Lathe Edited MANUAL BY Final T

CET DEPARTMENT OF MECHANICAL ENGINEERING
CET DEPARTMENT OF
MECHANICAL ENGINEERING
STUDENT WORK SHOP MANUAL FOR
CONVENTIONAL LATHE MACHINE
1/1/2013
Mizan-Teppi university
TENINET TESFAYE
STUDENT WORK SHOP MANUAL FOR CONVENTIONAL LATHE MACHINE

Contents
Table of contents…...………………………………………..…………………………………..i
list of figure………………………………………………………………………………………v
SAFETY MEASURES.............................................................................................................................i
SAFETY MEASURES......................................................................................................................................v
General information...............................................................................................................................vi
1, CONVENTIONAL LATHE............................................................................................................................1
1.1, INTRODUCTION................................................................................................................................1
1.2, MAIN PARTS OF THE CONVENTIONAL LATHE MACHINE...................................................................1
1.2.1 Head stock..................................................................................................................................2
1.2.2 Tail Stock:....................................................................................................................................3
1.2.3 Bed:.............................................................................................................................................3
1.2.4 Carriage:.....................................................................................................................................3
1.2.5 Feed Mechanism.........................................................................................................................5
1.3, BASIC CONTROLLING PARTS.............................................................................................................5
1.3.1, R/F SPEED CHANGE LEVER.........................................................................................................5
1.3.2, SPEED CHANGE LEVER...............................................................................................................5
1.3.3, TOOL POST BOLT........................................................................................................................6
1.3.4, TOOL POST HANDLE...................................................................................................................6
1.3.5, COMPOUND HAND WHEEL........................................................................................................6
1.3.6, APRON HAND WHEEL................................................................................................................6
1.3.7, QUILL CLAMPING LEVER............................................................................................................6
1.3.8, TAIL STOCK HAND WHEEL..........................................................................................................6
1.3.9, CLAMPING BOLT........................................................................................................................6
1.3.10, SURFACE HAND WHEEL;-.........................................................................................................6
1.3.11, HALF NUT OPERATING LEVER..................................................................................................6
1.3.12, NORTON OPERATING LEVERS;-................................................................................................6
1.4, ASSEMBLY WISE LUBRICATION INSTRUCTION..................................................................................6
1.4.1) HEAD STOCK..............................................................................................................................6
1.4.2) TAILSTOCK.................................................................................................................................7
STUDENT WORK SHOP MANUAL FOR CONVENTIONAL AND CNC LATHE MACHINE
PAGE i
1.4.3)APRON;-......................................................................................................................................7
1.4.4)SADDLE;-.....................................................................................................................................7
1.4.5) COMPOUND SLIDE.....................................................................................................................7
1.4.6) NORTON GEAR BOX...................................................................................................................7
1.4.7) LEAD SHAFT & FEED SHAFT;-.....................................................................................................7
1.5, Lathe operation................................................................................................................................7
1.5.1,Facing..........................................................................................................................................8
1.5.2, Center drilling:...........................................................................................................................8
1.5.3,Turning.......................................................................................................................................8
1.5.4, Plain turning:.............................................................................................................................9
1.5.5, Step turning:..............................................................................................................................9
1.5.6, Taper turning...........................................................................................................................10
1.5.8, Knurling....................................................................................................................................11
1.5.9, Drilling......................................................................................................................................12
1.5.11, Eccentric turning....................................................................................................................12
1.5.12, Eccentricity:...........................................................................................................................12
1.5.13, Chamfering............................................................................................................................13
1.5.14, Grooving:...............................................................................................................................13
1.6, Machine parameters......................................................................................................................13
1.6.1, Speed.......................................................................................................................................13
1.6.2, Feed.........................................................................................................................................13
1.6.3 Cutting speed............................................................................................................................13
1.6.4, Depth of Cut............................................................................................................................13
1.6.5, Machining Time.......................................................................................................................14
1.7, Turning models and its working procedure....................................................................................14
1.7.1, Model N0. 01..........................................................................................................................14
1.7.2, Model No. 02...........................................................................................................................17
1.7.3, MODEL N0.3............................................................................................................................19
1. 7.4, Model No.4.............................................................................................................................21
1.8, LATHE SPESIFICATION.....................................................................................................................23
1.9 Work holding and supporting devices in machining process:..........................................................24
PAGE ii
1.9.1, Chucks......................................................................................................................................24
1.9.2, Centers;-..................................................................................................................................24
1.9.3, Carriers....................................................................................................................................24
1.9.4, Face plates...............................................................................................................................24
1.9.5, Follower and Steady rests........................................................................................................24
1.9.6, Mandrels..................................................................................................................................24
1.9.7, Drill chuck;-..............................................................................................................................24
1.10, Lubrication:...................................................................................................................................24
1.11, Advantages of using cutting fluids during machining....................................................................24
1.12 Maintenance..................................................................................................................................25
1.12.1, Preventive maintenance and its advantages.........................................................................25
1.13, Nomenclature of single point cutting tool :..................................................................................25
Final assessment........................................................................................................................................27
REFERENCES..............................................................................................................................................29
PAGE iii
LISTOF Figure
1. Fig(1)2D Model of Lathe machine……………………………………………………………..1
2.Fig (2), 3D Model of lathe machine

