operate 2 ½
times speed of high-speed steel • Weaker
and more brittle than high-speed steel
3. Cemented Tungsten carbide WC
Carbide Cutting Tools • First used in
Germany during WW II as substitute for
diamonds • Various types of cemented
(sintered) carbides developed to suit
different materials and machining
operations • Good wear resistance •
Operate at speeds ranging 150 to 1200
sf/min (It is defined as the number of linear feet that a location on a rotating
component travels in one minute. Its most common use is in the measurement
 of cutting speed (surface speed) in machining. It is a unit of velocity that describes how

)• Can machine
fast the cutting edge of the cutting tool travels.

metals at speeds that cause cutting edge

to become red hot without loosing harness
Manufacture of Cemented Carbides •
Products of powder metallurgy process •
Tantalum, titanium, niobium • Operations •
Blending • Compaction • Pre sintering •
Sintering
Cemented-Carbide Applications • Used
extensively in manufacture of metal- cutting
tools • Extreme hardness and good wear-
resistance • First used in machining
operations as lathe cutting tools • Majority
are single-point cutting tools used on lathes
and milling machines
Additive Characteristics • Titanium carbide •
Addition provides resistance to tool
cratering • Content increased • Toughness
of tool decreased • Abrasive wear resistance
at cutting edge lowered • Tantalum carbide •
Addition provides resistance to tool
cratering • Without affecting abrasive wear
resistance • Addition increases tool's
resistance to deformation
 4. Coatings • Titanium carbide • High wear
and abrasion resistance (moderate speed)
• Used for roughing and finishing •
Titanium nitride • Extremely hard, good
crater resistance • Excellent lubricating
properties • Aluminum oxide • Provides
chemical stability • Maintains hardness at
high temperatures

5. Ceramics
6. Cubic Boron Nitride (cBN)
7. Diamond

UNIT-2
Machine Tools: Construction, Types, Important Mechanisms, Working
Principle, Operations, Accessories, Attachments and Applications of Lathe,
Drilling Machine, Milling Machine, Shaper, Slotter, Planer, Broaching and
Boring Machines, Multiple Point Cutting Tool Geometry and Types, Dividing
Head, Types of Indexing, Installation of Machine Tools and Safety Measures.
LATHE MACHINE
 https://technobyte.org/lathe-machine-working-types-operations-applications/

Lathe machines are probably the most common and important machine in a mechanical tool room. In this post,
we will understand a lathe machine’s working principle, its types, and features, and the operations we can
perform on it.

All the parts of a lathe machine (Source)

Contents
 What is the working principle of a Lathe machine?
 What are the different types of lathe machines? How are lathe machines classified?
 How does an engine/center lathe machine work?
 Block diagram of a lathe machine (Engine/Center lathe)
o Bed of a lathe
o The headstock of a lathe
o The tailstock of a lathe
o The carriage of a lathe
o Legs of the lathe
 What are the three cutting parameters of lathe machines?
 What are the different operations that can be done on a lathe machine? What are the different applications of a lathe
machine?
o Turning
o Facing
o Chamfering
o Parting off
o Knurling
o Drilling and Reaming
o Boring
o Thread cutting
What is the working principle of a Lathe machine?
 The article that we are machining using the lathe machine is known as the job.
 The tool that we attach to the lathe machine to perform a particular operation on the job is known as a
tool/cutting tool.
 In a lathe machine, the job is held between two centers. These centers support the job and hold it
firmly in place. The job needs to be held down securely.
 The job rotates about its own axis.
 The cutting tool is placed on the tool post. (Check out the diagram for a four-way tool post below.)
 Due to the relative motion of the job and the cutting tool, the material gets removed from the job in the
form of chips and shavings.

What are the different types of lathe machines? How

are lathe machines classified?
There are seven main types of lathe machines that we will be looking at in this course:

1. Speed lathe
2. Engine/Center lathe
3. Bench lathe
4. Tool room lathe
5. Capstan and Turret lathe
6. Automatic lathe
7. Special purpose lathe.

Difference between capstan and turret lathe

Capstan and Turret Lathe:

This is an advanced technology of the manufacturing industry.

The capstan and turret lathe machine used for Mass production (large Quantity) and it is a modified version of
the engine lathe machine.

This machine is used where their sequence of operation is performed on the workpiece, there is no alternative operation
performed on this machine.

