Fundamental of Mechanical

Manufacturing
Professor: Dr. Hu

Name Barua Saikat

Id 201939030028

Major Mechanical Engineering

School School of Mechatronic Engineering

 Analysis of how to select the proper cutting tool for lathe operation.

1. Goal

 I learn how to lathe machine works.

 I learn how to cutting tools works.
 I how to select the proper cutting tool for lathe operation.
 I learn Carbide-tipped tools and on the right, carbide-insert tools.

2. Introduction

In the Mechanical Engineering field Lathe machine plays an important role in

Manufacturing. In this article, I am going to discuss the Lathe machine in detail.

 A lathe is a machine tool which is used to remove unwanted metals from the work piece
to give desired shape and size.
 Lathe machine is one of the most important machine tools which is used in the
metalworking industry.
 It operates on the principle of a rotating work piece and a fixed cutting tool.
 The cutting tool is feed into the work piece which rotates about its own axis causing the
workpiece to form the desired shape.
 It is also known as” the mother/father of the entire tool family”.
 It was invented by DAVID WILKINSON (05 Jan. 1771 – 03 Feb. 1852).

3. Video Explanation
The selection of a cutting tool is probably the most important decision of machinists can
make. Work lathe tools are made of many different types of materials in many size an
styles, the three types. In this video I can see from the left high speed steel tools carbide
tip tools and on the right carbide insert tools high speed steel tools can be used for many
turning operations on all, but the toughest alloys the tools are sold as blanks in many
sizes and grades the machinist grinds the point of the tool depending on the type of metal
he's cutting and the type of turning operation. HE intends to do a good machinist
handbook will give you the standard guidelines for grinding high speed steel tools. The
cutting edge of a carbide tip tool is braised to the end of a steel shank the shape of the
cutting edge. It’s profile and hitting angle are manufacturing into the tool a little clean-up
on a green wheel a silicon carbide grinding wheel and the tool is ready to go cemented
carbide will handle much more heat than high speed, steel so carbide tools are able to cut
tougher metals and cut at higher speeds cemented carbide is also used to make small
inserts that are clamped to a tool shank. This style insert is manufactured with a cutting
edge on each of its three sides after an edge is dulled the insert can be unclamped and
rotated to the next side after. All the edges have dulled the insert is thrown away and
replaced by a new one although this type of cutting tool was designed for the demands of
high production work it's really a great tool for the beginner. Because it allows even the
 person with little or no tool sharpening experience the ability to easily maintain a
properly formed sharp tool no matter what type of material the cutting tools is made of.
It's the shape of the tool that determines how it can be used the profile of the tools points
determines the type of cut the tool is designed to make. The location of the cutting edge
on the point of the tool determines the direction in which the tool will cut turning and
facing tools are either right- or left-hand tools depending on which side of the tool shank.
The cutting edge is ground right hand tools cut from right to left because the cutting edge
is on the left side of the tools point facing from the center of a part to the outer edge
cutting right to left requires a right hand facing tool lest hand turning and facing tools cut
from left to right cutting away from the headstock in a turning operation or from the outer
edge to the center in a facing operation the cutting edges on these tools are on the right
side of the tools point sending a tool straight into a workpiece is called a plunge cut this
type of cut requires a tool that has the cutting edge square of the nose of the tool here
we're using a high speed steel cutoff blade and holder. The position of the cutting tool in
the tool holder is very important tools should always be placed as far into the tool holder
as possible to give the cutting-edge adequate support and to rescue the possibility of the
tool vibrating in the case of a boring tool. Only the lengths needed to clear the hole
should extend out beyond the tool holder the height of the tool should be set to match the
center of the lathe axis a lathe center placed in the tailstock can be used as a gauge to set
the height on this tool holder shims and spacers are used to raise the tool the tailstock is
also used as a tool holder for drilling reaming countersinking and thread tapping
operations on the lathe.

4. How do I choose a cutting tool?

The selection of right cutting tools is
based on the material to machine, power
available on machine, fixture stability,
machine dynamics which leads to the
right selection of cutting tool material,
grades, geometries, depth of cuts and the
feeds.
5. Which cutting tool is used in lathe machine?

A tool bit is a non-rotary cutting tool used in metal lathes, shapers, and planers. Such cutters are
also often referred to by the set-phrase name of single-point cutting
tool, as distinguished from other cutting tools such as a saw or water
jet cutter.

6. What are the factors to consider in selecting the proper cutting

tool's to be used?