3. Fig (3) Carriage...............................................................................................................4
4.Fig (4) operation of lathe machine
5.Fig (5)turning operation
6.Fig (6) outside and inside tapper turning
7.Fig (7) tape turning operation
8.Fig(8) thread cutting operation
9.Fig (9) knurling cutting tool…………………………………………………………………..11
10.Fig(10)knurling operation………………………………………………………………….....12
11.Fig(11) drilling operation……………………………………………………………………12
12. Fig (12) boring operation………………………………………………………..…...............12
13.Fig(13) eccentric turning and chamfering

14. Fig (14) Pictorial View of Single point cutting tool…………………………...…………….26
PAGE iv
SAFETY MEASURES
1. Do not attempt to operate the machine before receiving the instructions from the foreman.
2. Never leave safe guards of lathe machine.
3. Do not attempt to lift heavy article (more than 20 kg.) without assistance.
4. Before starting any operation, always see the work and cutting tools secured first.
5. Disengages all the operating levers and place them in neutral position before starting the
motor.
6. Never leave the machine when it is running.
7. Never mount or remove the work when machine is in running position.
8. Never wear loose clothing. Tie your sleeves up at wrist. Never handle chips or shavings
with you bare hands; you should use special hook brushes or scrubbers to pull them away
from the machine.
9. Do not take measurement of the works while the machine is running.
10. Do nottray to shop the chuck with your hands.
11. Keep the work place clean and tidy. Never allow the work pieces or other objects to line
on the floor around the machine.
12. During mounting the work piece on the lathe be sure to see the Centre hole are correct.
(andsufficient depth of center hole is likely to result in the work breaking away while it is
revolving).
13. See that the chuck key is removed after the work has been clamped in the chuck.
14. The machine should be always earthed, if electric motor, lightning appliances or the
wires insulation get out of order report it to the foreman or electrician on duty.
15. Do not operate the machine if you are not sure of what you are doing, call for help by
some who can!
16. Always wear safety glasses when you are near the machine! A broken cutter / chip /
material can shoot out of the machine during operation.
17. Always make sure that the spindle is tightened! A loose tool will cause vibrations and can
be shoot away during cutting.
18. Make sure the stock material is properly tightened! The material need to be firmly
secured to the table.
19. Hit the Emergency Stop / Escape Key if something goes wrong! This quickly stops the
machine preventing danger.
20. Never put your Fingers / Hand / Head near the spinning cutter! Don't risk your fingers,
stop the machine by Feed hold, adjust then resume.
PAGE v
General information
This laboratory is aimed at providing an introduction to the Know-how of common processes
usedindustries for manufacturing parts by removal of material in a controlled manner. Auxiliary
methods for machining to desired accuracy and quality will also be covered. The emphasis
throughout the laboratory course will be on understanding the basic features of the processes
rather than details of constructions of machine (or) common practices in manufacturing or
acquiring skill in the operation of machines. Evidently, acquaintance with the machine is
desirable and the laboratory sessions will provide adequate opportunity for this. In most of the
engineering institutions, the laboratory course forms an integral form of the basic course in
Machine Tool and Machining at undergraduate level. The experiments to be performed in a
laboratory should ideally be designed in such a way as to reinforce the understanding of the basic
principles as well as help the students to visualize the various phenomenon encountered in
different applications. The objective of this manual is to familiarize the students with practical
skills. It is intended to make this manual self-contained in all respects, so that it can be used as a
laboratory manual. In all the experiments, the relevant theory and general guidelines for the
procedure to be followed have been given.
The students are advised to refer to the relevant text before interpreting the results and writing a
permanent discussion. The questions provided at the end of each experiment will reinforce the
students understanding of the subject and also help them to prepare for viva-voce exams.
PAGE vi
1, CONVENTIONAL LATHE
1.1, INTRODUCTION
The main function of a lathe is to remove metal from a piece of work to give it the required
shape and size by holding the work securely and rigidly on the machine and then turning it
against cutting tool which will remove metal from the work in the form of chips. The most
common and widely used is the center or engine lathe for preparing of various turning parts by
different turning process.
1.2, MAIN PARTS OF THE CONVENTIONAL LATHE MACHINE
Fig(1) 2D Model of Lathe
STUDENT WORK SHOP MANUAL FOR CONVENTIONAL LATHE MACHINE 1

Fig(2), 3D Model of lathe machine
1.2.1 Head stock: -
Head Stock is situated at the left side of the lathe bed and it is the house of the driving
mechanism and electrical mechanism of a Lathe machine tool.
 It holds the job on its spindle nose having external screw threads and internally Morse
taper for holding lathe center. And it is rotating at a different speed by cone pulley or all
geared drive. There is a hole throughout spindle for handling long bar work.
 Head Stock transmits power from the spindle to the feed rod, lead screw and thread
cutting mechanism.
A separate speed change gearbox is placed below headstock to reduce the speed in order to have
different feed rates for threading and automatic lateral movement of the carriage. The feed rod is
used for most turning operation and the lead screw is used for thread cutting operation.
1.2.1.1 Chuck:
Chuck is used to holding the workpiece securely.
There are generally 2 types of chucks:
PAGE 2
1. 3 jaw self-centering chuck

