Module

4 General Purpose Machine Tools

Version 2 ME, IIT Kharagpur
Lesson
23 Construction, Operation and Tool layout in Semiautomatic and Automatic lathes
.
Version 2 ME, IIT Kharagpur
Instructional objectives
This lesson will enable the students ; (i) Illustrate the constructional feature
s and uses of semiautomatic and automatic lathes. (ii) Show the kinematic system
and explain the working principles of semiautomatic and automatic lathes of com
mon use. (iii) Plan and visualise tool layout for machining in semiautomatic and
automatic lathes.
(i) Constructional Features And Uses Of General Purpose Semiautomatic And Automa
tic Lathes.
Automation is incorporated in a machine tool or machining system as a whole for
higher productivity with consistent quality aiming meeting the large requirement
s and overall economy. Such automation enables quick and accurate auxiliary moti
ons, i.e., handling operations like tool – work mounting, bar feeding, tool inde
xing etc. repeatably with minimum human intervention but with the help of specia
l or additional mechanism and control systems. These systems may be of mechanica
l, electro-mechanical, hydraulic or electronic type or their combination. It is
already mentioned that according to degree of automation machine tools are class
ified as, • Non automatic where most of the handling operations irrespective of
processing operations, are done manually, like centre lathes etc. • Semiautomati
c • Automatic where all the handling or auxilliary operations as well as the pro
cessing operations are carried out automatically. General purpose machine tools
may have both fixed automation or flexible automation where the latter one is ch
aracterised by computer Numerical Control (CNC). Amongst the machine tools, lath
es are most versatile and widely used. Here automation of lathes only have been
discussed. The conventional general purpose automated lathes can be classified a
s, (a) Semiautomatic : • • • • (b) Automatic :• • • • capstan lathe (ram type tu
rret lathe) turret lathe multiple spindle turret lathe copying (hydraulic) lathe
Automatic cutting off lathe Single spindle automatic lathe Swiss type automatic
lathe multiple spindle automatic lathes
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The other categories of semiautomatic and automatic lathes are : ο Vertical turr
et lathe ο Special purp se lathes ο N n c nventi nal type, i.e., flexibly aut ma
tic CNC lathes, turning centre etc. (a) Semiaut matic lathes The characteristic
features f such lathes are ; • s me maj r auxiliary m ti ns and handling perat
i ns like bar feeding, speed change, t l change etc. are d ne quickly and c nsi
stently with lesser human inv lvement • the perat rs need lesser skill and putt
ing lesser eff rt and attenti n • suitable f r batch r small l t pr ducti n • c
stlier than centre lathes f same capacity. Capstan and Turret lathes The semia
ut matic lathes, capstan lathe and turret lathe are very similar in c nstructi n
, perati n and applicati n. Fig. 4.7.1 schematically sh ws the basic c nfigurat
i n f capstan lathe and Fig. 4.7.2 sh ws that f turret lathe.
Fig. 4.7.1
Schematic c nfigurati n f capstan lathe.
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Guide r d
Fig. 4.7.2 Schematic c nfigurati n f turret lathe. In c ntrast t centre lathes
, capstan and turret lathes • are semiaut matic • p ssess an axially m vable ind
exable turret (m stly hexag nal) in place f tailst ck • h lds large number f c
utting t ls; upt f ur in indexable t l p st n the fr nt slide, ne in the re
ar slide and upt six in the turret (if hexag nal) as indicated in the schematic
diagrams. • are m re pr ductive f r quick engagement and verlapped functi ning
f the t ls in additi n t faster m unting and feeding f the j b and rapid sp
eed change. • enable repetitive pr ducti n f same j b requiring less inv lvemen
t, eff rt and attenti n f the perat r f r pre-setting f w rk–speed and feed r
ate and length f travel f the cutting t ls • are relatively c stlier • are su
itable and ec n mically viable f r batch pr ducti n r small l t pr ducti n. The
re are s me differences in between capstan and turret lathes such as, • Turret l
athes are relatively m re r bust and heavy duty machines • Capstan lathes genera
lly deal with sh rt r l ng r d type blanks held in c llet, whereas turret lathe
s m stly w rk n chucking type j bs held in the quick acting chucks • In capstan
lathe, the turret travels with limited str ke length within a saddle type guide
bl ck, called auxiliary bed, which is clamped n the main bed as indicated in F
ig. 4.7.1, whereas in turret lathe, the
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• •
heavy turret being m unted n the saddle which directly slides with larger str k