These machines provided by hexagonal turret head instead of the tailstock in which multiple operations (Turning, facing,
boring, reaming) performed in a sequence without changing its tool manually, after each operation the turret rotated.
It also consists of three tool post. It requires more floor space than other lathe machines.

Capstan and turret lathe is using for only large jobs.

The main advantage of using capstan and turret lathe is even less skilled operators can do a job.

Capstan and Turret lathes are the advancements of the Engine lathes and centre lathes in which

the tailstock is replaced by a hexagonal turret tool head with 6 different tools in the turret where

the turret tool is rotated according to process requirements in each operation. The capstan and

turret lathe although appear to be identical in the first sight but a lot of differences in

construction, operation, and use. In this article, you can check it out some difference between

these two lathe machines.

Capstan lathe :

 Lightweight machine.

 These are usually horizontal lathe.

 Turret head is mounted on a slide called ram which is mounted on the saddle.

 Suitable for bar work.

 The saddle is locked at a particular point and the ram is moved to provide feed to the

tool.
  Only a limited amount of feed and depth of cut are provided for machining.

 The cross slide is mounted on a carriage which rests on bed ways between the

headstock and the ram.

 The turret tool head is indexed automatically.

 Feed stop screws are used to control the distance of tool movement which is at the

rear side of the turret.

 No such facility to moving turret at right angles.

 Feed rod gives for longitudinal feed.

 Used for mass production of small size equal part.

 It has hand-operated collet chucks.

 Heavy cuts on workpiece can’t be given because of non-rigid construction.

Turret lathe :

 Heavyweight machine.

 Turret tool head is directly fitted on the saddle and both of them appear like one unit.

 Suitable for heavier chucking work.

 The saddle is moved to provide feed to the tool.

 They are heavy and durable.

 More feed and depth of cut are provided for machining.

 Some turret type lathes are equipped with side hung type carriage.

 To index the turret tool head, a clamping lever is released and the turret is rotated

manually.

 Limit dogs are used to control the distance of tool movement.

 Some turret lathes have the facility of moving the turret at right angles to the lathe

axis.

 Feed rod does not give for longitudinal feed.

 Used for mass production of large size equal part.

 It is accommodated with power chucks.

 Heavy cuts on a workpiece can be given because of the rigid construction of a

machine.

 These are available in the horizontal and vertical lathe.

How does an engine/center lathe machine work?
We are going to completely understand every working principle and every function of the engine/center lathe
machine. Let’s kick things off with a gander at the block diagram of the lathe machine.

Block diagram of a lathe machine (Engine/Center

lathe)
The figure highlights the main parts of a lathe machine. We will dive into each of them and understand their
purpose and functions. The main parts of a lathe machine are:

1. Bed
2. Headstock
3. Tailstock
4. Carriage
5. Legs
6. Feed mechanism

Bed of a lathe
 The bed is the foundation of the lathe machine on which all the other major parts lie.
 The top of the bed has two longitudinal guideways.
 These guideways are made with precision to ensure the accurate alignment of other parts.
 The tailstock can also slide on these guideways.
 The bed of a lathe machine is strong enough to resist vibrations due to cutting forces.
 The bed of the lathe machine is made using cast iron.

The headstock of a lathe

 It is permanently fastened at the left end of the lathe on the bed.
 The headstock serves the following purposes:
 It supports the spindle and provides provisions for a rotating live center.
 The headstock provides the power required for rotating the work at various speeds. It also
provides power for tool movement. The headstock receives this power from an electric motor, and
it uses pullets and gears for obtaining different speeds on the spindle.
 The external surface of the front end of the headstock is threaded to provide attachment facilities for
job holding devices such as chucks and drives etc.
 In modern lathes, pulleys are replaced by gears.

The tailstock of a lathe

 The tailstock of a lathe is mounted at the right end of the bed. It is opposite in position to the
headstock.
 The tailstock can move along the bed of the lathe to accommodate different lengths of the work.
 Here are some of the uses of the tailstock of the lathe:
 The tailstock is used as a support when the job is turning between the centers.
 It is used to support the job when a chuck is used at the headstock too.
 It is also used for attachments of tools like drills, tap, etc. These tools or the dead center can be
attached at the front of the spindle, which has a tapered hole.
 The tailstock can be moved forward or backward by using a screw.
 The spindle is also movable and can be moved in and out of the barrel.
 A handwheel is used for lateral movement.