2. 4 jaw independent chuck
1.2.1.2 Main Spindle:

The spindle is a hollow cylindrical shaft in which long jobs can pass through it.
It is designed so well that the thrust of the cutting tool does not deflect the spindle.
1.2.2 Tail Stock:

Tail Stock is situated on the right side above the lathe bed.
It is used for:
 Support the long end of the job for holding and minimizes its sagging.
 It holds the tool for performing different operations like drilling, reaming, tapping, etc.
 And it is also used for a small amount of taper for a long job by offsetting the tailstock.
1.2.3 Bed:
It is the base of the lathe machine. It is made of single piece casting of Semi-steel (Chilled Cast
Iron). The bed consists of two heavy metal slides running lengthwise, with ways or ‘V’ formed
upon them and rigidly supported with cross girths.
 It is sufficiently rigid and good damping capacity to absorb vibration.

 It prevents the deflection produced by the cutting forces.
 It supports the headstock, tailstock, carriage and other components of the lathe machine.
1.2.4 Carriage:
The carriage is used for support, guide and feed the tool against the job when the machining is
done.
 It holds moves and controls the cutting tool.

 It gives rigid supports to the tool during operations.
 It transfers power from feed rod to cutting tool through apron mechanism for longitudinal
cross-feeding.
 It simplifies the thread cutting operation with the help of lead screw and half nut
mechanism.
It is consists of:
1. Saddle
2. Cross-slide
3. Compound rest
4. Toolpost
5. Apron
PAGE 3
It provides three movements to the tool:
1. Longitudinal feed-through carriage movement

2. Cross feed-through cross slide movement
3. Angular feed-through top slide movement
Fig (3) Carriage
1.2.4.1 Saddle:
Generally, it is made up of ‘H’ shaped casting and it has a ‘V’ guide and a flat guide for
mounting it on the lathe bed guideways.
1.2.4.2 Cross-slide:
It is assembled on the top of the saddle. The top surface of the cross-slide is provided with T-slot.
1.2.4.3 Compound rest:

It supports the tool post and cutting tool in its various positions. It can be swiveled at any desired
position in the horizontal plane. It is necessary for turning angles and boring short tapers.
1.2.4.4 Tool post:

It is the topmost portion of the carriage and it is used to hold various cutting tools or tool holders.
1.2.4.5 Apron:
An apron is a house of the feed mechanism. It is fastened to the saddle and hangover in front of
the bed.
PAGE 4
1.2.4.6 Lead screw:

A lead screw is also known as a power screw or a translation screw. It converts rotational motion
to linear motion. Lead Screw is used for Thread Cutting operation in a lathe machine tool.
1.2.4.7 Feed Rod:

Feed rod is used to move the carriage from the left side to the right side and also from the right
side to the left side.
1.2.5 Feed Mechanism

Feed mechanism is the combination of different units through which motion of headstock spindle
is transmitted to the carriage of lathe machine. Following units play role in feed mechanism of a
lathe machine.
1. End of bed gearing
2. Feed gear box
3. Lead screw and feed rod
4. Apron mechanism
The gearing at the end of bed transmits the rotary motion of headstock spindle to the feed gear
box. Through the feed gear box the motion is further transmitted either to the feed shaft or lead
screw, depending on whether the lathe machine is being used for plain turning or screw cutting.
The feed gear box contains a number of different sizes of gears. The feed gear box provides a
means to alter the rate of feed, and the ration between revolutions of the headstock spindle and
the movement of carriage for thread cutting by changing the speed of rotation of the feed rod or
lead screw.
The apron is fitted to the saddle. It contains gears and clutches to transmit motion from the feed
rod to the carriage, and the half nut which engages with the lead screw during cutting threads.
1.3, BASIC CONTROLLING PARTS
1.3.1, R/F SPEED CHANGE LEVER

The function of this lever is to change the direction of motion of lead screw. It is advisable to
operate this lever only after the machine stops.
1.3.2, SPEED CHANGE LEVER

We can obtain 8 various speed as per our requirement by operating this lever. Don’t operate this
lever when the machine is in running condition.
PAGE 5
1.3.3, TOOL POST BOLT

The cutting tool is holding by these bolts. Always use spanner to tighten & loosen
1.3.4, TOOL POST HANDLE

During the turning process sometimes it is necessary to give an angle to the cutting tool. By
means of this lever we can clamp the tool post at required position.
1.3.5, COMPOUND HAND WHEEL

This hand wheel in longitudinal direction operates the compound upper side. A graduated dial
ring is provided with this hand wheel. On this dial ring 1 division = 0.021mm.
1.3.6, APRON HAND WHEEL

This hand wheel is used to give longitudinal travel to the carriage with surface and compound
slide on the bed guide ways. On apron hand wheel 1 division = 0.200 mm.
1.3.7, QUILL CLAMPING LEVER

By means of this lever, tailstock quill can be clamped in required position.
1.3.8, TAIL STOCK HAND WHEEL

This hand wheel operates the tailstock quill. The graduated dial ring is provided on this hand
wheel. On this dial ring 1 division = 0.050 mm.
1.3.9, CLAMPING BOLT