e length n the main bed as indicated in Fig. 4.7.2 One additi nal guide r d r
pil t bar is pr vided n the headst ck f the turret lathes as sh wn in Fig. 4.7
.2, t ensure rigid axial travel f the turret head External screw threads are c
ut in capstan lathe, if required, using a self pening die being m unted in ne
face f the turret, whereas in turret lathes external threads are generally cut,
if required, by a single p int r multip int chasing t l being m unted n the
fr nt slide and m ved by a sh rt leadscrew and a swing type half nut.
Fig. 4.7.3 and Fig. 4.7.4 are sh wing the pict rial views f a typical capstan l
athe and a h riz ntal turret lathe respectively.
Fig. 4.7.3 Pict rial view f a capstan lathe
Ram type turret lathes, i.e., capstan lathes are usually single spindle and h ri
z ntal axis type. Turret lathes are als m stly single spindle and h riz ntal ty
pe but it may be als • Vertical type and • Multispindle type S me m re pr ducti
ve turret lathes are pr vided with pre ptive drive which enables n-line presett
ing and engaging the next w rk-speed and thus help in reducing the cycle time.
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Ramp type turret lathes, i.e., capstan lathes are usually single spindle and h r
iz ntal axis type. Turret lathes are als m stly single spindle and h riz ntal t
ype but it may be als • Vertical type and • Multi-spindle type S me m re pr duc
tive turret lathes are pr vided with pre- ptive drive which enables n-line pres
etting and engaging the next w rk-speed and thus help in reducing the cycle time
. • Multi-spindle Vertical Turret lathe
Fig. 4.7.4 Pict rial view f a turret lathe. Multiple spindle Vertical Turret la
the Turret lathes are m stly h riz ntal axis single spindle type. The multiple s
pindle vertical turret lathes are characterised by : • Suitably used f r large l
t r mass pr ducti n f j bs f generally ; Δ chucking type Δ relatively large
size Δ requiring limited number f machining perati ns • Machine axis – vertica
l f r Δ lesser fl r space ccupied Δ easy l ading and unl ading f blanks and f
inished j bs Δ relieving the spindles f bending l ads due t j b – weight. • Nu
mber f spindle – f ur t eight. Fig. 4.7.5 visualise the basic c nfigurati n f
multiple spindle vertical turret lathes which are c mprised mainly f a large d
isc type spindle carrier and a t l h lding vertical ram as sh wn.
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Such vertical turret lathes are f three categ ries : Parallel pr cessing type
: The spindle carrier remains stati nary. Only the t l slides m ve with cuttin
g t ls radially and axially. Identical j bs (say six) are simultane usly m unte
d and machined in the chucks parallely at all stati ns each ne having same set
f axially and / r radially m ving cutting t ls.
L ading – unl ading stati n
Fig. 4.7.5 Basic c nfigurati n f multispindle aut matic vertical lathe Pr gre
ssively pr cessing type :
The spindle carrier with the blanks fitted in the chucks n the r tating spindle
is indexed at regular interval by a Geneva mechanism. At each stati n the j b u
nderg es a few preset machining w rk by the axially and / r radially fed cuttin
g t ls. The blank getting all the different machining perati ns pr gressively
at the different w rk stati ns is unl aded at a particular stati n where the fin
ished j b is replaced by an ther fresh blank. This type f lathes are suitable f
r j bs requiring large number f perati ns.
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C ntinu usly w rking type :
Like in parallel pr cessing type, here als each j b is finished in the respecti
ve stati n where it was l aded. The set f cutting t ls, m stly fed nly axiall
y al ng a face f the ram c ntinu usly w rk n the same blank thr ugh ut its ne
cycle f r tati n al ng with the spindle carrier. The t l ram having same t l
sets n its faces als r tate simultane usly al ng with the spindle carrier whi
ch after each r tati n halts f r a while f r unl ading the finished j b and l ad
ing a fresh blank at a particular l cati n. Such system is als suitable f r j b
s requiring very few and simple machining perati ns. • Hydraulic c pying (trace
r c ntr lled) lathes J bs having steps, tapers and / r curved pr files, as typi
cally sh wn in Fig. 4.7.6, are c nveniently and ec n mically pr duced in batch
r l t in semiaut matically perated tracer c ntr lled hydraulic c pying lathe. T
he m vement f the stylus al ng the template pr vided with the same desired j b-
pr file) is hydraulically transmitted t the cutting t l tip which replicates t
he template pr file.
Fig. 4.7.6
A typical j b suitable f r c py turning.
(b)
General Purp se Aut matic lathes
Aut matic lathes are essentially used f r large l t r mass pr ducti n f small
r d type f j bs. Aut matic lathes are als classified int s me distinguished c