Here we will review some of the macro considerations in metal cutting tool selection.

a. The Most Important Tool.

b. Fit for the Machine.
c. Fit for the Material.

d. Size of Tool.
e. Indexable versus Regrind able.

f. Tool Material and Grades.

g. Power Requirements.
h. Number of Edges.
a. The Most Important Tool:  If anyone tool stops working, production stops. But it does
not follow that each tool deserves equal attention.  The tool with the longest cut time
will have the most influence on cycle time, so all things being equal this tool should
command your greatest attention.  Give extra attention to the tool that cuts critical part
features and the tightest tolerance. Also, tools that are most likely to produce poor
chips (e.g., drilling, grooving and threading) deserve more attention. Bad chips cause
downtime.

b. Fit for the Machine: Tools come in hands—right and left—so it’s important to pick the
correct hand.  Normally right-hand tools fit machines running CCW (as viewed looking
into the spindle) and left-hand tools fit machines running CW.  If you have several lathes
 —some that use left-hand tools and others able to use right or left hand—choose left-
hand tools. For mills there is a tendency to use a tool with too much reach. While
extended-reach tools will cover more parts, you rapidly give up rigidity, increase tool
deflection, reduce cutting rates, and they are more likely to chatter.  Tool changers have
limits on size and weight.  If you paid for coolant thru the spindle, select tools that have
this capability.

c. Fit for the Material: Most machined materials are carbon steel, so most cutting tools
are designed to best cut carbon steel.  Grade selection is dependent upon the material
cut.  For no steels, tool manufacturers offer lines of toolholders and matching insert
geometry designed for these materials—such as high-temperature alloys, titanium,
aluminum, composites, plastics and pure metals, etc. If you cut any of these, ask for
information about tools designed specifically for those materials.

d. Size of Tool: A common mistake is selecting a lathe tool that is too small and a mill that
is too large. Large lathe tools are more rigid, while larger milling tools are higher priced
and spend more time cutting air. In general, larger tools cost more than smaller tools.

e. Indexable versus Regrind able: This one is simple: avoid grinding tools. With the few
exceptions of some drills and end mills, you should select an insertable or indexable
design, when offered. You will save labor costs and get more consistent results.

f. Tool Material and Grades: This is a function of the material you are cutting and the
machine’s speed and feed limits. Select the most universal grade for a material class,
which will most likely be a coated grade. Use the manufacturer’s grade selection charts.
A common mistake is to use a brand grade cross reference chart to solve a tool life
problem. If what you have isn’t working and you select the closest like brand you are
likely to get similarly poor results. Focus on the mode of failure.

g. Power Requirements: Here the guiding principle is use what you paid for.  If you bought
a 20-hp mill, then you should select tools and cutting data that uses 80 percent of the
available power, when part and fixtures allow.  Pay special attention to the power/rpm
charts in the machine owner’s manual.  Select tools designed to best cut in the efficient
zone of the machine’s power band.

h. Number of Edges: The rule here is the more, the better.  A lathe tool with twice the
number of cutting edges normally doesn’t cost twice as much. During the last decade,
advances in the design of grooving and cutoff, and some milling inserts, doubled the
number of cutting edges per insert.  It’s not uncommon to replace an old-design milling
cutter having four cutting edges with a modern design having up to 16 cutting edges.
The number of effective teeth has a direct effect on table federate and productivity.
7. Types of Lathe Operation.

The working of the lathe machine changes with every operation and cut desired. There is
a lot of operation used for using the lathe machine. Some of the common lathe operations
are:

Facing: This is usually the first

step in a lathe operation. The
metal is cut from the end to fit
the right angle of the axis and the
markings removed.

Tapering: Tapering is to cut the

metal to nearly a cone shape with
the help of the compound slide.
This is something in between the
parallel turning and facing off. If
one is willing to change the
angle then they can adjust the
compound slide as they like.

Parting: The part is removed so that it faces the ends. For this, the parting tool is
involved slowly to make perform the operation. For to make the cut deeper the parting
tool is pulled out and transferred to the side for the cut and to prevent the tool from
breaking.

Parallel Turning: This operation is adopted in order to cut the metal parallel to the axis.
Parallel turning is done to decrease the diameter of the metal.

Contour turning: In this operation of the lathe machine, the tool is not fed in a straight
path. Instead, the tool follows a contour. A contoured form is created in the turned part.
Feed: Contoured feed. Not parallel to the axis of w/p rotation.
 Rough turning: It is a process of removal of excess material from the workpiece in
minimum time by applying a high rate of feed and heavy depth of cut. The depth of cut is
around 2 to 5mm and the rate of feed is 0.3 to 1.5mm/revolution.

Form turning: In this method, a specially shaped tool is used. The tool is inserted
radially.

Feed for forming: Radial. Diagram for lathe machine operation which involves facing,
forming, and contour turning.

Chamfering: Only the cutting edge is used at the corner of cylindrical shapes which is
used for stress relieving of the workpiece.

