Contents

2.1 Introduction and Working Principle of Lathe ............................................................................ 2.2

2.2 Types of Lathe ............................................................................................................................ 2.2
2.3 Construction and parts of lathe machine ................................................................................. 2.4
2.4 Capstan and Turret Lathe ........................................................................................................ 2.11
2.5 Lathe Accessories And Attachements ................................................................................... 2.13
2.6 Operation on Lathe ................................................................................................................... 2.17
2.7 Specification of lathes ............................................................................................................. 2.21
2.8 Alignment test in lathe ............................................................................................................. 2.21
2.9 Lathe Parameters ..................................................................................................................... 2.27
2.10 Reference .................................................................................................................................. 2.27
2.1 Introduction and Working Principle of Lathe
 Lathe is one of the most versatile and widely used machine tools all over the world. It is commonly
known as the mother of all other machine tool.
 The main function of a lathe is to remove metal from a job to give it the required shape and size.
 The job is securely and rigidly held in the chuck or in between centers on the lathe machine and
then turn it against a single point cutting tool which will remove metal from the job in the form of
chips. Figure shows the working principle of lathe. An engine lathe is the most basic and simplest
form of the lathe.
 It derives its name from the early lathes, which obtained their power from engines. Besides the
simple turning operation as described above, lathe can be used to carry out other operations also,
such as drilling, reaming, boring, taper turning, knurling, screwthread cutting, grinding etc.

Fig.2.1 Working Principle of lathe

2.2 Types of Lathe

2.2.1 Speed Lathe

 Speed lathe is simplest of all types of lathes in construction and operation. The important parts of
speed lathe are following-
(1) Bed
(2) Headstock
(3) Tailstock, and
(4) Tool post mounted on an adjustable slide.
 It has no feed box, leadscrew or conventional type of carriage.
 The tool is mounted on the adjustable slide and is fed into the work by hand control.
 The speed lathe finds applications where cutting force is least such as in wood working, spinning,
centering, polishing, winding, buffing etc.
 This lathe has been so named because of the very high speed of the headstock spindle.

2.2.2 Centre Lathe or Engine Lathe

 The term “engine” is associated with this lathe due to the fact that in the very early days of its
development it was driven by steam engine.
 This lathe is the important member of the lathe family and is the most widely used. Similar to the
speed lathe, the engine lathe has all the basic parts, e.g., bed, headstock, and tailstock. But its
headstock is much more robust in construction and contains additional mechanism for driving the
lathe spindle at multiple speeds.
 Unlike the speed lathe, the engine lathe can feed the cutting tool both in cross and longitudinal
direction with reference to the lathe axis with the help of a carriage, feed rod and lead screw. Centre

Mr. Ankur N Tank, Department of Mechanical Engineering

2.2 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
 lathes or engine lathes are classified according to methods of transmitting power to the machine.
The power may be transmitted by means of belt, electric motor or through gears.

2.2.3 Bench Lathe

 This is a small lathe usually mounted on a bench. It has practically all the parts of an engine lathe
or speed lathe and it performs almost all the operations. This is used for small and precision work.

2.2.4 Tool Room Lathe

 This lathe has features similar to an engine lathe but it is much more accurately built. It has a wide
range of spindle speeds ranging from a very low to a quite high speed up to 2500 rpm. This lathe
is mainly used for precision work on tools, dies, gauges and in machining work where accuracy is
needed.

2.2.5 Capstan and Turret Lathe

 The development of these lathes results from the technological advancement of the engine lathe
and these are vastly used for mass production work.
 The distinguishing feature of this type of lathe is that the tailstock of an engine lathe is replaced
by a hexagonal turret, on the face of which multiple tools may be fitted and fed into the work in
proper sequence.
 Due to this arrangement, several different types of operations can be done on a job without re-
setting of work or tools, and a number of identical parts can be produced in the minimum time.

2.2.6 Special Purpose Lathes

 These lathes are constructed for special purposes and for jobs, which cannot be accommodated
or conveniently machined on a standard lathe.
 The wheel lathe is made for finishing the journals and turning the tread on railroad car and
locomotive wheels.
 The gap bed lathe, in which a section of the bed adjacent to the headstock is removable, is used to
swing extra-large-diameter pieces. The T-lathe is used for machining of rotors for jet engines.
 The bed of this lathe has T-shape. Duplicating lathe is one for duplicating the shape of a flat or
round template on to the job.

2.2.7 Automatic Lathes

 These lathes are so designed that all the working and job handling movements of the complete
manufacturing process for a job are done automatically. These are high speed, heavy duty, mass
production lathes with complete automatic control.