ateg ries based n c nstructi nal features, perati nal characteristics, number
f spindles and applicati ns as f ll ws • Single spindle Δ Aut matic cutting ff
lathes Δ Aut matic (screw cutting) lathe Δ Swiss type aut matic lathe • Multisp
indle aut matic lathe
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Aut matic cutting ff lathe These simple but aut matic lathes are used f r pr du
cing sh rt w rk pieces f simple f rm by using few cr ss feeding t ls. In addit
i n t parting s me simple perati ns like sh rt turning, facing, chamfering etc
. are als d ne. Single spindle aut matic lathe The general purp se single spind
le aut matic lathes are widely used f r quantity r mass pr ducti n (by machinin
g) f high quality fasteners; b lts, screws, studs etc., bushings, pins, shafts,
r llers, handles and similar small metallic parts fr m l ng bars r tubes f re
gular secti n and als ften fr m separate small blanks. Fig. 4.7.7 sh ws a typi
cal single spindle aut matic lathe. Unlike the semiaut matic lathes, single spin
dle aut mats are : • preferably and essentially used f r larger v lume f pr duc
ti n i.e., large l t pr ducti n and mass pr ducti n • used always f r pr ducing
j bs f r d, tubular r ring type and f relatively smaller size. • run fully au
t matically, including bar feeding and t l indexing, and c ntinu usly ver a l
ng durati n repeating the same machining cycle f r each pr duct • pr vided with
upt five radial t l slides which are m ved by cams m unted n a cam shaft • f
relatively smaller size and p wer but have higher spindle speeds
Fig. 4.7.7
A typical single spindle aut matic lathe.
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Swiss type aut matic lathe The characteristics and applicati ns f these single
spindle aut matic lathes are : • In respect f applicati n : Used f r l t r mas
s pr ducti n f thin slender r d r tubular j bs, like c mp nents f small cl ck
s and wrist watches, by precisi n machining; J b size (appr ximately) ⎯ Diamet
er range – 2 t 12 mm ⎯ Length range – 3 t 30 mm Dimensi nal accuracy and surfa
ce finish – alm st as g d as pr vided by grinding • In respect f c nfigurati n
and perati n ο The headst ck travels enabling axial feed f the bar st ck agai
nst the cutting t ls as indicated in Fig. 4.7.8 ο There is n tailst ck r turr
et ο High spindle speed (2000 – 10,000 rpm) f r small j b diameter ο The cutting
t ls (upt five in number including tw n the r cker arm) are fed radially ο
Drilling and threading t ls, if required, are m ved axially using swivelling de
vice(s) ο The cylindrical blanks are prefinished by grinding and are m ved thr u
gh a carbide guide bush as sh wn.
Fig. 4.7.8
Basic principle f Swiss type aut matic lathe.
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Multispindle aut matic lathes F r further increase in rate f pr ducti n f j bs
usually f smaller size and simpler ge metry. Multispindle aut matic lathes hav
ing f ur t eight parallel spindles are preferably used. Unlike multispindle tur
ret lathes, multispindle aut matic lathes ; ο are h riz ntal (f r w rking n l n
g bar st cks) ο w rk m stly n l ng bar type r tubular blanks Multiple spindle
aut mats als may be parallel acti n r pr gressively w rking type. Machining f
the inner and uter races in mass pr ducti n f ball bearings are, f r instance
, machined in multispindle aut matic lathes.
(ii)
Kinematic Systems And W rking Principles Of Semi Aut matic And Aut matic Lathes
The kinematic systems and basic principles f w rking f the f ll wing general p
urp se semi-aut matic and aut matic lathes f c mm n use have been visualised an
d briefly discussed here : (a) Semi-aut matic lathes : • Capstan and single spin
dle turret lathe • Hydraulic c pying lathe (b) Aut matic lathes • Single spindle
aut matic (screw cutting) lathe • Swiss type aut matic lathe Kinematic system a
nd w rking principle f capstan lathe Like general c nfigurati ns and applicati
ns, the basic kinematic systems are als very similar in capstan lathes and turr
et lathes (particularly single spindle bar and h riz ntal types) in respect f t
heir maj r functi ns, i.e., ο bar feeding mechanism ο turret m ving and indexing
ο speed and feed drives Bar feeding mechanism f capstan lathe Fig. 4.7.9 typic
ally sh ws the kinematic arrangement f feeding and clamping f bar st ck in cap
stan lathes. The bar st ck is held and tightly clamped in the push type spring c
llet which is pushed by a push tube with the help f a pair f bell-crank lever
s actuated by a taper ring as sh wn in Fig. 4.7.9. Bar feeding is acc mplished b
y f ur elementary perati ns; ο unclamping f the j b – by pening the c llet ο
bar feed by pushing it f rward ο clamping f the bar by cl sing the c llet ο fre
e return f the bar-pushing element