The carriage of a lathe

The carriage of a lathe is a part that provides attachments whose function is to support, guide, and control the
cutting tool. These are the main parts of the carriage of the lathe:

1. Saddle
2. Cross slide
 3. Compound rest
4. Tool post
5. Apron

Saddle

 The saddle is an H shaped casting. It fits on the bed.

 The saddle slides between the headstock and tailstock.
 It carries the cross slide and the toolpost.

Cross slide

 The cross slide is mounted on the saddle and supports the compound rest.
 The cross slide is used to move the cutting tool in a perpendicular direction to the axis of the lathe.
 It moves using a feed screw. A handwheel controls the feed screw.

Compound Rest

 The compound rest is mounted on the cross slide. It supports the tool post.
 The compound rest can swivel in any desired angle in the horizontal plane.
 The base of the compound rest is graduated in degrees to indicate its current angular settings.
 It is movable.
 The compound rest of a lathe is used for obtaining angular cuts, short taperings as well as to position
the tool.

The tool post

 It is mounted on the compound rest and supports the tool.

 The tool post’s job is to hold the tool in place and to enable us to adjust it to a convenient position.
 Four-way tool posts can hold four tools at once.

Apron

 An apron is attached to the saddle where it hangs.

 The apron contains gears, clutches, and levers for operating the carriage.
 There is a hand wheel for manual movement of the carriage.

Legs of the lathe

 The legs are the support of the lathe machine. They carry the entire load of the machine.
 The legs are made up of cast iron. They can be secured to the ground using bolts for extra stability.
 The left-hand leg houses the electric motor.

Feed mechanism of the lathe

 The relative motion between the tool and the work is known as ‘feed.’
 So, the feed mechanism consists of all the parts that cause or support this relative motion. The
carriage is a part of the feed mechanism. Similarly, the gears, the levers, and the pulleys which
transmit motion from the headstock spindle to the carriage are all parts of the feed mechanism of the
lathe.
 There are three types of feed of the tool:
 Longitudinal feed: When the tool moves in parallel to the lathe axis, via a carriage.
  Cross-slide: When the tool moves in a perpendicular direction to the lathe axis.
 Angular feed: When the tool moves at an angle to the lathe axis with the help of compound rest.

What are the three cutting parameters of lathe

machines?
1. Cutting speed: This is the speed at which material is removed by the tool from the workpiece. It’s
generally expressed in meters/minute. In lathes, the cutting speed is obtained from the rotary motion
given to the work.
2. Feed: It is the distance which the tool moves for each revolution of the work. We express it in
mm/revolution.
3. Depth of cut: It is the depth of penetration of the tool into the workpiece during machining. It is usually
expressed in millimeters. In a lathe, depth of cut is the perpendicular distance between the machined
and unmachined parts of the work.

What are the different operations that can be done on a

lathe machine? What are the different applications of a
lathe machine?
Here are the different operations that can be done on a lathe:

1. Turning
2. Facing
3. Chamfering
4. Parting off
5. Knurling
6. Drilling and Reaming
7. Boring
8. Thread Cutting

Let’s understand each of these operations one by one.

Turning
  In Turning, two centers support the job.
 The job rotates on its own axis.
 The tool is fixed on the toolpost.
 In this operation, the diameter of the work is reduced due to the relative motion between the tool and
the job to a desirable dimension. The tool moves in parallel to the axis.
 If the diameter reduces uniformly throughout the length of the work, it’s known as straight turning.
 When different diameters are obtained over the length, it’s called step turning.
 If the diameter is reduced in an angle, it’s called taper turning.
 Shoulder turning, eccentric turning, and rough turning are the other three types of turning operations.

Facing

 In Facing, two centers support the job. The job rotates on its own axis.
 The tool is fixed on the toolpost. And it is held slightly inclined to the job though its motion is
perpendicular to the axis of the job due to the cross-slide.
 In facing operation, the ends of the work are made flat, and the length of the job is reduced.
 The cutting tool moves perpendicular to the job. Due to the relative motion between the job and the
tool, part of the job gets removed in the form of chips.

Chamfering
  Job supported by two centers and rotates on its own axis.
 The tool is fixed on the toolpost. It’s held at a small angle to the job and moves perpendicular to the
job.
 Due to the relative motion, the edges of the job undergoes tapering.
 Chamfering is a safety feature. It is done to make sure that the sharp edges of something don’t harm
someone who is handling the job.