2.2.8 Computer-controlled Lathes.

 In the most advanced lathes, movement and control of the machine tool and its components are
achieved by computer numerical control (CNC).
 These lathes generally are equipped with one or more turrets, and each turret is equipped with a
variety of tools and performs several operations on different surfaces of the workpiece To take
advantage of new cutting-tool materials, computer-controlled lathes are designed to operate faster
and have higher power available compared with other lathes.
 They are equipped with automatic tool changers (ATCs). Their operations are reliably repetitive,
maintain the desired dimensional accuracy, and require less skilled labor (once the machine is set
up). They are suitable for low- to mediumvolume production.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.3
Unit – 2 Metal Cutting Lathes
2.3 Construction and parts of lathe machine
 In the year 1797 Henry Maudslay, an Englishman, designed the first screw cutting lathe machine.
 Lathe is one of the most important machine tools in the metal working industry.
 A lathe operates on the principle of a rotating work piece and a fixed cutting tool.
 The lathe can be defined as a machine tool which holds the work between two rigid and strong
centers, or in chuck or face plate while the tool cuts material from the work.

Fig.2.2 Parts of Lathe Machine

Parts of Lathe Machine

 Headstock
 Bed
 Cross slide
 Compound rest
 Tail stock
 Carriage
 Lead screw
 Leg
 Thread Cutting Mechanism

2.3.1 Bed
 The bed is the foundation of the lathe machine. All other components are fitted on lathe bed.
 The V-shape of the bed maintains accurate alignment of the headstock and tailstock.
 It also works as rails to guide the carriage on which the cutting tool is mounted.
 On the top of bed, there are two sets of slides and guide ways. The guiding surfaces are accurately
machined to make them parallel to the lathe axis.
 To get sufficient accuracy, the lathe axis.

Fig.2.3 Function of Machine ToolS

Mr. Ankur N Tank, Department of Mechanical Engineering

2.4 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.3.2 Tailstock

Fig.2.4 Tailstock

 Tailstock is mounted on the tail side of the lathe bed or right side of the operator.
 The work piece is held in chuck and supported by the tailstock from other end. Tailstock is used to
hold the tools like drill, reamer, tap etc.
 It is commonly provided with a hardened ball bearing at the center and that can be moved in and
out by wheel adjustment.
 It is also provided with set over screws at its base for taper turning operation.
 It feed a drill or similar tool toward the work when making holes in the castings and forging.
 It can be moved along the bed of the lathe to accommodate different lengths of the work pieces.
 The barrel is hollow and is bored with a morse taper, this taper locates the taper shank of dead
center and it also locates taper shank drill, drill chucks, etc.

2.3.3 Carriage
The carriage is composed of mainly the following parts :
 Saddle : This is fitted to the carriage and slides along the guides.
 Cross slide : This permits the transverse (perpendicular to axis of work piece) movement of the
tool.
 Compound rest or Compound slide : This helps in angular tool movement of the tool. This will be
useful for taper turning operation.
 Apron : This contains the driving mechanism which is necessary to move the carriage along the
guide ways. This can be operated either by hand or power feed.
 Tool Holder : It is mounted on compound slide.

2.3.3.1 Saddle
 The saddle is H shaped casting that is machined to fit the outer ways of the lathe bed.
 Saddle can move on ways either manually or by power, through gear mechanism in apron box.
 Saddle carries the cross slide and compound slide with suitable tool post.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.5
Unit – 2 Metal Cutting Lathes
2.3.3.2 Cross Slide
 It is mounted on the carriage and has two fold purpose.
 It support the compound slide and allows movement of the cutting tool at right angle to lathe center
line.
 It is fitted with indexing dials.
 It can be moved with power feed or hand wheel.

Fig.2.5 Lathe Carriage

2.3.3.3 Compound Slide

 A compound slide is mounted on cross slide.
 It supports the tool post.
 It allows movement of tool along a path not parallel to the lathe center line. This permits the turning
of conical or tapered surfaces.
 It does not have any power feed.
 The hand feed is used when taper turning is required which is done by graduated circular scale
setting.

2.3.3.4 Tool Post

 It is essential condition of turning that the cutting tool or cutter be rigidly and securely held and the
device used for the purpose is known as tool post.
 It can be moved left or right with the help of compound slide and it can be clamped in place also.
 The tool post can be rotated also as the work at whatever angle is best for the job.
 Quick release tool post is now being increasingly used.
Mr. Ankur N Tank, Department of Mechanical Engineering
2.6 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.3.3.5 Apron
 The apron is bolted to the front of the saddle.
 The apron houses gears and controls for the carriage and the feed mechanism.
 The control lever held in the apron are levers which engage and reverse the feed lengthwise or
crosswise and the lever which engages the threading gear.
 Locking-off lever inside apron prevents engaging split-nut lever and automatic feed lever at same
time
 Apron hand wheel turned manually to move carriage along lathe bed.
 Manual Feed
 In manual feed is given by rotating carriage hand wheel shown if fig. 2.5 in which as carriage hand
wheel rotates the gear G5 also rotates due to engagement of G5 to G3, G3 also rotates that G3
gear is already engaged with rack and this leads to forward and as rotation direction change
motion also changes from forwards to reverse. This is how feed is given manually.
 Automatic Feed
 In Automatic Feed when feed selection lever changes from position N to U as shown in figure this
results gear G2 enggags with gear G4 and G4 is also same shaft where gear G3 is mounted thus
power will be transmited feed road to worm, worm to worm gear, worm gear to G2 and as G2 is
already enggaged to G4, power will also transmits to G4, then G4 and G5 rotates and this leads to
automatic forward motion of carriage.