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After a j b is c mplete and part ff, the c llet is pened by m ving the lever m
anually rightward t withdraw the push f rce n the c llet. Further m ving f th
e lever in the same directi n causes f rward push f the bar with the help f th
e ratchet – paul system sh wn. After the pr jecti n f the bar fr m the c llet f
ace t the desired length c ntr lled by a pre-set st p – st ck generally held in
ne face f the turret r in a separate swing st p, the lever is m ved leftward
resulting cl sing f the c llet by clamping f the barst ck. Just bef re clampi
ng f the c llet, the leftward m vement f the lever pushes the bar feeder (ratc
het) back freely against the paul. Turret indexing mechanism in capstan and turr
et lathes Turret indexing mechanism f capstan and single spindle turret lathe i
s typically sh wn schematically in Fig. 4.7.10. The turret (generally hexag nal)
h lding the axially m ving cutting t ls have the f ll wing m ti ns t be c ntr
lled mechanically and manually ; ο f rward axial traverse c mprising; Δ quick a
ppr ach – manually d ne by r tating the pini n as sh wn Δ sl w w rking feed – au
t matically by engaging the clutch Δ st p at preset p siti n depending up n the
desired length f travel f the individual t ls quick return – manually d ne
by disengaging the clutch and m ving the turret back indexing f the turret by
60 ( r multiple f it) – d ne manually by further m ving the turret slide back
.
Fig. 4.7.9 Typical bar feeding mechanism in capstan lathe.
Just bef re indexing at the end f the withdrawn by the lever which is lifted at
against the hinged wedge as indicated in travel f the turret slide causes r ta
ti n f
return str ke, the l cking pin is its ther end by gradually riding Fig. 4.7.10
(a). Further backward the free head by the indexing pin Versi n 2 ME, IIT Kharag
pur
and lever as indicated in Fig. 4.7.10 (b). R tati n f the turret head by exact
angle is acc mplished by inserti n f the l cking pin in the next h le f the si
x equispaced h les. After indexing and l cking, the turret head is m ved f rward
with the next cutting t l at its fr nt face when the r ller f the lever retur
ns thr ugh the wider sl t f the wedge with ut disturbing the l cking pin as ind
icated in the figure. The f rward m ti n f the turret head is aut matically st
pped when the set-screw c rresp nding t the w rking t l is arrested by the mec
hanical st p. The end p siti n and hence length f travel f the t l is g verne
d by presetting the screw. There are six such screws, each ne c rresp nds with
particular face r t l f the turret. The drum h lding th se equispaced six scr
ew with different pr jecti n length is r tated al ng with the indexing (r tati n
) f the turret head by a pair f bevel gears (1:1) as indicated in Fig. 4.7.10
(a). The b tt m m st screw, which c rresp nds with the t l n the fr nt face f
the turret, when hits r t uches the st p, the turret m vement is st pped eithe
r manually by feeling r aut matically by disengaging the clutch between the fee
d r d and the turret slide.
st p
(a) secti nal view
(b) t p (inner) view Fig.4.7.10 Turret indexing in capstan and turret lathe.
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Kinematics and w rking principle f hydraulic c pying lathe Hydraulic drive is
ften preferably used in s me machine t ls f r sm th m ti ns with ut jerk and n
ise, self lubricati n, flexible transmissi n system and stepless variati n in s
peed and feed despite the limitati ns like larger space requirement, il leakage
, difficult maintenance etc. Fig. 4.7.11 typically sh ws the circuitry f a hydr
aulically driven (t l travel) drilling machine. The directi n and length f tra
vel f the drilling head fitted n the m ving pist n are c ntr lled by m vement
f the sp l f the directi n c ntr l valve which is actuated by the pil t valve
and g verned by the electr mechanical st p as indicated in the figure. The rate
f travel f the drill head i.e., the feed rate is g verned by the thr ttle r
metre c ntr lling valve which is again c ntr lled by a template like cam and a f
ll wer c upled with the sp l f the thr ttle valve as sh wn in Fig. 4.7.11. T
keep feed rate c nstant irrespective f the w rking f rce n the pist n, a pres
sure reducing valve is pr vided pri r t the thr ttle valve. The pressure reduci
ng valve helps keep its exit pressure i.e., input pressure f the thr ttle valve
fixed t a preset value irrespective f the input pressure f the pressure redu
cing valve which varies with the w rking l ad n the drill pist n. C nstant pres
sure difference keeps c nstant fluid fl w rate thr ugh the thr ttle valve result
ing c nstant feed rate irrespective f the cutting f rce.
Fig. 4.7.11 Circuitry and kinematic system f hydraulically driven machine t l