The function of this bolt is to locate the tail stock body at required position on the bed guide
ways.
1.3.10, SURFACE HAND WHEEL;-This handle operates the surface in transverse direction. A
graduated dial ring is provided on this hand wheel. On this dial ring 1 division = 0.10 mm.
1.3.11, HALF NUT OPERATING LEVER;-This lever is used to engage or disengage the lead screw
while threading operation is performed.
1.3.12, NORTON OPERATING LEVERS;-Norton gear box is operated by means of this lever so
that various pitch of thread can be selected.
1.4, ASSEMBLY WISE LUBRICATION INSTRUCTION
1.4.1) HEAD STOCK

Threads on the spindle nose should be always cleaned and oiled before mounting the chuck plate
or faceplate.
Head stock body should be filled with oil. The level of the oil should be always maintained. The
oil used for head stock is EP – 90 Gear Oil.Oil nipple, on the various parts like brackets…Etc.
must be properly filled with oil.
PAGE 6
1.4.2) TAILSTOCK
There are two oil holes plunged by oil cup and by oil nipple. Oil cup carry oil to the housing and
tailstock quill.
1.4.3)APRON;-
A hole is provided in the front face of apron to pour oil in apron. Pour the oil till level comes up
to the “Red Mark” on the oil sight glass of the apron. The oil used for apron is EP–140 Gear Oil.
All the rotating parts and bearings of the apron are splash lubricated. An oil-drain plug is
provided at the bottom to change the oil
1.4.4)SADDLE;-
Two oil cups are provided on the top face of the saddle. Fill these cups with oil daily. Oil flows
and reaches to the Flat and V- guide ways of the bed. Surfaces Screw should be lubricated by the
nipple, which is given on the screw boss. Two oil nipples are provided on the top face of the
surface slide, which carry oil in both the guide ways of the saddle.
1.4.5) COMPOUND SLIDE

Two oil nipples are provided on the front face of the compound slide, which carry the oil for
both the guide ways of the slide. To oil the housing of the compound slide oil nipple is provided
on the compound boss.
1.4.6) NORTON GEAR BOX

Norton gear box should be filled up by Gear EP–90 to get proper efficiency of the gear box. An
oil sight glass is provided on the Norton to check the oil level. Change the oil when it is required.
1.4.7) LEAD SHAFT & FEED SHAFT;-

Clean the lead shaft, feed shaft & rack with the cotton waste daily & oil the same properly. Both
lead screw brackets (Front and Rear) having an oil nipple on the tiny top face, which supply oil
to the bearing and housing.
PAGE 7
1.5, Lathe operation
Fig (4) operation of lathe machine
1.5.1,Facing: Facing is the operation of machining from the work-face by feeding the tool at
right angles to the work axis at end of a work piece to produce flat surface.
Purpose:
 To remove the rough surface on the face of the work and have finished faces.
 To have a face at right angles to the axis of the work.
 To have a reference plane to mark and measure the lengths of the work.
 To maintain the total length of the work.
1.5.2, Center drilling:

Centering is the operation of producing conical holes in work pieces at the ends to
 Provide bearing surface for lathe centers.

 The axis of the work coincides with the lathe axis.
PAGE 8
1.5.3,Turning:-Turning is the process to remove excess material from the work piece basically to
produce cylindrical or cone shaped objects, to the required shape and size. The most common
center or engine lathe is used for preparing of various turning parts by different turning process.
Straight turning produces a cylindrical surface by feeding the single point cutting tool against the
rotating work parallel to the work.
Fig (5)turning operation

The work pieces are given cylindrical shapes by:
 Longitudinal turning
 Tapers by taper turning
 Threads by thread cutting
In addition, counter sink, drilling, reaming, grooving, knurling, parting off (operations) are
carried out. Grinding and milling operations are carried on the lathe with special attachments.
The lathe is also used for manufacturing of cylindrical bolts, cylindrical shafts, shafts with square
cross section, Eccentric shafts, crank shafts, bushes, sleeves, pulleys, knobs, machine handles,
spindles, washers and machining of housing and casting etc.
1.5.4, Plain turning:The plain turning operation involves removal of metal diametrically fromthe
raw material by feeding the tool parallel to the axis of the work to bring the work torequired size.
1.5.5, Step turning: Wherever more than one diameter is machined on a shaft, the section joining
each diameter is called step or shoulder.
PAGE 9
Outside turning inside turning
Fig (6) outside and inside tapper turning

Uses:
 Easy assembly and disassembly of parts.

