Chapter 23

Machining Process: Turning

Kazi Billah, Ph.D.

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Basic components of a lathe machine

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All the components in the lathe machine

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Types of cutting operations in lathe machine

✓ Turning: to produce straight, conical, curved, or grooved workpieces (Figs. a through d), such as shafts, spindles, and pins.
✓ Facing: to produce a flat surface at the end of the part and perpendicular to its axis (Fig. e), useful for parts that are assembled with other components.
✓ Face grooving produces grooves for applications such as O-ring seats (Fig. f).
✓ Cutting with form tools: (Fig. g) to produce various axisymmetric shapes for functional or aesthetic purposes.
✓ Boring: to enlarge a hole or cylindrical cavity made by a previous process or to produce circular internal grooves (Fig. h).
✓ Drilling: to produce a hole (Fig. i), which may be followed by boring to improve its dimensional accuracy and surface finish.
✓ 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 (Fig. j).
✓ Threading: to produce external or internal threads (Fig. k).
✓ Knurling: to produce a regularly shaped roughness on cylindrical surfaces, as in making knobs and handles (Fig. l).
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Turning process
• “Turning is a machining process in which a single-point cutting tool removes material from the surface of a
rotating workpiece”

Turning

Turning
Drilling

(a) Photograph of a turning operation, showing insert and discontinuous chips. The cutting tool is traveling from right to left in this photograph. (b) Schematic illustration of the basic turning
operation, showing depth of cut, d; feed, f; and spindle rotational speed, N, in rev/min. The cutting speed is the surface speed of the workpiece at the tool tip.
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Single point cutting tool in turning process

Designations for a right-hand tool. Right-hand means that the tool travels from right to left.

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Material removal rate
• The material-removal rate (MRR) in turning is the volume of material removed per unit time (units of mm3/min).

𝐷0 +𝐷𝑓
• The average diameter 𝐷𝑎𝑣𝑔 =
2

• Material removal rate, 𝑀𝑅𝑅 = 𝜋𝐷𝑎𝑣𝑔 𝑑𝑓𝑁

• Another form is , 𝑀𝑅𝑅 = 𝑑𝑓𝑉

𝑡
• Cutting time (t) for a workpiece length L is, 𝑡 =
𝑓𝑁

• Rotational speed of workpiece is N

• Feed is F
• Depth of cut is d
• Final diameter Df
• Initial diameter D0

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Forces in turning
• The cutting force (FC) acts downward on the tool tip and thus tends to deflect the tool
downward and the workpiece upward.

• The cutting force supplies the energy required for the cutting operation.

• The product of the cutting force and its radius from the workpiece center determines the
torque on the spindle.

• The product of the torque and the spindle speed determines the power required in the
turning operation.
Forces acting on a cutting tool in turning. Fc is the
• The thrust force (Ft) acts in the longitudinal direction. It also is called the feed force, because cutting force, Ft is the thrust or feed force (in the
direction of feed), and Fr is the radial force that
it is in the feed direction of the tool. tends to deflect the tool away from the workpiece
being machined.

• The radial force (Fr) acts in the radial direction and tends to push the tool away from the
workpiece.

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Summary of turning parameters

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Math: material removal rate and cutting forces in turning
A 150-mm-long, 12.5-mm-diameter 304 stainless steel rod is being reduced in diameter to 12.0 mm by turning on a lathe. The spindle
rotates at N = 400 rpm, and the tool is traveling at an axial speed of 200 mm/min. Calculate the cutting speed, material-removal
rate, cutting time, power dissipated, and cutting force.

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Sample question from this chapter (23)
o Define turning operation?
o Drawing the diagram of turning operation and label it.
o Math problems based on the material removal rate and forces
o Write the design considerations for Turning Operations.
o Write the guidelines for Turning Operations
o Definition and basic sketch of various turning operations
o Write at least 7 key components of a lathe machine
o What is the thrust force in turning? What is the cutting force? Which one is used to calculate the power formula?
o Draw a single point cutting and label it
o What is rake angle?
o What is side rake angle?
o Nose radius
o Relief angle
o Cutting edge angle

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