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Fig.4.7.12 schematically sh ws the principle f typical hydraulic c pying lathe.
The cr ss feed is c ntr lled, under fixed l ngitudinal feed, hydraulically. Whe
n the stylus m ves in the transverse directi n slightly (by say Δx) due t sl pe
r pr file in the fixed template, the p rts pen enabling the high pressure flu
id enter in the l wer chamber. Since the pist n is fixed, the sliding cylinder h
lding the cutting t l will start m ving d wn. When the t l als retracts by Δ
x the p rts get cl sed. This way the incremental r discrete m ti n f the stylu
s is replicated by the t l tip resulting true c pying f the pr file fr m the t
emplate t the j b.
Fig.4.7.12 •
Principle f hydraulic c py turning.
Kinematic system and w rking principle f aut matic lathes f c mm n use.
ο Single spindle aut matic lathe This general purp se and widely used autmatic l
athe is als kn wn as single spindle aut matic screw cutting lathe (ssASCL) beca
use such lathes were intr duced aiming mainly mass pr ducti n f fasteners havin
g screw threads. Fig. 4.7.13 schematically sh ws the typical kinematic system f
single spindle aut mat. The maj r characteristic functi ns that are aut matical
ly acc mplished in sequence and pr per synchr ny in such lathes are : Δ spindle
speed change – magnitude and directi n f r tati n Δ bar feeding Δ transverse t
ls – feeding Δ turret indexing and travelling Versi n 2 ME, IIT Kharagpur
Single rev luti n clutch
Cylindrical cam
spindle
c llet
Finger c llet barst ck clutch Trip d g II I clutch
turret T l slide Cam f ll wer
Cam
Trip d g
Fig. 4.7.13 Typical kinematic system f single spindle aut matic lathe.
Δ Change f spindle speed Repetitive pr ducti n in large v lume and limted range
s f j b – t l materials and j b – diameter necessitate a small number f spind
le speeds in aut matic lathes unlike centre lathes. H wever, at least tw speeds
, high and l w (f r threading etc.) and pr visi n f reversal f th se speeds ne
ed t be pr vided in aut matic lathes. P wer and speed are transmitted fr m the
m t r t shaft – I thr ugh belt-pulley and a speed gear b x (SGB) if required as
can be seen in Fig. 4.7.13. The tw gear l sely m unted n shaft I are in mesh
with tw gears fixed n shaft II. R tati ns are transmitted fr m shaft II t th
e spindle by tw pairs f chain and spr ckets as indicated in the kinematic diag
ram (Fig. 4.7.13). The tw spr ckets are l sely m unted n the spindle and simu
ltane usly r tate at the same speed, l w r high, but in pp site directi ns. Th
e spindle is made t r tate at high r l w speed and cl ckwise r anticl ckwise
by engaging the clutches n shaft I and the spindle respectively. The clutch is
shifted by a lever and cylindrical cam which is r tated at the desired m ment by
ne rev luti n nly with the help f a single
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rev luti n clutch which is again triggered by a trip d g c ntr lled by the camsh
aft as sh wn in the figure. Δ Bar feeding mechanism F r feeding the barst ck t
a desired pr jecti n length after c mpleting machining and parting a j b, first
the c llet is pened by withdrawing the push f rce by m ving the taper ring utw
ard by a lever aut matically with the help f the cylindrical cam. Then the cam
at the ther end f the cylinder pushes the r d f rward using the lever, a slide
and finger c llet. Next half f the r tati n f that cylindrical cam acc mplish
es clamping c llet and return f the finger c llet by m ving the levers in pp s
ite directi n. Here again, the cylindrical cam is r tated by nly ne rev luti n
by actuating an ther single rev luti n clutch at the pr per m ment by a trip d
g as indicated in the figure. Δ Transverse t l feeds The radially m ving cuttin
g t ls (upt five) are fed sequentially at preset timings and desired length an
d rate f travel by individual cams m unted n the cam shaft which r tates sl wl
y with ne r tati n f r ne machining cycle i.e., ne pr duct. All the single re
v luti n clutches are m unted n the auxiliary shaft which p sitively r ates at
a c nstant speed f 120 rpm. R tati n is transmitted fr m that t the cam shaft
thr ugh speed reducti n and a feed gear b x (FGB) t vary the cam-shaft speed de
pending up n the cycle time f r each j b. Feed m ti ns f the axially fed cuttin
g t ls m unted n the turret Δ The end p ints, length and rate f travel f the
six t ls n the turret are g verned by a single plate cam having six l bes c r
resp nding t the t ls in the turret as sh wn in the figure. The r tati nal spe
ed f that cam is kept same as that f the cam shaft. Turret indexing mechanism
Δ The hexag nal turret is r tated (f r indexing) by a Geneva mechanism where a G
eneva disc having six radial sl ts is driven by a rev lving pin. Bef re starting
r tati n, the l cking pin is withdrawn by a cam lever mechanism sh wn in the di