 Giving self-alignments in assembled parts.
 Transmission of power (Clutch plates.)
1.5.6, Taper turning: Taper is a gradual increase or decrease in diameter along the length of the
job.
Fig (7) tape turning operation
PAGE 10
1.5.7, Thread cutting :-by using single point cutting tool: The principle of thread cutting is to
produce helical groove on a cylindrical or conical surface by rotating the job at a constant speed
and moving the tool longitudinally at the rate equal to pitch of the thread per revolution of the
job.
Fig(8) thread cutting operation

Uses of thread:
 Transmission of motion (Half nut with lead screw)

 Fastening purpose (Nut and Bolt)
 Precision measuring instruments. (Micrometer)
 Lifting of load (Screw Jack)
 Elevating arm of drilling, milling and shaping machines.
1.5.8, Knurling: Knurling is the operation of producing straight lined diamond shaped or cross
lined pattern on a cylindrical external surface by pressing a tool called knurling tool. Knurling is
not cutting operation, but it is a forming operation.
Purpose of knurling:
 A good grip and make positive handling

 Good appearance
 For raising the diameter to a small range
PAGE 11
Fig (9) knurling cutting tool fig(10)knurling operation

1.5.9, Drilling: Drilling is the production of cylindrical holes of definite diameter in a work piece
by using multipoint cutting tool called drill. It is the first operation done internally for any further
operations.
Fig(11) drilling operation

1.5.10, Boring: Boring is the process of enlarging and turning an existing drilled or core hole
with a single point cutting tool.
fig (12) boring operation
PAGE 12
1.5.11, Eccentric turning: Concentricity: when different diameters are turned in a same axis, it is
said to be concentric turning.
1.5.12, Eccentricity: When different diameters are turned on a different axes, it is said to be
Eccentric turning
Uses of eccentric turned jobs:
 Used in automobiles industry to convert rotary motion in to reciprocating motion

 Used in power press and press breaks.
 Used in automatic controls.
Fig (13) eccentric turning and chamfering

1.5.13, Chamfering: Chamfering is the operation of beveling the extreme end of the work piece.
1.5.14, Grooving: Grooving is the process of reducing the diameter of a work piece over a very
narrow surface.
1.5.15, Undercutting: Undercutting is similar to grooving operation performed in side a hole

called undercut
1.6, Machine parameters

1.6.1, Speed: Speed is the number of circular motion of the spindle/work piece in one minute of
time expressed is RPM.
1.6.2, Feed: Feed is the length at which the tool travels forward for one revolution of the work
piece expressed in meter/rev or mm/revolution.
1.6.3 Cutting speed: The cutting speed of a tool is the speed at which the metal is removed by
the tool from the work piece. It is the rate of cutting length on the main motion in meter/minute.
It is denoted by a letter, v;
v = πDN/100
Where;-
PAGE 13
v = cutting speed.
d = diameter of the work piece.
n = number of revolutions per minute.
1.6.4, Depth of Cut: It is the advancement of the tool in the job in a direction perpendicular to the
surface being machined.
 Depth of cut is generally expressed in mm
 In a lathe, depth of cut is expressed as,
Depth of cut = D1 – D2 (mm) 2 Where,
D1 – Diameter of the work piece before machining, (mm)
D2 – Diameter of the machined work piece(mm)
1.6.5, Machining Time: The machining time in a lathe work can be calculated for a particular
operation, speed of the work piece and feed length of the work piece is known. Machine time is
generally expressed in minutes
Machining Time = Length of cut (l) , minutes Feed (f) x Speed(N)

l = Length of cut, mm
f = Feed, mm/rev
N=Speed, rpm
Example: A brass pin has a length of 500mm and of 40mm dia. Find the turning to reduce
the pin to 38.8mm in one pass, when cutting speed is 60m/min and feed is 0.8mm/min.
π xDxN
cutting sped =
1000
π x 40 x N
60=
1000
N = 478 rpm
lengith of cut
machine time=
feed∗RPM
500
machine time =
0.8∗478
= 1.31 min
PAGE 14
1.7, Turning models and its working procedure
1.7.1, Model N0. 01

Knurling on ᶲ24
Note: all dimensions are in mm only
Material:
Size: ᴓ25*105
Tolerance: ±0.50
D−d
Tapere turnning calculation tan ∅=
2l
∅=tan
−1
( D−d
2l )
PAGE 15
SI NO. Detail of Work Operation Tool setting in correct operation
1 Prepare and study the To draw sketch using all conventions and notations
drawing.
2 Hold the work piece in 3 Holding 3 jaw self-centering chuck with chuck key
jaw self-centering chuck
by keeping 60-70 mm
away from chuck.
3 To remove rough surface Hold the facing tool in tool post in
on face of the work to have Facing correct position and set speed and feed.
a finish face by feeding the Depth of cut 0.25mm Speed 500-600rpm
tool at right angle to the
axis of the work.
4 To provide axis of the Center Hold 3/60 countersunk drill bit in drill chuck,
work coincides with lathe drilling or insert tail stock spindle and feed into the work
axis. Counter face
Sinking
5 To remove metal Hold the tool in tool post in correct position,
diametrically by feeding Plain turning select the required speed.
the tool parallel to axis of
the work.
6 Machining or turning more Step turning Hold the tool in tool post in correct position,
the one diameter on a shaft to ø19 to select the required speed and feed.
10mm
7 Machining of grooving 24 Grooving Grooving tool
to 19
8 Gradual increase or Taper turning Swiveling compound rest method
decrease in diameter. 24 to 19 Taper angle =tan-1 D-d 2l Feed is given with
compound rest feed handle.
9 Remove and reverse the work piece to fix again in 3 jaw self-centering chuck for turning
remaining portions.
10 Chamfering 0.5mm in all corners
11 Repeat the operation Facing
12 Repeat the operation Center
drilling
13 Repeat the operation Step turning
to ø19
14 Repeat the operation Plain turning

to ø23.7mm
for knurling
15 Take the support with
PAGE 16
revolving center of
tailstock for nose grip
16 To form or emboss a Knurling Hold the knurling tool in the tool post and
straight line diamond pressed against the work piece uniformly and
shaped pattern on the chamfering on corner.
surface of the work piece
to have more grip on work
piece.
Table (1.1) Working procedures to perform Model N0 .01 in lathe machine
Inspection Instruments: Steel scale, Varner caliper, micrometer.
SI No. Dimension as Actualdimension Deviation (±) Remarks

per drawing inmm
inmm
1
2
Total No. of deviations:
1.7.2, Model No. 02
Note: All dimensions are in mm only
Material: M S bright rod