Fig.2.6 Apron Mechanism

 Automatic Feed to cross slide

 When feed selecting lever sets from N to D the gear G2 will enggages to gear G6, This rotetes gear
G6 and G6 is connected to Crossfeed screw and cross feed screw fitted in nut due to that cross
slide moves across and thus depth of cut of cross movement of cross slide is possible.
 Half Nut Lever and lead Screw
 It is a long square threaded shaft slightly below and parallel to the bed ways extending from the
headstock and tailstock. One end of the lead screw goes to the headstock and is geared to the
headstock.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.7
Unit – 2 Metal Cutting Lathes
 Fig.2.7 Working of Halfnut

 Lead screw transmits the power to the carriage through a gearing and clutch arrangement in the
carriage apron.
 Whenever threading operation is to be performed the half nut is engaged with the lead screw and
carriage moves automatically towards the headstock following the path of the threads of screw
lead screens.

2.3.3.6 Head Stock

 It is permanently fastened to the inner ways at the left hand end of the bed.
 It serves to support the spindle and driving arrangements.
 All lathes receive their power through the headstock, which may be equipped with a step-cone
pulleys or a gear head drive (the modern lathes are provided with all geared type head stock to get
large variations of spindle speeds).
 In order to allow the long bar or work holding devices to pass through, the headstock spindle is
made hollow. A tapered sleeve fits into the tapered spindle hole.

Fig.2.8 Head Stock

 The headstock is the source of power for the tool and the work piece.
 The headstock is the part of the lathe, which is located at left side of the operator. The headstock
of the lathe consists of driving pulleys, back gears, bearings to support machine spindle and gears.

- The functions of headstock :

 (i) To support the spindle,
 (ii) To provide different speed to the spindle,
 (iii) To carry driving mechanism

Mr. Ankur N Tank, Department of Mechanical Engineering

2.8 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
 Back Geared Head Stock
 The cone pulleys in the headstock give three possible spindle speeds.
 When spindle speeds slower than those obtainable by the direct belt drive are required, especially
for thread cutting, the back gear is brought into operation.
 A back gear doubles the number of speeds by providing the same number of slower speeds.
 These slower speeds helps turning larger diameters of work and to take heavier cuts.
 Threads on the jobs are cut using back gear.
 When back gear is engaged the spindle speed reduces considerably, so it’s used when necessary
to have slower speed of spindle that cannot otherwise be obtained by direct speed.

Fig.2.9 Back Geared Head Stock

 All Geared Head Stock

 Modern and especially larger lathes incorporates all gear headstocks, enabling the spindle speed
to be readily changed by the operation of external handles or levers.
 Speed changes on most geared head lathes may be made only while the machine is stopped.
 The gear wheels are located on splines on the spindle and lay shafts, and are brought into mesh
by the appropriate levers.
 Lubrication is usually provided by splash from an oil bath in boxed headstock.
 Oil level must be frequently checked, a dip stick or observation window being provided for this
purpose.

Fig.2.10 All Geared Head Stock

Mr. Ankur N Tank, Department of Mechanical Engineering
Manufacturing Process (3141908) 2.9
Unit – 2 Metal Cutting Lathes
  Advantages Of All Geared Drive Over Cone Pulley Drive
 The design permits a totally compact unit with better appearance and large range of spindle
speeds.
 The power input and that available at tool edge are roughly constant at all spindle speeds.
 No belt shifting is necessary.
 All changes in the spindle speed, being made by simple movement of one or more levers, with more
quickly and no chance of any accident.
 No overhead shafting is needed, as the power is normally taken from an independent motor.

2.3.3.7 Thread Cutting Mechanism

 The principle of thread cutting is to produce a helical groove on a cylindrical or conical surface by
feeding the tool longitudinally when the job is revolved between centers or by a chuck.
 The longitudinal feed should be equal to the pitch of the thread to be cut per revolution of the w/p.

Fig.2.11 Thread Cutting Mechanism

 The leadscrew of the lathe, through which the saddle receives its traversing motion, has a definite
pitch.
 The ratio between longitudinal feed and rotation of the headstock spindle should be found to know
relative speed of rotation of the work and the leadscrew will result in the cutting of a screw of
desired pitch.

Leg
 They are supports which carry the entire load of the machine over them.
 The prevailing practise is to use cast legs. Both the legs are family secured to the floor by means
of foundation bolts in order to prevent vibrations in the machine.
 One of this legs usually the one on the left hand side of the operator,serves as a housing for the
electric motor and countershaft,etc.
 Both these legs should be rebust construction.

