General Lathe Set Up

Lathe Manual JH compilation 3.3.06

Machine Shop Safety............................................................................................................................ 2

General Lathe Set-Up ............................................................................................................................... 4
Facing, Turning, and Shouldering: ................................................................................................... 4
Three things matter with your tool bit position: ............................................................................... 5
1. Height, 2. Front clearance and 3. Side clearance. See below. .................................................... 5
Identifying a Quality Tool-bit Set-up ....................................................................................................... 6
The complete set-up.......................................................................................................................... 7
Facing: .............................................................................................................................................. 8
Turning and Shouldering .................................................................................................................. 8
Centerdrill/Countersink: ................................................................................................................. 10
Tapping on a Lathe: ........................................................................................................................ 10
Lathe Speeds and Other Rules........................................................................................................ 13
For Facing and Turning of Diameter of Soft Metal Stock.................................................................. 13
For Facing and Turning of Diameter of Plastic Stock........................................................................ 13
For Drilling on the Lathe .................................................................................................................... 13
Other Rules of Lathe Use ................................................................................................................... 13
Machine Tool Items and Shop Supplies Commonly Purchased from Travers Tool ...................... 14
Description
Part Number.................................................................................................................. 14
Decimal Equivalents ....................................................................................................................... 15
Tap Drill Size Chart........................................................................................................................ 16

Machine Shop Safety

Lathe Manual JH compilation 3.3.06

Safety Glasses
EVERYONE MUST WEAR SAFETY GLASSES IN THE SHOP.
Even when you're not working on a machine, you must wear safety glasses. A chip from a machine someone else
is working on could fly into your eye.
Clothes and Hair
Check your clothes and hair before you walk into the shop. In particular:
o REMOVE JEWELERY
o IF YOU HAVE LONG HAIR OR A LONG BEARD, TIE IT UP.
If your hair is caught in spinning machinery, it will be pulled out if you're lucky. If you're unlucky, you
will be pulled into the machine.
o NO LOOSE CLOTHING.
Ties, scarves, loose sleeves, etc. are prohibited
o NO GLOVES
o WEAR APPROPRIATE SHOES
No open toed sandals. Wear shoes that give a sure footing. If you are working with heavy objects, steel
toes are recommended.
Safe Conduct in the Shop
Be aware of what's going on around you. For example, be careful not to bump into someone while they're cutting
with the bandsaw (they could lose a finger!).
Concentrate on what you're doing. If you get tired, leave.
Don't hurry. If you catch yourself rushing, slow down.
Don't rush speeds and feeds. You'll end up damaging your part, the tools, and maybe the machine itself.
Listen to the machine. If something doesn't sound right, turn the machine off.
Don't let someone else talk you into doing something dangerous.
Don't attempt to measure a part that's moving.
Machining
IF YOU DON'T KNOW HOW TO DO SOMETHING, ASK!
BEFORE YOU START THE MACHINE:
o
o
o

Study the machine. Know which parts move, which are stationary, and which are sharp. Spin the chuck
by hand to insure that all is clear!
Double check that your workpiece is securely held.
Remove chuck keys and wrenches.

DO NOT LEAVE MACHINES RUNNING UNATTENDED!

CLEAN UP MACHINES AFTER YOU USE THEM!
A dirty machine is unsafe and uncomfortable to work on.
Do not use compressed air to blow machines clean. This endangers people's eyes and can force dirt into machine
bearings.
Courtesy of the U.S. Army

Lathe Manual JH compilation 3.3.06

General Lathe Set-Up

Facing, Turning, and Shouldering:
Below is an overhead shot of the set-up for facing and turning.
What you see is a right-handed tool bit in a left-handed holder mounted in a rocker-type tool post. In
the lathe headstock chuck is a dead center, but a live-center chucked on its cylindrical body can also
work to help establish proper tool bit height.

Lathe Manual JH compilation 3.3.06

Three things matter with your tool bit position:

1. Height, 2. Front clearance and 3. Side clearance. See below.

Remember that the left-handed holder is used for facing, turning, and shouldering.

Lathe Manual JH compilation 3.3.06

Identifying a Quality Tool-bit Set-up

The Tool Post is positioned left of center in the compound
rest.

The Tool Bit Holder is choked up in the tool post to

minimize chatter.

The Tool Bit extends out of the holder just enough this
minimizes chatter and prolongs tool life. In this
instance, the tool bit extends out from the holder
approximately .

Lathe Manual JH compilation 3.3.06

The complete set-up

Lathe Manual JH compilation 3.3.06

Facing:
Position the tool bit just in front of the center of the part, as
shown.

Using the carriage handwheel, cut into the stock. Then, using
the cross slide, proceed to center of the stock.
At this point, hold onto the carriage hand wheel to prevent
the carriage from floating away from the stock.