agram. The single r tati n f the disc h lding the indexing pin is derived fr m
the auxiliary shaft with the help f an ther single rev luti n clutch as indicat
ed • Kinematic system and perating principle f Swiss type aut matic lathe
The kinematic diagram f typical Swiss type aut matic lathe is schematically sh
wn in Fig. 4.7.14. B th the high speed f the spindle and the l w speed f the c
am shaft are derived fr m the m t r as indicated in the diagram. All the cutting
t ls m unted n the transverse slides are travelled t desired depth and at de
sired feed rate by a set f plate cams m unted n the cam shaft. The headst ck w
ith the spindle having the barst ck clamped in it is m ved f rward and
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returned at desired feed rate by a set f plate cams m unted n the camshaft as
sh wn.
Fig. 4.7.14
Kinematic system f Swiss type aut matic lathe.
Feeding f the bar, after c mpleti n and parting f a j b is d ne sequentially b
y Opening the c llet by shifting the taper ring by a cam as sh wn Pushing the ba
r, against the last w rking t l, by a gravitati nal f rce C llet clamping by re
turn f the ring
(iii) Pr cess Planning And T l Lay ut F r Machining A Pr duct In Semi-Aut matic
And Aut matic Lathes.
The pr cedural steps t be f ll wed in sequence f r batch r l t pr ducti n f a
j b by machining in semi-aut matic and aut matic general purp se machine t ls
are : (a) Th r ugh study f the j b t be pr duced: in respect f : • v lume f
pr ducti n, i.e., number f pieces f the specific j b t be pr duced • material
and its pr perties • size and shape • surfaces t be machined • required dimens
i ns with t lerances and surface finish • end use f the pr duct
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(b) Selecti n f machine t l (after studying the j b): in respect f ; • type •
size • precisi n • kind and degree f aut mati n (c) Selecti n f blank (based
n j b and machine selected): in respect f; • bar chucking r h using type • pr
ef rmed by; casting, f rging, r lling etc. • if bar type; cr ss secti n (circula
r, tubular, square, hexag n etc.) • n minal size based n largest dimensi ns and
availability • pref rmed by h t w rking r c ld w rking (d) Identificati n and
listing f the elementary machining perati ns required, depending up n the pr d
uct c nfigurati n (e) C mbine elementary machining perati ns as much as p ssibl
e f r saving time (f) Sequence the perati ns (after c mbining) (g) Select cutti
ng t ls: in respect f; • type • material • size • ge metry • availability depe
nding up n the machining perati ns (after c mbining) and w rk material (h) w rk
scheduling r preparati n f the instructi n sheet r perati n chart giving c
lumn-wise : • descripti n f the machining w rk t be d ne in sequence • cutting
t ls : type and l cati n • speed and feed f r each perati n • length f trave
l f the t ls • cutting fluid applicati n; yes r n t required type f cutt
ing fluid (i) T l lay ut : schematically sh wing the type and c nfigurati n f
the cutting t ls and their l cati n and m unting. A typical t l lay ut f r a p
articular j b being machined in a single spindle aut matic lathe is schematicall
y sh wn in Fig. 4.7.15.
Versi n 2 ME, IIT Kharagpur
Fig. 4.7.15 T l lay ut f r a typical j b in single aut matic lathe.
(Iv) Case Study : As An Example
• Task (say) : 2500 pieces f h ll w hexag nal headed mild steel b lts, as sh wn
in Fig. 4.7.16, are t be pr duced by machining.
ο Machine t l selected : Single spindle aut matic lathe f r • L t pr ducti n (f
r smaller v lume f pr ducti n capstan lathe is better) • Circular bar type j b
• C mm n machinable material • Simple machining perati ns required
Versi n 2 ME, IIT Kharagpur
Fig. 4.7.16 Shape and dimensi n f the specific j b ο Blank selected : H t r lle
d hexag nal secti n mild steel bars f r; • saving machining f the hexag nal hea
d p rti n • the hexag nal head is f standard size which is available • j b size
– reas nable f r single spindle aut matic • n t being precisi n j b ο Elementar
y machining perati ns – identified and listed : • Facing • Centering • Chamferi
ng (1) – fr nt • Chamfering (2) – middle p rti n • Chamfering (3) – b lt head •
R ugh turning (1) – t make circular fr m hexag n • R ugh turning (2)
– t reduc
e diameter t 12 mm • Finish turning – t φ10 • Drilling • Grooving ( orming) •
Thread cutting • Initial parting • Parting
Version 2 ME, IIT Kharagpur
ο C mbining elementary perati ns Δ c mbining perati ns t be d ne by a c mp un
d t l in a single travel fr m ne t l p siti n Δ paralleling r verlapping p
erati ns t be d ne by different t ls m ving in different directi ns. The liste
d elementary perati ns can be c mbined and sequenced as f ll ws : 1 2 3 4 5 6 7
• R ugh turning (1), initial parting