Parting off
 The job is attached to a chuck.
 It rotates about its own axis.
 The parting tool is mounted on the tool post, and the feed is perpendicular to the axis of the job.
 In parting off, we remove a part of a particular length from the remaining job.

Knurling ( The operation is performed for producing indentations on a part of a

workpiece. Knurling allows hands or fingers to get a better grip on the knurled object
than would be provided by the originally smooth metal surface).
  The job is supported by two centers. It rotates about its own axis.
 Knurling operation is done to provide some grip on the job. E.g.: watch turners.
 The knurling tool is kept on the toolpost and pressed perpendicularly to the job until the patterns on the
rollers are formed on the job.
 These patterns are usually square or diamond in shape.
 Note that material is not removed, knurling only creates an impression.

Drilling and Reaming

What is the difference between drilling using a lathe and drilling using a drilling
machine?
In the drilling operation that we perform on a lathe machine, the job rotates while the tool stays still. Whereas in
a drilling machine, the job stays still, and the tool rotates.

 The job rotates about its own axis, but the tool (drill) is fit into the tailstock instead of the toolpost.
 In a drilling operation, a hole is made into the job.
 The drill is fed along the axis of the rotating job, and due to relative motion, we get a hole of a
desirable diameter.

 After drilling, reaming is the process where the hole undergoes correction to a desirable size.
 A small amount of material is removed in reaming.

Boring
 The job is attached to a chuck. The job rotates on its own axis.
 The boring tool is fitted to the tool post.
 In the boring operation, an already drilled hole is enlarged through relative motion between job and
tool.
 However, boring cannot be done prior to drilling.
 If an operation is carried out up to a certain length of the job, it’s called counter-boring.
Thread cutting

 Work is held between two centers and rotates about its own axis.
 Thread cutting is an important operation where helical grooves are produced on the job by feeding the
tool longitudinally on the rotating job.
 The longitudinal feed should be equal to the pitch of the grooves. Automatic movement of the carriage
is required for constant pitch.

Longitudinal feed = pitch/revolution

 The ratio of longitudinal feed to the speed of headstock spindle should be such that the relative speeds
of work and lead screw cause the grooves.
 Change gears are used to engage relative motion between the lead screw and half nut, achieving
automatic motion of the carriage.
 The speed of the lead screws controls the pitch.
This is an excellent two video series that makes a machinist hammer from scratch. A lot of the operations that
we have seen in this post are shown. Check it out. Next up, we have a similar guide for drilling machines for
you.

(Image source: By Glenn McKechnie - Own work, CC BY-SA 3.0,

https://commons.wikimedia.org/w/index.php?curid=933532)

Bed:

It is the base of the lathe machine. It is made of single piece casting of Semi-steel ( Chilled Cast Iron). The bed consists of two
heavy metal slides running lengthwise, with ways or 'V' formed upon them and rigidly supported with cross girths.

 It is sufficiently rigid and good damping capacity to absorb vibration.

 It prevents the deflection produced by the cutting forces.
 It supports the headstock, tailstock, carriage and other components of the lathe machine.

Tail Stock:

Tail Stock is situated on the right side above the lathe bed.

It is used for:
  Support the long end of the job for holding and minimizes its sagging.
 It holds the tool for performing different operations like drilling, reaming, tapping, etc.
 And it is also used for a small amount of taper for a long job by offsetting the tailstock.

Carriage:

The carriage is used for support, guide and feed the tool against the job when the machining is done.

 It holds moves and controls the cutting tool.

 It gives rigid supports to the tool during operations.
 It transfers power from feed rod to cutting tool through apron mechanism for longitudinal cross-feeding.
 It simplifies the thread cutting operation with the help of lead screw and half nut mechanism.

It is consists of:

1. Saddle
2. Cross-slide
3. Compound rest
4. Toolpost
5. Apron

It provides three movements to the tool:

1. Longitudinal feed-through carriage movement

2. Cross feed-through cross slide movement
3. Angular feed-through top slide movement
(Source: By Glenn McKechnie - Own work, CC BY-SA 3.0, https://commons.wikimedia.org/w/index.php?curid=931394)

Saddle:

Generally, it is made up of 'H' shaped casting and it has a 'V' guide and a flat guide for mounting it on the lathe bed
guideways.

Cross-slide:

It is assembled on the top of the saddle. The top surface of the cross-slide is provided with T-slot.