Size: Ø25 x 105 Length
Tolerance: ±0.50
Blank size for thread cutting
PAGE 17
Blank size = Major diameter – Blank size = Major diameter –

= 24 - = 24 –
=24 – 0.25 = 24 – 0.25
= 23.8 mm = 23.75 m
Table (1.2) Working procedures to perform Model N0 .02 in lathe machine
SI Detail of Work Operation Tool setting in correct

NO. operation
1 Prepare and study the drawing. To draw sketch using all conventions and notations
2 Hold the work piece in 3 jaw self- Holding 3 jaw self-centering chuck
centering chuck by keeping 60-70 mm with chuck key
away from chuck
3 To remove rough surface on face of the Hold the tool in tool post
work to have a finish face by feeding the Facing in correct position and set speed
tool at right angle to the axis of the Depth of cut 0.25mm
work. Speed 500-600rpm
4 To provide axis of the work coincides Center drilling Hold 3/60 countersunk drill bit in
with lathe axis or Counter drill chuck, insert tail stock
Sinking spindle and feed into the work face
5 To remove metal diametrically by Plain turning Hold the tool in tool post in correct
feeding the tool parallel to axis of the position, select the required speed.
work.
6 Machining or turning more the one Step turning Hold the tool in tool post in correct
diameter on a shaft position, select teeth
7 Machining of grooving 24 to 19 Grooving Grooving tool
8 Thread cutting on ø 23.8mm for a length Thread cutting Hold the threading tool in tool
of 20mm post in correct position.
Ref Norton thread chart for
selection of knob and lever for
2mm pitch RH thread.
* Spindle speed 90rpm
9 Chamfering 0.5mm in all corners take the support with revolving center of tailstock for nose grip.
10 Remove and reverse the work piece to fix again in 3 jaw self-centering chuck for turning
remaining portions.
12 Repeat the operation Center drilling
13 Repeat the operation Step turning to
ø17mm and
length 20mm
14 Plain turning to ø23.80mm for thread cutting to length of
PAGE 18
20mm
15 Thread cutting on ø 23.8mm for a length of Thread * Hold the threading tool in tool
20mm. cutting post in correct position.
* Ref Norton thread chart for
selection of knob and lever
for 2mm pitch RH thread.

per drawing inmm
inmm
1
2
1.7.3, MODEL N0.3

Size: Ø25 x 105 Length
Tolerance: ±0.50
PAGE 19
Table (1.2) Working procedures to perform Model N0 .03in lathe machine
SI Detail of Work Operation Tool setting in correct

NO. operation
1 Prepare and study the drawing. To draw sketch using all conventions and notations
2 Hold the work piece in 3 jaw self- Holding 3 jaw self-centering chuck with
centering chuck by keeping 60-70 mm chuck key
away from chuck.
3 To remove rough surface on face of the Hold the facing tool in tool post in
work to have a finish face by feeding the Facing correct position and set speed and
tool at right angle to the axis of the feed. Depth of cut 0.25mm Speed
work. 500-600rpm
4 To provide axis of the work coincides Center drilling Hold 3/60 countersunk drill bit in
with lathe axis. or Counter drill chuck, insert tail stock spindle
Sinking and feed into the work face
5 To remove metal diametrically by Hold the tool in tool post in correct
feeding the tool parallel to axis of the Plain turning position, select the required speed.
work. ø23.7
6 Machining or turning more the one Step turning to Hold the tool in tool post in correct
diameter on a shaft ø17to 20mm position, select the required speed
and feed.
7 Machining of grooving 24 to 19 Grooving Grooving tool
8 Thread cutting on ø 23.8mm for a length Thread cutting * Hold the threading tool in tool
of 20mm. post in correct position.
* Ref Norton thread chart for
selection of knob and lever for
2mm pitch RH thread.
9 Remove and reverse the work piece to fix again in 3 jaw self-centering chuck for performing
Remaining operations.
11 Repeat the operation Center drilling

ø18 and length
15mm
ø18 for a length
of 6mm.
14 Concave shape is formed by using forming tool as per
sketches
15 Taper turning from ø24 to 18mm by means of *Swiveling compound rest method
*Tangent of the half of the taper angle = tan-1 D-d 2l
PAGE 20
*Feed is given with compound rest feed handle.


per drawing inmm
inmm
1
2
1. 7.4, Model No.4

Aim:To perform various turning operations on the given aluminum Work piece as per the given
drawing