and rear chamfering (3) R ugh turning (t

φ12) and
drilling and

centering ( or the next job) Finish

turning (φ10) Spot ac
ing and ront cham ering (1) Grooving and central cham ering (2) Thread cutting
Parting
Scheduling – operation chart indicating tools and tool positions and machining c
onditions.



N = spindle speed (rpm), s
= eed (mm/rev), L = tool travel,

CF = cutting luid
HT (1) = hexagonal turret ace 1, RS = Rear slide, FS = ront slide, VS = vertic
al slide Table – 1 : Scheduling; operation chart
S L CF Sl. Operation Tool Tool
N No. position 1 Stop stock & bar Stop HT (1) N eed 2 Rough turning

(1) Turning
tool HT(2) 640 0.10 30 Y Initial parting Formed RS 0.05 6 Y Cham ering (3) Part
ing tool 3 Rough parting (2) Turning tool Drill HT(3) 640 0.10 50 Y Drilling

(φ6
) centering 4 Finish turning
Turning tool HT(4) 640 0.05 25 Y 5 Spot acing Comp
ound HT(5)

640 0.05 5 Y Cham ering (1) tool 6 Grooving Form tool FS 640 0.05 10
Y Cham ering (2) 7 Threading Solid die HT(6) 56 2 20 Y 8 Parting Parting tool VS
640 0.05 12 Y
]
]
] ]
Version 2 ME, IIT Kharagpur
•


Tool layout – The possible tool layout made based on the scheduling made or the
product is schematically shown in Fig. 4.7.17.


Fig. 4.7.17 Tool layout or machining the given job in single spindle automatic
lathe
Version 2 ME, IIT Kharagpur