Mr. Ankur N Tank, Department of Mechanical Engineering

2.10 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.4 Capstan and Turret Lathe

2.4.1 Capstan Lathe

 The turret of the capstan lathe machine is mounted on a slide or ram which can be moved
longitudinally on the saddle for feeding the tools.

Fig.2.12 Capstan Lathe

 The saddle itself is mounted on the bed.
 The turret is generally hexagonal but may also be square or round.
 This type of machine is lighter in construction and is suitable for machining bars of up to 60 mm
in diameter.
 More than one tool may be mounted on the same face on the turret making it possible to machine
more than one surface at the same time
 Capstan Lathe Parts
 Head stock  Carriage  Saddle for ram
 Bed  Tool post  Lead screw
 Feed box  Hexagonal turret  Ram

2.4.2 Turret Lathe

 The tool turret is mounted directly on the saddle and the feed is given by moving the entire unit.
 The turret lathe can thus operate under more serve condition accommodating heavier work pieces
with higher cutting speeds, feeds and depth of cut.
 Turret lathes are capable of turning bars up to 200 mm diameter using collets as well as handling
irregular jobs like castings and forgings with chucks.
 Some turret types lathes are equipped with crosswise movement of the hexagonal tool turret by
hand or power.
 Turret machines provided with so called side hung type of carriage do not require any support from
the rear slide of the bed.

Fig.2.13 Turret Lathe

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.11
Unit – 2 Metal Cutting Lathes
  Turret Lathe Parts
 Head stock  Tool post  Feed rod
 Bed  Carriage  Hexagonal turret
 Feed box  Lead screw  Saddle

2.4.3 HowThese lathes different from the engine lathe following respects:
 They do not have tail stock. The work piece is supported at the head stock and alone.
 They carry a much larger number and variety of tools than the engine lathe.
 More than one tool may be set to operate simultaneously.
 Capstan and turret lathes are production lathes used for production of large number of identical
parts in minimum time.

2.4.4 Difference of Capstan and turret Lathes

Mr. Ankur N Tank, Department of Mechanical Engineering

2.12 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.5 Lathe Accessories And Attachements
 The devices employed for handling and supporting the work and the tool on the lathe are called its
accessories.
 Function : to hold work piece of different sizes and shapes and holding dif. Tools for different types
of operations
 2 types : Standard and special
 Chucks : 3 Jaw (for circular),4-Jaw (for irregular).
 Face Plate : Holding large size W.P. , several holes in plate.
 Live Centers :
 Dead Centers :

2.5.1 Chucks
 Used extensively for holding work for lathe machining operations
 Work large or unusual shape
Most commonly used lathe chucks
 Three-jaw Universal - Magnatic Chuck
 Four-jaw Independent - Collet

Three-jaw universal Four-jaw independent

 It is called scroll or self centering chuck.
 It is most frequently used work holding
device.
 The jaws can opened or closed with the
help of chuck key depending upon the size
of the job held in the chuck.
 The opening and closing force is exerted
through an internal scroll plate which has
continuous threads.
 All 3 jaws close uniformly and
automatically center the round or
hexagonal w/p.
 Internal and external jaws are available.
 It has not only more gripping surface but
each jaw can be independently adjusted
also.
 It can securely grip rectangular and
irregular shapes
 Jaws can be reversed for holding
externally or internally on the w/p.
 Heavy cut can be taken easily.
 Even if the chuck wears out, there is no
loss of accuracy.
 Chuck is bulky and heavy to handle on
the lathe.
 Chuck fine can be easily damage during
setting

Fig.2.14 Three Jaw and Four Jaw Chuck

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.13
Unit – 2 Metal Cutting Lathes
2.5.1.1 Magnetic Chuck
 It is also known as electro-magnetic chuck.
 It implies the use of the electric current for developing a strong electromagnet which holds the job
centrally in the chuck.
 Although many designs of these chucks are still the rotary type is in common use.
 It can not capable of withstanding heavy cuts on the job which it grips.
 One of the limitation of this chuck is it only holds iron and steel parts.
 Used to hold iron or steel parts that are too thin or may be damaged if held in conventional chuck.

Fig.2.15 Megnetic Chuck

2.5.1.2 Collet
 Collet is an essential component of a spindle because it held the spindle in a machine tool.
 Collet is a cone shaped sleeve generally used for holding circular or rod like pieces in so many
machines typically in lathe.
 It is generally cylindrical inside and a conical outside and has edges along its length to permit it to
expand and contract.
 Collet is an adjustable metal part that is used to tightly grip a tool or any workpiece.

Fig.2.16 Collet

2.5.2 Face Plates

 It is usually a circular cast iron disc, having a threaded hole at its centre so that it can be screwed
to the threaded nose of the spindle.
 It consists of a number of holes and slots by means of which the work can be secured to it.
 A number of other things like bolts, nuts, washers, clamping plates and metallic packing pieces,
etc., are required for holding the work properly on a face plate.
 Certain irregular w/p cannot be machined by mounting them directly onto the face plate.
 For such jobs angle plate having two working sides machined at right angle is attached to the face
plate and in turn the work is clamped to the angle plate.