Compound rest:

It supports the tool post and cutting tool in its various positions. It can be swiveled at any desired position in the horizontal
plane. It is necessary for turning angles and boring short tapers.

Tool post:

It is the topmost portion of the carriage and it is used to hold various cutting tools or tool holders.

There are three types of tool post commonly used and those are:

1. Ring and rocker tool post

2. Squarehead tool post
3. Quick change tool post

Apron:
An apron is a house of the feed mechanism. It is fastened to the saddle and hangover in front of the bed.

Lead screw:

A lead screw is also known as a power screw or a translation screw. It converts rotational motion to linear motion. Lead
Screw is used for Thread Cutting operation in a lathe machine tool.

Feed Rod:

Feed rod is used to move the carriage from the left side to the right side and also from the right side to the left side.

Chuck:

Chuck is used to holding the workpiece securely.

There are generally 2 types of chucks:

1. 3 jaw self-centering chuck

2. 4 jaw independent chuck

Main Spindle:

The spindle is a hollow cylindrical shaft in which long jobs can pass through it.

It is designed so well that the thrust of the cutting tool does not deflect the spindle.

Leg:

Legs are carrying an entire load of a lathe machine tool and transfer to the ground. The legs are firmly secured to the floor by
the foundation bolt.

Schematic diagram of the lathe machine:

Types of Lathe Machine

Lathe machine tool which is used for removing the excess material from the workpiece to give required shape and size to the
workpiece.

So how many types of Lathe Machine are there? Lathe machine has been categorized into the following types:

 Center or Engine Lathe

 Speed Lathe
 Capstan and Turret Lathe
 Tool Room Lathe
 Bench Lathe
 Automatic Lathe
 Special Purpose and
 CNC Lathe Machine
We are going to study each and every important point of these 8 different types of lathe machines.

Center or Engine Lathe Machine:

Center or Engine Lathe Machine is the most widely used lathe machine and still, it is, in every workshop, this
machine is present.

The operation like Turning, facing, grooving, Knurling, threading and more, such operations are performed on this type of
machine.

Engine lathe machine has all the parts such as bed, Saddle, headstock, and tailstock, etc. The headstock of an engine lathe
is rigid and tailstock is moveable which is further used to support an operation like knurling.

It can easily feed the cutting tool in both directions i.e. longitudinal and lateral directions with the help of feed mechanisms.

Center Lathe machines are driven by the gear mechanism or pulley mechanism.

It has three types of driven mechanisms, and those are Belt-driven, Motor-driven, Gearhead type.

Engine Lathe (Image courtesy: IndiaMart)

Speed Lathe:

Speed lathe is also called as Wood Lathe.

As the name indicates “Speed” the machine works with high speed. The headstock spindle is rotating at a very high speed.
The parts having like headstock, tailstock, but it's not having feed mechanism like center or engine lathe having. The feed we
provide is manually operated.

The speed ranges of this machine operated between 1200 to 3600 RPM.

Speed lathe is used for spinning, centering, polishing and machining of wood.
Speed Lathe (Image courtesy: Indiamart)

Tool Room Lathe:

The toolroom lathe machine operates to speed up to 2500 rpm.

The parts are almost the same similar to engine lathe machine but the parts are built very accurately and should be arranged
in proper sequence because this lathe is used for highly precious work with very fewer tolerances.

It is mainly used in grindings, working on the tool, dies gauges and in machining work where accuracy is needed.
Toolroom lathe (Image courtesy: IndiaMart)

Bench Lathe:

Bench lathe machines are mounted on the bench.

This type of lathe machine is small in size and use for very small precision work. It has all the similar parts of engine lathe
and speed lathe.
Bench Lathe (Image courtesy: IndiaMart)

Automatic Lathe:

As the name indicates “Automatic lathe” performs work automatically.

Standard lathes have some drawbacks i.e. they are not used for mass production. But automatic lathes are used for mass
production. Some mechanisms are responsible for the automation in it.

Here there is no need to change the tool manually because it changes automatically.

Having this machine the main advantage is that a single operator can handle machines more than 4 to 5 machines
at a time.

These types of lathes are high speed and heavy-duty.

Automatic lathe (Image courtesy: Indiamart)

Special Purpose Lathe:

As the name indicates “special purpose lathe” the machine performs the special types of operation which can not be
performed on standard and other machines.

It is known for the heavy-duty production of identical parts.