Once at center, immediately begin drawing the cross slide

toward the exterior of the part, toward you.
1. Do not extend the tool bit beyond center of the stock.
2. Make certain you are holding the carriage steady at
the handwheel throughout the entire process this
prevents the part from doming.
Continue drawing the cross slide toward you until the stock is
completely faced.

Turning and Shouldering

Lathe Manual JH compilation 3.3.06

The same tool bit set up used for facing can be used for turning to a specific diameter and creating a 90
degree shoulder on the workpiece.

Floating Micrometer Scale

When turning, the cross
slide advances the tool
bit.
The micrometer scale
allows the operator to
control the amount of
material removed.
The scale can be rotated
independently of the
cross slide, then locked in
position to assist the
operator with precision
dimensioning of the work
piece.

Lathe Manual JH compilation 3.3.06

Centerdrill/Countersink:
Centerdrill/Countersinks serve three purposes: The cylindrical center-point is used to create a pilot for
drilling holes, the tapered countersink is used to chamfer and countersink, and to provide a tapered
center for insertion of a live center.

Tapping on a Lathe:
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To ensure that internal threads are cut square, a live center can be placed in the tailstock to support the
tap handle. As the part is threaded, the ram is drawn forward, not to push the tap, but simply to insure
that no lateral forces are placed on the tap while threading a key to reducing tap breakage.

Setting up to copy a mouthpiece taper:

A dial indicator is used when one needs to re-set a mouthpiece taper or adjust the shank. Note
the dead-center used to support the mouthpiece in the chuck and the live-center supporting the

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backbore. The taper is copied by adjusting the compound slide to the same angle as the shape
the dial indicator providing an accurate read on progress.

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Lathe Speeds and Other Rules

For Facing and Turning of Diameter of Soft Metal Stock

(brass, aluminum, cold-rolled steel, bronze)
examples:

300 diameter of part = chuck speed

chuck speed for a diameter piece should be approximately 600 rpm
chuck speed for a 5/8 diameter piece should be approximately 480 rpm
chuck speed for a 1 diameter piece should be approximately 300 rpm
***************************************************************

For Facing and Turning of Diameter of Plastic Stock

(abs, delrin)
400 diameter of part = chuck speed

For Drilling on the Lathe

300 Diameter of Drill Bit

Other Rules of Lathe Use

Parts should never extend out of the headstock chuck more than 3X the diameter of the part
without live center support.

Example: The maximum extension for a 5/8 diameter piece chucked in the headstock chuck should be 2 before live
center support is required.

Rams should be extended 1 on their body rule before inserting any tailstock accessory.

Inspect compound slides to ensure they are in the middle of their travel stroke before any
lathe is used.

Tool bit height is set at center, whether facing or turning.

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13

Machine Tool Items and Shop Supplies Commonly Purchased from Travers
Tool

Description
6-Flute Countersink
Hacksaw Blades
Lathe File (10)
3M Diamond Files (400 grit)
3M Diamond Files (800 grit)
Wheel Dresser
Diamond Sharpening Stone
Diamond Lapping Pad (fine)
Craytex Deburring Wheels (2 dia.)
Dial Caliper
Micrometer
Dial Indicator Set
Granite Surface Plate
Telescoping Gauge Set
Small Hole Gauge Set
60 Center Gauge
Drill Press Vise
Brass Shim Assortment
#1 Gold Cutting Fluid (pint)
Stick Wax
LPS2 Lubricant (aerosol)
Red Bearing Grease
Never-Seez Epoxy Stick
Pre-Solve Degreaser (aerosol)
Thermomelt Temperature Indicator (500)
Drills
Taps/Dies
Thread Inserts
HSS + Carbide Tool Bits
Boring Bars

Lathe Manual JH compilation 3.3.06

Part Number
07-040-032
26-300-140
51-732-555
54-580-831
54-580-832
53-410-000
53-810-010
54-514-987
53-700-326 (X-fine)
57-015-006
57-001-001
57-080-602
57-037-609
57-025-011
57-045-001
57-071-778
61-200-000
71-201-901
81-007-050
81-004-001
81-001-110
81-006-540
81-006-573
81-001-190
81-004-500

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Tube Chamfering
Beveling Edges
Tone Hole Leveling
Tone Hole Leveling
General Purpose
Polishing
Deburring
Lathe Precision Turning
Straightening Tbone Slides
Internal Measuring
Tone Hole Measuring
Tool Bit Grinding
Multi-Purpose
Turning/Drilling
Dent Ball Lube
Tool Lubrication
Slide Grease
Main T.S. Molds
Lacquer Prep
Soldering

Decimal Equivalents

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Tap Drill Size Chart

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16