Boring: A single point tool head is fed linearly to the end of the workpiece. Feed:
Linear.

Drilling: Drilling and reaming are done by feeding the lathe tool along the axis of the
rotating job part.

Knurling: It is a metal forming method that creates a regular cross- hatched pattern. It is
not a machining process. It does not involve any cutting of the metal.

Reaming operation: Reaming is the operation for sizing or finishing a drilled hole to the
required size by a tool called a reamer. This tool is fitted on tail-stock.

Spinning operation: In this operation, the job of this sheet metal is held between the
former and the tail-stock center rotates at high speed with the former. The long round
nose forming tool rigidly fixed on a special tool post presses the job on the periphery of
the former. So, the job is taken exactly the shape of the former. This is a chipless
machining process.

8. Lathe Cutting Tools

A lathe is a machine that rotates the workpiece about an axis of rotation to perform various
operations such as turning, undercutting, knurling, drilling, facing, boring, and cutting, with
lathe cutting tools that are applied to the workpiece to create an object with symmetry about
that axis. For general purpose work, the tool used is a single point tool, but for special
operations, multipoint tools may use. Watch the below-mentioned video to get understand
lathe machine operation.
9. Types of Lathes Cutting Tools

There is a wide range of lathe tools that can be classified according to materials, structures
and purposes or uses.
Turning Tool: Turning tools are designed for removing the materials from the stock, a rough
turning tool is used to remove the maximum amount of material and the finishing turning
tool is serve for good surface quality, just remove a small amount, to make the piece more
accurate.

Boring Bar: A boring bar is required when you want to make an existed hole bigger, a
boring bar can easily bore into the hole that is already drilled, and widen its diameter. It can
enlarge the hole quickly and process it in the proper size to fit other components correctly.
Chamfering Tool: Chamfer is a transitional edge between two faces of an object, also
defined as a form of the bevel. The chamfering tool is used to create a bevel or furrow on the
part. A chamfer can be used to smooth sharp or hazardous edges on a workpiece.

Knurling Tool: Knurling tools are used to produce knurled lathe parts, through creating or
pressing a pattern onto a round section, used as a grip for a handle, also usually created on
fasteners like nuts. A knurling tool is designed with a specific pattern.

Parting Tool: A parting tool refers to a narrow-bladed tool used in turning or planning or for
cutting a piece in two, or defined as a tool used for cutting off pieces from the main body of
stock being machined, it is manufactured in many forms. Thread Cutting Tool: Thread
cutting tools are used to cut a thread on the lathe part. In external thread cutting, the piece can
be held in a chuck or mounted between two centers, in internal thread cutting, the part is held
in a chuck, the tool moves across the part linearly, taking chips off the workpiece with each
pass.

Facing Tool: A facing tool is used for facing operation on

the lathe to cut flat surface perpendicular to the piece’s
rotational axis, the tool is mounted into a tool holder that
rests on the carriage of the lathe, during the process, the
facing tool will feed perpendicularly across the rotational
axis of the part.
 Grooving Tool: A grooving tool is usually a carbide insert mounted in a special tool holder,
it’s designed to an insert with multiple tips, often ground to the dimensions and shape
required for a particular job, including cutting a slot and complete other work.

Forming Tool: Forming tools are made flat or circular in shape when used in the lathe.
Simple forming tools have cutting edges ground to the shape of the groove, undercut, or
thread to be cut.

Shoulder Turning Tool: A square shoulder is turned by a knife-edge turning tool or facing
tool. A beveled shoulder may be turned by a straight turning tool having a side cutting edge
angle and zero nose radius. A filleted shoulder is turned by a straight turning tool with a nose
radius corresponding to the fillet radius of the work.

Counterboring Tool: The counterboring operation can be performed by an ordinary boring

tool. The tool cutting edge is so ground that it can leave a shoulder after turning. A
counterbore having multiple cutting edges is commonly used.

Undercutting Tool: Undercutting or grooving tool has a point and form of the cutting edge
exactly similar to the form of the required groove. Clearance angle is given at all the sides of
the tool. For the recessing groove cutting edge, the longitudinal feed is employed. The front
clearance angle depends upon the bore of the work.

10. Conclusion

As we discussed lathe machine has a wide range of applications in manufacturing industries.

Performing any operation on the lathe is much easier than other machines and learning about
this machine is equally easier. A lathe machine provides us with a variety of options for
reducing metal to a useful workpiece. However, we must ensure that we are utilizing the
correct instrument for the job. Select the appropriate cutting tool material for cutting metal
without distorting it, as well as one to create a feature in the workpiece. Also, make sure the
tool is well seated in the shank so that cutting is a breeze. With all of these stages, we can
produce a high-quality end result in the lathe.