Mr. Ankur N Tank, Department of Mechanical Engineering

2.14 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
 Fig.2.17 Faceplate and Drive plates

Fig.2.18 Angle Plate

2.5.3 Lathe Centers

 They act as solid bearings to support the work during the operation.
 Cast steel or high grade tool steel is the common material used for their manufacture. They are
then hardened and ground to correct angle. Sometimes, when very high speeds are to be employed,
tips made of some other materials like cemented carbide or high speed steel are used which are
fitted into usual types of shanks.
 The centre which is used in the headstock spindle revolves with it and it is known as live centre,
whereas one fitted in tailstock remains stationary and is called dead centre.

Fig.2.19 Lathe Centers

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.15
Unit – 2 Metal Cutting Lathes
2.5.4 Lathe Mandrels
 A "mandrel' can be described as a solid steel shaft or spindle which is used for holding bored parts
for machining their outside surfaces on lathe. They are also known as arbors.
 Mandrels are usually employed for those jobs (relatively small) which have a finished hole which
is concentric with the outer surface that is to be machined.
 The common types of mandrels are : Solid or plain, collar, stepped, expanding and double cone
mandrels.

Fig.2.20 Mandrel

2.5.5 Lathe Dog or Carrier

Fig.2.21 Lathe Dog

 Drives work machined between centers.

 Has opening to receive work and setscrew to fasten the dog to work.
 Tail of dog fits into slot on drive plate and provides drive to workpiece.
 Made in variety of sizes and types to suit various workpieces.

Mr. Ankur N Tank, Department of Mechanical Engineering

2.16 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.5.6 Rests
 When a very long job is to be turned between centers on a lathe, due to its own weight it provides
a springing action and carries a lot of bending moment. The result is that the turning tool is spoiled
very soon and may even break sometimes. To avoid this, such jobs are always supported on an
attachment known as 'steady rest or centre rest.
 Sometimes, when the job is too flexible, it becomes necessary to support the job very close to the
cutting edge of the tool throughout the operation. In such cases a 'follower rest, is used instead of
the steady rest. It is attached to the saddle of the lathe carriage and thus travels along with the tool
throughout the operation.

Fig.2.22 Rests

2.6 Operation on Lathe

 Turning: To remove material from the outside diameter of a work piece to obtain a finished surface
and produce straight, conical, curved, or grooved workpieces
 Facing: to produce a flat surface at the end of the part or for making face grooves.
 Boring: to enlarge a hole or cylindrical cavity made by a previous process or to produce circular
internal grooves.
 Drilling: It is an operation of producing a cylindrical hole in a workpiece. For this operation, the
work is held in a suitable device, such as chuck or face plate, as usual, and the drill is held in the
sleeve or barrel of the tailstock.The drill is fed by hand by rotating the hand wheel of the tailstock.
 Reaming : Reaming is the operation which usually follows the earlier operation of drilling in case
of those holes in which a very high grade of surface finish and dimensional accuracy is needed.The
tool used is called the reamer.The reamer is held on the tailstock spindle and is held stationary
while the work is revolved at very low speed.
 Threading: Threading is an operation of cutting helical grooves on the external cylindrical surface
of the w/p. In this operation, as shown in fig, the work is held in a chuck or between centres and
the threading tool is longitudinally to the revolving work. Thread of any pitch, shape and size can
be cut on lathe machine using single point cutting tool. The cutting tool must travel a distance
equal to the pitch as the work piece completes a revolution. The definite relative rotary and linear
motion between job and cutting tool is achieved by locking or engaging a carriage motion with lead
screw and nut mechanism and also fixing the gear ratio between head stock spindle and lead
screw.
 Knurling: It is an operation of embossing a diamond shaped pattern on the surface of a w/p. The
purpose of knurling is to provide an effective gripping surface on a w/p to prevent it from slipping
Mr. Ankur N Tank, Department of Mechanical Engineering
Manufacturing Process (3141908) 2.17
Unit – 2 Metal Cutting Lathes
 when operated by hand. The operation is performed by a special knurling tool which consists of 1
set of hardened steel rollers in a holder with the teeth cut on their surface in a definite pattern. The
tool is held rigidly on the tool post and the rollers are pressed against the revolving w/p.
 Cutting Off: In this operation job or bar cutting is being done by parting off tool.

Fig.2.21 Function of Machine ToolS

 Taper Turning :A taper may be defined as a uniform increase or decrease in diameter of a piece of
work measured along it’s length.In lathe taper turning means to produce a conical surface by
gradual reduction in diameter from a cylindrical w/p.

Method of Taper Turning

1.By nose form tool.

2.by setting over the tailstock centre.
3.By swivelling the compound rest.
4.by a taper turning attachment.
5.by combining longitudinal and cross feed in a special lathe.

