Elements of Mechanical Engineering.

Unit 5: Lathe and Drilling Machines.

Cutting tools:- Tools which are used to separate/remove material stock from the work piece are
known as cutting tools. Ex hack saw, chisel etc.
Machine tools: - Machine tools are power driven cutting tools or machines which enable the
removal of excess stock of material from the work piece.
Relative Motion: - change in position of a obect ! fixed/moving" with respect to the other obect
!fixed/moving"is called as relative motion.
#athe:-
#athe is one of the most widel$ used machine tools in metal cutting work.
#athe is usuall$ used for machining !metal removal" the ob which is rotated and a cutting
tool is fed to cause the cutting action.
#athe is generall$ used for machining c$lindrical obs.
Working principle of Lathe
The work piece is hold firml$ in the work holding device called the chuck and is supported b$ the
dead center as shown in the fig.above
The chuck is rotated at a particular speed b$ some mechanisms% the cutting tool is moved against the
rotating work piece to facilitate the removal of material.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
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Elements of Mechanical Engineering.
chematic diagram of Lathe Machine.
!. "ed: The lathe bed provides a heav$ rigid frame on which all the main components like
headstock, tail stock and carriage are mounted. (t comprises inner and outer guide rails that are
precision machined. bed is made out of cast iron allo$.
#. $eadstock: (t is mounted in a fixed position at the left end on the bed. (t carries a hollow spindle
which can rotate at different speeds.
The spindle carries a work-holding device which in turn rotates the ob to be machined. The spindle
speed is controlled b$ a stepped cone pulle$ and back
gear arrangement both of which are housed inside the headstock.
%. &ailstock: (t is mounted at the left end on the bed and can slide towards the headstock. (t can be
fixed at an$ position on the bed to suit the length of the work to hold a lathe center, drill bit or other
such tool. The tailstock is used for drilling,
reaming, tapping, threading and centering parts.
'. Carriage: (t moves on the guide wa$s of the lathe bed. ) cutting tool is fixed in the tool post, the
movement of which is guided b$ the carriage. The carriage is e*uipped with levers, clutches and
gears that control its movement either b$ hand or b$ power feed. (t carries the following
units.
( addle: (t is the main part or the base of the carriage which slides along the bed wa$s. (t supports
cross-slide, compound rest and tool post. +enerall$, it uses a hand wheel to move along the bed but it
can also be power operated through the apron mechanism.
( Cross slide: (t is mounted on the saddle and slides in a direction perpendicular to the axis of the
spindle
( Compound rest: (t is mounted on the top of the cross-slide. (t can swivel to an$ desired
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
angle in a hori,ontal plane. (t is operated b$ a handwheel through the compound rest.
.Tool post: It is fixed on top of the compound rest and mounts the tool holder, in which the cutting
tools are clamped.
. Apron is attached to the front of the carriage and bears the mechanism which controls the
movement of the carriage and the cross slide.
. Legs: The whole machine is supported on two legs made out of cast iron. The leg on left side
houses the electric motor and the headstock, the right side leg houses tailstock and other parts.
Lathe Operations
The lathe is the most versatile general-purpose machine tool. (t is capable to perform a large variet$
of operations .
-ollowing are a few operations that can be performed on a lathe:
.. Turning: Turning is a lathe operation in which the cutting tool removes metal from the outside
diameter of a workpiece. (n other words, reduction in the diameter of the workpiece is called turning.
&epending upon the ob re*uirement, the turning operation ma$ be of various t$pes
such as
a. 'traight turning
b.'tepped turning
c.Taper turning
d./ontour turning.
0. -acing: -acing is the process of removing metal from the end of a workpiece to produce a flat
surface.
(n other words a reduction in length of the workpiece is called facing. The cutting tool is fed into the
workpiece in a direction perpendicular to its axis
a. traight &urning b. tep &urning
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Elements of Mechanical Engineering.
&aper &urning )nurling