Tools Required:
Lathe Machine, Single Point Cutting Tool, Drill bit, Work piece, Vie Tool, Surface gauge,
surface plate, V-Block, Centre Punch, Tool kit (Chuck key, Tool post key, inside & outside
Caliper, Steel Scale, Packing pieces& Brush)
Sequence of Operations:
1) Using the Outside Calipers the diameter of the given work piece is measured.
PAGE 21
2) The facing operation is carried out on both sides of the work piece and a counter hole is
drilled at the center.
3) The work piece is placed in the 3 jaw chuck.
4) The tail stock is moved so that the work piece is held between the chuck and the dead center.
5) The tool aligned by placing such that, the tip of the tool is perpendicular to the tip of the dead
center. The tool post is tightened using align key.
6) The tool is made to touch the work piece & the depth of the cut is adjusted to get the diameter
of 23mm using a micrometer provided in compound rest or in the carriage.
7) Cutting parameters like speed, feed, depth of cut, are selected before the machine is turned on.
8) Plain turning operation is carried out for required length of 1 50mm.
9) Markings are made to perform step turning operation.
10) Step turning operations are made to get the desired shape of the work piece by giving depth
of cut on each run.
11) Groove turning operations are made to get the desired shape of the work piece by giving
depth of cut on each run
12) Taper turning angle is calculated using the taper angle formula and the compound rest is
swiveled to the angle “” in degrees (as per the calculation) with the help of align key. The taper
turning at this angleis performed for a length of 25 mm and depth of cut of 1 mm on each run.
( D−d )
ɵ=tan−1
2l
Where ɵ = Swivel the compound rest to the calculated angle.
D = Major diameter.
d = Minor diameter.
L= Length of the taper.
13) Knurling operation is carried out by using special knurling tool.
14) To carry out thread cutting required pitch is noted down & depth of cut is calculated using
formula. Using a standard chart the auto feed varying mechanism is set for 2mm pitch for the
PAGE 22
right hand thread cutting operation & 2.5mm pitch for left hand thread is carried out by engaging
lead screw which rotates at required speed & direction for the mentioned thread along with
suitable gears in gear train.
15) The procedure is repeated 13 times with an increment in depth of cut by 0.2 mm divisions
each time. In case of right hand thread cutting operation feed will be from right to left.
16) The procedure is repeated 16 times with an increment in depth of cut by 0.2 mm divisions
each time. In case of left hand thread cutting operation feed will be fromleft to right.
17) For ‘V’ – thread cutting, Angle of thread is 600, According to the ISO standard metric thread
depth = 0.65X pitch (60 to 65%)
18) After turning with the help of pitch gauge check the accuracy of the thread pitch and with the
help of venire caliper, check the diameter of turned part.
19) Finishing operation is done by giving very small depth of cut (say 0.2mm) on medium feed.
Result: The required turning operations are carried out on the given work piece as per the figure
given with the dimensional accuracy.
Observations &Calculations:
1. Work piece material: ………………………
2. Cutting Tool Material: ………………………
3. Feed: ……………………………….mm/revolution.
4. Depth of Cut: ……………………….mm
5. Selected Cutting Speed: ……………m/min.
6. Plain Turning: ………………………m/min
7. Step Turning: ……………………….m/min
8. Taper Turning: ……………………….m/min
9. Thread Cutting: ………………………m/min
10. Profile Turning: ……………………..m/min
11. Knurling operation: …………………m/min
PAGE 23
1.8, LATHE SPECIFICATION

 The maximum diameter of a work that is held between canters.
 The swing over the bed (this is the perpendicular distance from the lathe axis to top of the
bed).
 The length of the bed.
 The length of the bed ways & type.
 The maximum length of work that can be turned b/n centers.
 The range of threads that can be cut.
 The capacity of lathe (Motor).
 Range of spindle speed.
 Range of feed.
 Size of the spindle nose
1.9 Work holding and supporting devices in machining process:

1.9.1, Chucks
Three jaw self-centering chuck – Used for holding round and other symmetrical works.
Four jaw independent chucks – used for irregular shapes (Ex: Square etc)
1.9.2, Centers;-Used for support work pieces and take up the thrust due to metal cutting.
1.9.3, Carriers ;-Used to drive the work pieces when it is held between the two centers.
1.9.4, Face plates;-Used for machining of flat plates.
1.9.5, Follower and Steady rests;- Used to hold long work piece is machined.
1.9.6, Mandrels;-Used to hold rotating a hollow piece of work.
1.9.7, Drill chuck;- Used to hold in a tail stock center.
1.10, Lubrication:
Proper lubrication is very important. The accuracy of the lathe depends on the proper and regular
lubrication. Lubrication instructions are displayed in a lubrication chart.
If the lubrication is neglected then the bearing surfaces may damage, impairing the accuracy and
shortening the life of the machine.
Before putting the machine in operation, all the Oil cups, Apron, Norton Gear Box &Head stock
should be checked and filled with oil until the oil reaches the “Red Line” in the oil
1.11, Advantages of using cutting fluids during machining

The advantages of cutting fluids in machining operations are:
PAGE 24
i. Increase of tool life by cooling the cutting edge.
ii. Decrease tool chip friction.
iii. Provide better finish on the work piece.
iv. Reduce forces on tool hence economic power consumption.
v. To maintain its dimensional accuracy
vi. Discourage corrosion of newly machined surface
vii. Lubricate machine movements.
1.12 Maintenance
1. Careful maintenance will increase the life and efficiency of the machine.
2. Any defect however small it should be immediately rectified otherwise this will lead to a
major breakdown of the machine resulting in loss of prevention and high cost of repair.
1.12.1, Preventive maintenance and its advantages.