2.6.1 Taper Turning By A Form Tool

Fig.2.22 Taper turning by form tool

Mr. Ankur N Tank, Department of Mechanical Engineering

2.18 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
  A broad nose tool having straight cutting edge is set on the work at half taper angle, and is fed
straight into the work to generate a tapered surface.
 The half angle of taper (α)will correspond to 90 minus side cutting edge angle of tool.
 This method is limited to turn short length of taper only.

2.6.2 Taper Turning By Compound Rest

Fig.2.23 Taper Turning by Compound Rest

 Once the compound rest is set at the desired half taper angle, the rotation of the compound slide
screw will cause the tool to be fed at that angle and generate a corresponding taper.
 This method is limited to turn a short taper owing to the limited movement of the compound rest.
 The movement of tool in this method being purely controlled by hand, this gives a low production
capacity and poorer surface finish.

2.6.3 Taper Turning By Setting Tailstock Centre:

 In this method it shift the axis of rotation of w/p, at an angle to the lathe axis, and feeding the tool
parallel to the lathe axis.
 This is done when the body of the tailstock is made to slide on its base towards or away from the
operator by a set over screw.

Fig.2.24 Taper turning by setting tail stock

 This method is suitable for turning small taper on long jobs.

 The main disadvantage of this method is that the live and dead centers are not equally stressed
and wear is not uniform.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.19
Unit – 2 Metal Cutting Lathes
2.6.4 Taper Turning By Taper Turning Attachment
 The principle of turning by a taper attachment is to guide the tool in a straight path set at an angle
to the axis of rotation of the w/p, while the work is being revolved between centers or by chuck
aligned to the lathe axis.
 The max. angle through which the guide bar may be swivelled is 10 to 12 on either side of centre
line.
 The required depth of cut is given by the compound slide which is placed at right angles to the
lathe axis.
 Accurate taper on a large number of w/p may be turned.
 Internal taper can be turned.

Fig.2.25 Taper turning attachment

2.6.5 Taper Turning By Combining Feeds

 In certain lathes both longitudinal and cross feeds may be engaged simultaneously causing the
tool to follow a diagonal path which is the resultant of the magnitude of the two feeds.
 The direction of the resultant may be changed by varying the rate of feeds by change gears
provided inside the apron.

Fig.2.26 Function of Machine ToolS

Mr. Ankur N Tank, Department of Mechanical Engineering

2.20 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.7 Specification of lathes
The size of a lathe is generally specified by the following means:
 (a) Swing or maximum diameter that can be rotated over the bed ways
 (b) Maximum length of the job that can be held between head stock and tail stock centres.
 (c) Bed length, which may include head stock length also
 (d) Maximum diameter of the bar that can pass through spindle or collect chuck of capstan lathe.

Figure illustrates the elements involved in specifications of a lathe. The following data also contributes
to specify a common lathe machine.

Fig.2.27 Function of Machine ToolS

The following specifications also useful
 Maximum swing over bed
 Maximum swing over carriage
 Height of centers over bed
 Maximum distance between centers
 Length of bed
 Width of bed
 Morse taper of center
 Diameter of hole through spindle
 Face plate diameter
 Size of tool post
 Number of spindle speeds
 Lead screw diameter and number of threads per cm.
 Size of electrical motor
 Pitch range of metric and inch threads etc.

2.8 Alignment test in lathe

2.8.1 Levelling of the Machine.

 Before the various tests on any machine tool are carried out, it is very essential that it should be
installed in truly horizontal and vertical planes. In horizontal plane, both longitudinal and transverse
directions are equally important.
 If, say, any long lathe bed is not installed truly horizontal the bed will undergo a deflection, thereby
producing a simple bend and undesirable stresses will be introduced.
 If the bed is not installed truly horizontal in transverse direction, twist will be introduced. Thus the
movement of the saddal can’t be in a straight line and true geometric cylinder can’t be generated.
For proper installation and maintenance of its accuracy, a special concrete foundation of
Mr. Ankur N Tank, Department of Mechanical Engineering
Manufacturing Process (3141908) 2.21
Unit – 2 Metal Cutting Lathes
 considerable depth must be prepared. Also this must be insulated from the surrounding floor by
introducing some form of damping.
 The level of the machine bed in longitudinal and transverse directions is generally tested by a
sensitive spirit level. The saddle is kept approximately in the centre of the bed support
feet. The spirit level is then placed at a-a (Fig. 16.1), the ensure the level in the longitudinal direction.
 It is preferable to take two readings in longitudinal and transverse directions simultaneously so
that the effect of adjustments in one direction may also be observed in the other. The readings in
transverse direction reveal any twist or wind in the bed. It may be noted that the two guideways
may be perfectly levelled in longitudinal direction, but might not be parallel to each other. This is
revealed by the test in transverse direction.

Fig.2.28 Leveling of Machine

2.8.2 True Running of Locating Cylinder of Main Spindle.

 Locating cylinder is provided to locate the chuck or face plate. However locating surface can’t be
threaded one as threads get worn out soon and thus introducing play in face plate or chuck. Thus
locating surface is cylindrical and this must run truly; for only then the face plate etc., can run truly.
The dial indicator is fixed to the carriage (or any other fixed member) and the feeler of the indicator
touches the locating surface. The surface is then rotated on its axis and indictor should not show
any movement of needle.

