LECTURE 2

TURNING AND RELATED OPERATIONS

Mahmoud Heshmat
PhD in IESM, 2018
Turning
 Mechanics of Turning

df
d

3
Tools

4
Standard Turning Tools

5
 Turning Time

l +l+l
la
lo
l tm = a o
f

f = S.N
N

S S

6
Surface Profile by Rounded Tool

7
Surface Profile by Pointed Tool

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 Reasons Behind Normal Roughness

▪ Built up edge
▪ Chatter/vibrations
▪ Inaccuracies in machine tool
▪ Defects in the workpiece structure.
▪ Discontinuous chip (Brittle materials)
▪ Tearing of the work material (Ductile materials)
▪ Surface damage caused by chip flow.

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 Cutting Speeds for Turning

Work material Cutting speed,

m/min
Aluminum alloys 200-1000
Cast iron, grey 60-900
Copper alloys 50-700
High-temperature alloys 20-400
Steels 50-500
Stainless steels 50-300
Thermoplastics and thermo sets 90-240
Titanium alloys 10-100
Tungsten alloys 60-150
Note (a): These speeds are for carbides and ceramic cutting tools. Speeds for high speed steel tools are lower than indicated.
The higher ranges are for coated carbides and cermets. Speeds for diamond tools are considerably higher than those indicated.
(b) Depths of cut, t, are generally in the range of 0.5-12 mm
(c) Feeds, s, are generally in the range of 0.15 to 1 mm/rev 10
 Turning Tool Features

Property level
Rake angle -20 to +30o normal
+5 to +20o recommended
Clearance angle 6 to 15o normal
8 to 12o recommended
Main edge inclination angle 0 to 5o
Auxiliary edge inclination angle 5 to 10o
Approach angle 45, 60 or 90 o
Nose radius 1 to 2 mm
Shank cross section rectangular (commonly used)
square (withstand bending stresses)
round (boring and threading tools)

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Thread Cutting

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 Gear Train

Gears supplied with lathes, generally, range from 20 T to 120 T.

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 Gear Ratio

Turns of leadscrew Teeth on C Teeth on E Teeth on Drivers

= X =
Turns of spindle Teeth on D Teeth on F Teeth on Driven

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Facing Lathes

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Capstan and Turret Lathes

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Cutting Conditions in Turning
 Turning Processes

(a) facing, (b) taper turning, (c) contour turning, (d) form turning
Turning Processes

(e) chamfering, (f) cutoff, (g) threading

 Turning Processes

(h) boring, (i) drilling, and (j) knurling

The Engine Lathe
Methods of Holding the Work in a Lathe
Boring Machines
See You Next Lecture