Preventive maintenance means planning and scheduling the maintenance in advance.
1. To avoid sudden break down of machine.
2. Damage of costly parts is avoided.
3. Shut down of production is avoided.
4. Longer life of the equipment is ensured.
5. Possibility of serial accidents is minimized.
6. Preventive maintenance is less cost than break down maintenance.
1.13, Nomenclature of single point cutting tool :

The signature is a sequence of numbers listing the various angles in degrees, and the size
of nose radius. The seven elements that comprise the signature of a single point cutting
tool stated in the following order:
8 – 14 – 6 – 6 – 6 – 15 – 4
has 80 back rake angle, 140 side rake, 60 end relief, 60 end or side relief, 60 end cutting
edge and 150 side cutting edge angles and 4 mm nose radius.
PAGE 25
Fig (13) Pictorial View of Single point cutting tool
NOTE:-Nose radius and cutting edge angle will generally be dedicated by type of operation
being performed when not specified, use 1.2 mm nose radius.
PAGE 26
Final assessment
1:- boring and internal thread cutting operation
2:- step turning and taper turning operation
3:- External thread cutting and knurling operation
PAGE 27
4:-step and taper turning operation
5:-taper turning and external thread cutting operation
PAGE 28
REFERENCES
1. Workshop Technology, (Volume II) by HazrachaudharySeropeKalpakjian,

Steuen.R. Sechmid, Pearson Education Asia, 5th Ed. 2006
2. Production Technology, R K Jain Khanna Publications, 2003
3. Production Technology, HMT, Tata McGraw Hill, 2001
4. Fundaments in Metal Machining and Machine Tools, G .Boothroyed, McGraw
Hill, 2001
5. Manufacturing Science, AmitabhaGhosh and Mallik, affiliated East West Press,
2003
6. Student CNC guide, by Viktor Stenberg
7. CNC Machine guide, KTH Royal Institute of Technology
PAGE 29
STUDENT WORK SHOP MANUAL FOR CONVENTIONAL LATHE MACHINE 0

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CET DEPARTMENT OF MECHANICAL ENGINEERING

STUDENT WORK SHOP MANUAL FOR CONVENTIONAL LATHE MACHINE

2.Fig (2), 3D Model of lathe machine

13.Fig(13) eccentric turning and chamfering

1.2, MAIN PARTS OF THE CONVENTIONAL LATHE MACHINE

Fig(1) 2D Model of Lathe

STUDENT WORK SHOP MANUAL FOR CONVENTIONAL LATHE MACHINE 1

Fig(2), 3D Model of lathe machine

1.2.1 Head stock: -

There are generally 2 types of chucks:

1. 3 jaw self-centering chuck

1.2.1.2 Main Spindle:

1.2.2 Tail Stock:

 It is sufficiently rigid and good damping capacity to absorb vibration.

 It holds moves and controls the cutting tool.

It provides three movements to the tool:

1. Longitudinal feed-through carriage movement

Fig (3) Carriage

1.2.4.3 Compound rest:

1.2.4.4 Tool post:

1.2.4.6 Lead screw:

1.2.4.7 Feed Rod:

1.2.5 Feed Mechanism

1. End of bed gearing

2. Feed gear box

3. Lead screw and feed rod

1.3, BASIC CONTROLLING PARTS

1.3.1, R/F SPEED CHANGE LEVER

1.3.2, SPEED CHANGE LEVER

1.3.3, TOOL POST BOLT

1.3.4, TOOL POST HANDLE

1.3.5, COMPOUND HAND WHEEL

1.3.6, APRON HAND WHEEL

1.3.7, QUILL CLAMPING LEVER

1.3.8, TAIL STOCK HAND WHEEL

1.3.9, CLAMPING BOLT

1.4, ASSEMBLY WISE LUBRICATION INSTRUCTION

1.4.1) HEAD STOCK

1.4.5) COMPOUND SLIDE

1.4.6) NORTON GEAR BOX

1.4.7) LEAD SHAFT & FEED SHAFT;-

1.5, Lathe operation

Fig (4) operation of lathe machine

1.5.2, Center drilling:

 Provide bearing surface for lathe centers.

Fig (5)turning operation

Outside turning inside turning

Fig (6) outside and inside tapper turning

 Easy assembly and disassembly of parts.

Fig (7) tape turning operation

Fig(8) thread cutting operation

 Transmission of motion (Half nut with lead screw)

 A good grip and make positive handling

Fig (9) knurling cutting tool fig(10)knurling operation

Fig(11) drilling operation

with a single point cutting tool.

fig (12) boring operation

Uses of eccentric turned jobs:

 Used in automobiles industry to convert rotary motion in to reciprocating motion

Fig (13) eccentric turning and chamfering

1.5.15, Undercutting: Undercutting is similar to grooving operation performed in side a hole

1.6, Machine parameters

d = diameter of the work piece.