*rooving Chamfering &hread cutting

Drilling "oring
+arting ,ff: (t uses a cutting tool to cut-off the workpiece at a specific length.. (t is normall$ used
to remove the finished end of a workpiece from the bar stock!raw material" that is clamped in the
chuck.
*rooving: (t is an operation of reducing diameter of the workpiece in the form of a neck or a narrow
groove of desired shape, ma$ be a round, a s*uare or a 1 shape.
Chamfering: (t is a process of cutting the sharp edge at the end of a ob to produce a beveled edge at
a desired angle.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
Drilling: (t is a lathe operation b$ which an axial hole is created in a solid workpiece. (t is done with
the help of a special multi-point tool called a drill.
Reaming: (t is an operation b$ which the surface of a drilled hole is finished. (t is done with the help
of a special multi-point tool called a reamer.feed !2.3-0 mm ".
"oring: (t is an operation b$ which a drilled hole is enlarged in diameter. (t is done with the help of a
single-point cutting tool called a boring bar.
)nurling: (t is a special operation b$ which a smooth-turned surface is made rough b$ impressing a
diamond shaped or straight line pattern. (t is done for the purpose of creating a better
gripping.surface.
4nurling is performed with special metal wheels called a knurling tool.
&hread Cutting: (t is a process of cutting helical grooves of a standard thread form. (t ma$ be of
two t$pes, namel$, external thread cutting and internal thread cutting.
!tapping,taperboring,undercutting,milling,counterboring,grooving,filling,polishing,spinning,spring
winding5 forming"
&aper &urning
Taper turning is the process of generating a conical surface.
Taper turning on a lathe is done b$ feeding the cutting tool at an angle to the axis of rotation the
workpiece.
) taper is a uniform increase or decrease in the diameter of the workpiece along its length.
There are four basic methods of turning tapers on a lathe:
6 b$ form tool%
6 b$ compound rest swivel%
6 b$ tailstock set-over%
6 b$ taper turning attachment.
Determination of angle of taper:
/onsider a c$lindrical workpiece of length # and diameter &.as shown in fig below (t is re*uired to
reduce the diameter & to d uniforml$ over the length #. The amount of taper in the workpiece is
usuall$ specified as conicity. (t is denoted b$ letter 4.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
7here &- dia at the larger end, d-dia at the smaller end, #8 length of workpiece
&aper &urning b- .iveling the Compound Rest
9The work piece is rotated on lathe axis .The cutting tool mounted on the compound rest is attached
to a circular base which can be swiveled and locked at an$ desired taper angle as shown in -ig.
9/ompound rest ma$ be swiveled at either side of the lathe. 7hen the compound rest set at the
desired taper angle is moved against the workpiece the cutting tool generates
the re*uired tapered surface on the workpiece.
9)s the compound tool rest has onl$ limited movement, this method can generate onl$ short
tapers.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
&aper &urning b- &aper &urning /ttachment
9:ere a taper attachment which is set at an angle to the axis of rotation of the workpiece. guide the
tool in a straight path to cut both internal and external tapers as shown in -ig. >The workpiece held
between the centers and is aligned to the lathe axis.
9The attachment consists of bracket or frame connected to the rear end of the lathe bed.
) guide bar having graduations in degrees ma$ be swiveled either side of the ,ero.
+raduation on a pivot mounted over the bracket as shown in fig.
The cross slide is made free from lead screw and its rear end is attached to the guide block b$ means
of a bolt.
7hen the longitudinal feed is given b$ moving the carriage, the guide block slides over guide bar set
at half the taper angle. The tool mounted on the cross slide follows the angular path and generates the
re*uired taper.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
&aper &urning b- &ailstock et0over
:ere the workpiece is held between the live center and the dead center of the tailstock. ;ut the
tailstock is offset at an angle e*ual to half the taper angle as shown in -ig.
The cutting tool is fed parallel to the lathe axis. )nd the desired taper is produced.
&aper &urning b- a 1orm &ool
9:ere a taper tool of broad nose having straight cutting edge is used to produce the desired taper
as shown in -ig.
9since this method produces taper onl$ for short length it is not widel$ used.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
pecification of Lathe:
) lathe is mainl$ specified b$ the maximum si,e of the work that it can handle.
<ther important specifications include the following
..The largest diameter of the workpiece, commonl$ called the swing.
0. The maximum distance between headstock and tailsstock centers.
=. power of the main drive, that is, motor%
>. range of spindle speeds%
3. range of feeds%
?. space occupied b$ the machine
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
Drilling is an operation of producing holes in a solid metal2non metals b- means of a revolving
tool called drill or t.ist drill.
The machines emplo$ed for drilling holes are called drilling machines. The drilling machine
.&rilling machine is the one of the essential machine tool used in fabrication, production shop and
tool rooms, for machining/producing holes.
The machine consists of a spindle which provides rotar$ motion to the drilling tool!twist". The
spindle ma$ also produce motion to table on which the work rests.