Some examples of special lathes include Vertical lathes, Wheel lathes, T-lathe, Multi Spindle lathes, Production
lathes, Duplicate or tracer lathes, etc.

Wheel lathe is used for machining of journals and rail rods. It is also used for turning the threads on locomotive wheels.

The “T -lathe” is used for machining rotors for jet engines. The axis of the lathe bed is at right angles to the axis of the
headstock spindle in the form of a T.

CNC Lathe Machine:

CNC stands for Computerized numerically controlled.

This is widely used as a lathe in the present time because of its fast and accurate working. It is one of the most advanced
types.

It uses computer programs to control the machine tool. Once the program is fed into the computer as per the program it
starts operation with very high speed and accuracy.

Even do preplanned programmed machine is there in which once code is set for the various operations it can starts operation
without changing code in the next time.
A semi-skilled worker can easily operate this after the initial setup is done.

These types of lathes are also used for mass production like capstan and turret but there is no programmed fed system.

The components manufactured by these lathes are very accurate in dimensional tolerances.

(Source: By Kentindustrialusa - Own work, CC BY-SA 4.0, https://commons.wikimedia.org/w/index.php?curid=46513649)

Now discuss the operations performed in a Lathe

A Lathe Machine consists of the following operation:

 Centering
 Facing
 Turning
 Chamfering
 Knurling
 Thread cutting
 Drilling
 Boring
 Reaming
 Spinning
 Tapping
 Parting off

Before continuing any operation in lathe we have to load the job and center it on the head-stock spindle.
In lathe operations, the headstock spindle holds the job and it rotates with the same speed as the spindle. The carriage
holding the tool on the tool post, also the carriage gives the tool post moves longitudinally or crosswise direction to give the
desired feed on the job.

These two motions (longitudinally and crosswise) helps to remove the chips of the metal and giving the proper shape of the
job.

The Lathe is such a versatile machine that it can produce another lathe.

It is tough to mentioned which operations are not performed in a lathe machine tool, though we discuss some important
lathe operations in detail.

Centering operation in the lathe:

We use this operation for producing a conical hole in the face of the job to make the bearing support of the lathe center when
the job is to hold between two centers. (Head-stock and Tail-stock).

CENTERING OPERATION

Facing operation in the lathe:

Facing operation is for making the ends of the job to produce a smooth flat surface with the axis of operation or a certain
length of a job.

In this operation,

1. Hold the job on Head-stock spindle using Three or four-jaw chuck.

2. Start the machine on desire RPM to rotate the job.
3. Give a desirable feed on the perpendicular direction of the axis of the job.
FACING OPERATION

Turning operation in the lathe:

The operation by which we remove the excess material from the workpiece to produce a cone-shaped or a cylindrical surface.

There are several types of turning operations, those are:

1. Straight turning
2. Shoulder turning
3. Rough turning
4. Finish turning
5. Taper turning
6. Eccentric turning

Straight turning:

This operation is done to produce a cylindrical surface by removing excess material from the workpiece.

It is done in the following ways:

1. Mount the job by suitable job holding device and check the trueness of the job axis with the lathe axis.
2. Hold the cutting tool on the tool post and set the cutting edge at the job axis or slightly above it.
3. Set the spindle as per the desired feed.
4. Give depth of cut as per finish or rough cut.
5. Start the machining.
6. Engage automatic feed to move the carriage with the tool to the desired length, then disengage the feed and
carriage is brought back to its starting.
7. The process is repeated until the job finished.
STRAIGHT TURNING OPERATION

Shoulder turning:

A shoulder turning is called which has a different diameter to form a step from one diameter to another.

There are four kinds of the shoulder.

1. Square
2. Beveled
3. Radius
4. Undercut
SHOULDER TURNING

Rough turning:

It is a process of removal of excess material from the workpiece in minimum time by applying a high rate of feed and heavy
depth of cut.

the depth of cut is around 2 to 5mm and the rate of feed is 0.3 to 1.5mm/revolution.

Finish turning:

The finish turning operation needs high cutting speed, minimum feed and a very small depth of cut to generate
the smooth surface.

In finish turning the depth of cut is around 0.5 to 1mm and the rate of feed is 0.1 to 0.3 mm/revolution.
ROUGH TURNING AND FINISH TURNING

Taper turning:

First, let me give you an idea about the taper.

A taper is defined as a uniform decrease or increase in the diameter of a workpiece along with its length.