Fig.2.29 True Running of Locating Cylinder of Main Spindle

2.8.3 Axial Slip of Main Spindle and True Running of Shoulder Face of Spindle Nose.
 Let us first distinguish between the axial play and the axial slip. Axial play means the indispensable
freedom of spindle movement in axial direction to prevent it from
seizing by heating.

Fig.2.30 Axial Slip of Main Spindle and True Running of Shoulder Face of Spindle Nose.

Mr. Ankur N Tank, Department of Mechanical Engineering

2.22 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
  The spindle is supported between two bearings. Due to running of spindle, there will be a rise in
temperature and thermal expansion of spindle would be there. If no axial play is allowed, it would
try to bend.
 Thus there will be no adverse effect of axial play if the direction of cutting forces remains same. If
the direction of cutting force changes, there would be some error introduced due to movement of
spindle axially in either direction.
 Under such conditions, therefore, it is advisable to cut threads in one direction only.Axial slip is
defined as the axial spindle movement which follows the same pattern and is due to the
manufacturing error. Actually this test is meant to check this error.
 To test this the feeler of the dial gauge rests on the face of the locating spindle shoulder and the
dial gauge holder is clamped to the bed (Fig.2.30).
 The locating cylinder is then rotated and the change in reading noted down. The readings are taken
at two diametrically opposite points. The total error indicated by the movement of the pointer
includes three main sources of errors.
 Axial slip due to error in bearings supporting the locating shoulder, i.e., the bearings are not
perpendicular to the axis of rotation and due to it a point on the shoulder will move axially in and
out at diametrically opposite points.
 Face of the locating shoulder not in a plane perpendicular to axis of rotation.
 Irregularities of front face.
 Due to axial slip, in screw cutting, the pitch will not be uniform due to periodic movement of the
spindle.

2.8.4 True Running of Headstock Centre.

 Headstock centre is live centre and the workpiece has to rotate with this centre. If it is not true with
the axis of movement of the spindle, eccentricity will be caused while turning a work, as the job
axis would not coincide with the axis of rotation of main spindle.
 For testing this error, the feeler of the dial indicator is pressed perpendicular to the taper surface
of the centre (Fig.2.31), and the spindle is rotated.The deviation indicated by the dial gauge gives
the trueness of the centre.

Fig.2.31 Function of Machine ToolS

2.8.5 Parallelism of the Main Spindle to Saddle Movement.

 This has to be checked in both vertical and horizontal planes. In this we require the use of mandrel.
An important precaution in the use of mandrels and dial indicator is mentioned here.
 The mandrel must be so proportioned that its overhang does not produce appreciable sag, or else
the sag must be calculated and accounted for.
 The rigidity indicator set up is also very important and must be carefully watched. Otherwise
variations in readings are recorded by pointer may be solely due to deflection of the indicator
mounting in different positions and it becomes very difficult to detect and isolate the spurious
deflection from the true variations.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.23
Unit – 2 Metal Cutting Lathes
  If axis of the spindle is not parallel to bed in horizontal direction, a tapered surface is produced.
Any deviation from parallelism of spindle axis from bed in vertical axis will produce a hyperboloid
surface. For this test, a mandrel is fitted in the taper socket of the spindle.
 Mandrel has a concentric taper shank which is close fit to the spindle nose taper. The feeler of the
dial indicator is pressed on the mandrel and the carriage is moved. The indication in horizontal
plane is given by dial (b) and in vertical plane by dial (a) (Fig. 2.32).

Fig.2.32 Parallelism of the Main Spindle to Saddle Movement

 In vertical plane the mandrel should be rising towards the free end in order to counteract the weight
of mandrel and job. But for counter-acting cutting forces, it should be lower towards free end. In
horizontal plane, mandrel should be inclined in a direction opposite to the direction of tool pressure.

2.8.6 True running of taper socket in main spindle.

 If the axis of tapered hole of the socket is not concentric with the main spindle axis, eccentric and
tapered jobs will be produced. To test it, a mandrel is fitted into the tapered hole and readings at
two extremes of the mandrel are taken by means of a dial indicator as shown in (Fig.2.33)

Fig.2.32 True running of taper socket in main spindle.

2.8.7 Parallelism of tailstock guideways with the movement of carriage.

 Sometimes the job is held between head-stock and tail stock centre for turning. In that case the
job axis must coincide with the tailstock centre.
 If the tailstock guideways are not parallel with the carriage movement there will be some offset of
the tailstock centre and this results in taper turning.
 To check the parallelism of tailstock mideways in both the planes i.e., horizontal and vertical, a
block is placed on the guideways as shown in (Fig. 2.34) and the feeler of the indicator is touched
on the horizontal and vertical surfaces of the block.
 The dial indicator is held in the carriage and carriage is moved. Any error is indicted by the pointer
of dial indicator.