TYPES OF DRILLING MACHINES
&rilling machines are manufactured in various si,es and varieties to suit different t$pes
work. The$ are classified as follows.
l" @ortable drilling machine
0" 'ensitive or bench drilling machine
=" Ap-right drilling machine
>" Badial drilling machine
3" +ang drilling machine
?" Multiple-spindle drilling machine
C" &eep-hole drilling machine
+ortable Drilling Machine:
(t is small drilling machine designed to drill small holes up to .D mm diameter. The machine can be
carried to the obs which normall$ cannot be brought to the workshop, such as concrete selling
slabs,walls,heav$ machiner$, and fabrication sites.
(t is ver$ light in weight and can be convenientl$ handled. -ig above shows a portable hand held
drilling machine.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
ensitive or "ench0&-pe Drilling Machine
The drilling head along with the column is mounted and clamped on a bench. The workpiece can be
clamed to the work table or on the base with the help of T-slots. The worktable can be moved up and
down along the vertical column and clamped at an$ desired height.
The drill is mounted in a drill chuck which is rotated b$ the drive s$stem of the machine.
The chuck is moved up and down b$ handle with the help of a rack-and-pinion mechanism.
'ensitive drilling machine is designed for drilling small holes, usuall$ less than .0 mm,
diameter. The name EsensitiveE is used because the machinist can EfeelE the action of the drill as it
goes into the work.
-ollowing are its main parts:
6 1ertical column: (t is the basic structure to hold the other parts.
6 &rilling head: This has a box-t$pe structure. (t houses the power drive and gear boxesF
change of speed and feed.
6 'pindle: (t holds and provides rotar$ motion and feed motion to the drill.
6 Table: (t has T-slots on the top surface. The ob is clamped on the table using a drilling
Gig or machine vice.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
Upright2+illar Drilling Machine
This machine is *uite similar to the bench drilling machine but of little larger si,e and higher
capacit$ and is fixed on the floor foundation.
This drilling machine is able to take larger drills.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
Radial Drilling Machine:
The machine consists of a vertical column mounted on a large base.
(t supports a radial arm which can swing about the column axis and move verticall$ up and down.
The radial arm carries a drill head which can slide in its guidewa$s and clamped at the desired
position. ) motor is mounted on the drill head to rotate the drill spindle. ) feed lever on the drill
head guides the feed motion.
) combination of these movements helps to locate the drill at an$ desired position. This t$pe of
drilling machine is used in tool rooms and in large scale manufacturing units.
,ther drillings machines
.. &eephole drilling machines
0. Aniversal drilling machines
=. +ang drilling machines
>. Multispindle drilling machine
3. /H/ drilling machines.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
Drilling
(t is a process of creating or originating a hole in a solid workpiece using a tool called Twist drill.
Reaming:
Beaming is the operation of finishing an alread$ drilled hole using a reamer. ) reamer which
matches the diameter of the alread$ existing hole is fitted in to the machine spindle and reaming
operation is carried over which is similar to drilling operation except higher spindle speed in reaming
.The material removed is ver$ less and the drilled hole surfaces are finished with high accurac$. The
accurac$ of a reamed hole is around 2.223 mm.
"oring
;oring is the operation of enlarging an alread$ drilled hole using a boring tool. The boring tool is
fixed to the boring bar which in turn fits into the machine spindle. The speed of rotation of a boring
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
tool is lesser than the speed of rotation of a corresponding reamer. :oles with accurac$ of 2.22 .03
mm can be obtained b$ this operation.
Counter0"oring
(t is a special operation performed on drilling machine for enlarging a limited portion of the hole.
The bottom surface of the enlarged hole is flat. (t is generall$ used when a bolt or cap head screw or
a nut is re*uired to sit below the level of a workpieceFs surface.
/ounter-boring is done with the help of a special tool called a counter-bore. The counter-bore is
guided in drilled hole with the help of a pilot fixed at its lower end.
Counter0inking:
I
(t is a process of making a conical hole to a limited depth at the entrance to c$lindrical hole. )
counter-sunk hole allows sitting the conical head of a bolt or a screw below surface of the workpiece.
(t is cut with the help of a tool called a counter-sinking tool.
/ounter sink cutters are manufactured with six common included angles which are ?2J, D0J, K2J,
.22,..2J or .02J.
&ept. of Mechanical Engineering, 'rinivas 'chool of Engineering, Mangalore.
Elements of Mechanical Engineering.
&apping:
(t is process of thread cutting inside a drilled or a bored hole using a tool called taL
) special attachment containing a reversing mechanism is re*uired for tapping.

pecification of drilling machine
(" The si,e of the working table and capacit$ of the machine.
0" Maximum si,e of the work piece on the particular machine.
=" Maximum diameter of drill on the particular machine.
>" Humber of spindles on the particular machine.
5) #ength of arm and column diameter must be specified for radial drilling machine.
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