The operation by which a conical surface of the gradual reduction in diameter from a cylindrical workpiece is produced is
called taper turning.
TAPER TURNING

Taper turning methods:

A tapering form may be done by anyone of the following methods.

1. Taper turning by form tool

2. By swiveling the compound rest
3. Tail-stock set over method
4. By taper turning attachment

Let me discuss them in brief.

Taper turning by form tool:

It is used to form a short length of taper by using a form tool or broad nose tool.

Any increase in the length of taper will require the use of a wider cutting edge which may destroy the workpiece due to the
vibration and spoil the workpiece.

In this operation, the tool angle must be half of the taper angle.

Taper turning by swiveling the compound rest:

This method is used for turning step and short tapers.

It is done as follows:

1. Set the compound rest by swiveling it from the centerline of the lathe center through an angle equal to a half taper
angle.
 2. Clamp the carriage in place.
3. After adjusting and setting the tool, feed is applied by the compound rest's feed handle to complete the taper.

Tail-stock set over method:

Set over of tail-stock from its center-line is done equal to half taper.

Job is held between the centers. The length of the workpiece will be long enough. An only a small taper on a long job is done
by this process.

It is used for external taper only.

By taper turning attachment:

It is done in the following ways:

1. The cross slide is first made free from lead screw by hinder screw.
2. The rear end of the cross slide is then tightened with a guide block by a belt.
3. Set the guide bar at an angle to the lathe axis. (Half taper angle)
4. The required depth of cut is given by the compound slide is at a right angle to the lathe axis.

Chamfering operation:

Chamfering is used for beveling the end of a job to remove burrs, to look better, to make a passage of the nut into the bolt.

This operation is done after thread cutting, knurling, rough turning.

CHAMFERING

Knurling operation:

It is the process of producing a rough surface on the workpiece to provide effective gripping.

Knurling tool is held rigidly on the tool post and pressed against the rotating job so that leaving the exact facsimile of the
tool on the surface of the job.
KNURLING

Thread cutting operation :

It is the operation that is used to produce a helical groove on a cylindrical or conical surface by feeding the tool longitudinally
when the job revolved between the two centers.

Tool setting for thread cutting operation:

The tool should be set exactly to the height of the centerline of the job and at 90 degrees to the job.

Tool setting gauge is used for this purpose.

Feeding during thread cutting operation:

It is done in two ways.

1. The tool may be feed exactly at 90 degrees to the job axis but it does not have good cutting action because only the
front end of the tool does cutting.
2. The tool may be feed at an angle from 27-30 degrees at which the compound rest may be set so that the complete
side of the tool is used for cutting action which gives a better polish on the threads.

Job speed during threading:

The job speed will be 1/3 to 1/4 th of the job speed in turning operation.

Drilling operation:
Drilling is an operation by which we can make holes in a job.

In this operation, the job is rotated at the turning speed on the lathe axis and the drilling tool fitted on the tail-stock spindle.
And the tail-stock is moved towards the job by hand feed.

DRILLING

Boring operation:

In this operation, we can enlarge the diameter of the existing hole on a job by turning inside with some farm tool known as
a boring tool.

The boring tool is also fitted on tail-stock.

BORING OPERATION

Reaming operation:

Reaming is the operation for sizing or finishing a drilled hole to the required size by a tool called reamer.

This tool is fitted on tail-stock.

REAMING OPERATION

Spinning operation:

In this operation, the job of this sheet metal is held between the former and the tail-stock center rotates at high speed with
the former.

the long round nose forming tool rigidly fixed on special tool post presses the job on the periphery of the former. So the job is
taken exactly the shape of the former.

This is a chipless machining process.

Tapping operation:

We use this operation for creating internal threads within a hole by means of a tool called tap.

Three taps are generally used in an internal thread.

1. Taper Tap
2. Second Tap
3. Plug Tap

Parting-off operation:

It is the operation of cutting off a bar type job after complete the machining process.

In this operation a bar type job is held on a chuck, rotates at turning speed, a parting off tool is fed into the job slowly until
the tool reaches the center of the job.
PARTING-OFF OPERATION

Specification of a Lathe:

A Lathe is generally specified by:

1. Swing- the largest work diameter that can be swung for the lathe bed.
2. The distance between the headstock and tailstock center.
3. Length of the bed in a meter.
4. The pitch of the lead screw.
5. Horsepower of the machine.
6. Speed range and the number of speeds of HS spindle.
7. The weight of the machine in a tonne.