2.8.8 Movement of upper slide parallel with main spindle in vertical plane.
 The dial indicator if fixed in the tool post. A mandrel is fitted in the spindle. The feeler of the dial
gauge is pressed against the mandrel in vertical plane and the upper slide is moved longitudinally.
 This error is not tested in horizontal plane because there is swivelling arrangement for taper
turning.

Mr. Ankur N Tank, Department of Mechanical Engineering

2.24 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
 Fig.2.33 Movement of upper slide parallel with main spindle in vertical plane.
 Parallelism of tailstock sleeve to saddle movement. If the tailstock sleeve is not parallel to the
saddle movement, the height of dead centre would vary as varying lengths of sleeve are taken out.
For the jobs held between two centres, it is necessary that the central axis of the dead centre be
coaxial with the job axis in both the planes.

Fig.2.34 alignment of tailstock quil

 If it is not so, the job may be tilted up or down or in sideways due to the support of the dead centre.
The test is carried out by fixing the dial indicator on the tool post and pressing the plunger against
the sleeves first in vertical and then in horizontal plane.
 The carriage is moved along the full length of the sleeve and deviations as indicated by dial
indicator are noted down. Tailstock sleeve should be rising towards the free end in vertical plane
and should be inclined towards the tool pressure in horizontal plane .

2.8.9 Parallelism of tailstock sleeve taper socket to saddle movement.

 A mandrel is put in the sleeve socket. The dial gauge is fixed on the tool post and plunger is pressed
against the mandrel and saddle is moved from one side to the other. This test is carried out in both
the horizontal and vertical planes.

2.8.10 Alignment of both the centres in vertical plane.

 Besides testing the parallelism of the axes individually (main spindle axis and tailstock axis) it is-
necessary to check the relative position of the axes also.

Fig.2.35 Alignment of both the centres in vertical plane

 Both the axes may be parallel to carriage movement but they may not be coinciding. So when a job
is fitted between the centres, the axis of the job will not be parallel to the carriage movement. This
test is to be carried out in vertical plane only.

Fig.2.36 Alignment both centers with mandrel

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.25
Unit – 2 Metal Cutting Lathes
  A mandrel is fitted between the two centres and dial gauge on the carriage. The feeler of the dial
gauge is pressed against the mandrel in vertical plane asshown in (Fig. 2.37) and the carriage is
moved and the error noted down.

2.8.11 Pitch accuracy of lead screw.

 The accuracy of the threads cut on any machine depends upon the accuracy of its lead screw.
Thus it is very essential that pitch of the lead screw throughout its length be uniform.
Test for this is performed by fixing a positive stop on the lathe bed.
 Against the stop, the length bars and slip gauges can be located. An indicator is mounted on the
carriage and first it makes contact against the calculated length of slip gauges. The initial loading
of the dial gauge against the slip gauge is noted.
 The slip gauges are then removed and the carriage is connected to the lead screw and lead screw
is disconnected from the gear train. An indexing arrangement is utilised for rotating the lead screw
and lead screw is given some revolutions so that distance travelled by carriage is equal to the
length of slip gauges.
 The reading of the dial indicator against the stop is noted down in this position. It it is same as
before, there is no error, otherwise it can be recorded. In this method, care must be taken not to
disturb the datum location when changing the gauges for testing different pitch lengths.
 A suitable method for recording the progressive and periodic errors is by using a suitably divided
scale, which is placed close to the line of centres. A microscope is rigidly mounted on the carriage
in a convenient position to note the readings on the scale.

2.8.12 Alignment of lead screw bearings with respect to each other.

 The alignment of the bearings decides the position of the lead screw. Misalignment of lead screw
i.e., it not being parallel to the bed in vertical plane or horizontal plane can cause additional stresses
due to bending, when carriage is moved.
 Due to it the lead screw might get damaged and the precision of the machine is reduced
Alignment of lead screw bearing with split nut in both the planes is also essential.

2.8.13 Axial slip of lead screw.

 The thrust face and the collars of the lead screw (or the abuttment collar and the thrust bearing of
the screw) must be exactly square to the screw axis, otherwise a cyclic endwise movement is set
up which is of the same nature as the axial slip in the main spindle.

Fig.2.37 Axial Sleep of Lead Screw

 Thus a periodic pitch error will be additional to any true periodic errors in the pitch of the screw.
For testing the axial slip in lead screw, a ball is fitted in the end of lead screw and the feeler of the
dial gauge is pressed against the ball. The lead screw is rotated and deviation, if any, in any
direction is noted down.
Mr. Ankur N Tank, Department of Mechanical Engineering
2.26 Manufacturing Process (3141908)
Unit-2 Metal Cutting Lathes
2.9 Lathe Parameters

2.9.1 Cutting Speed (V):

 It is the speed at which the metal is removed by the cutting tool from the workpiece. In case of
lathe machine cutting speed is the peripheral speed of the work past the cutting tool. It is expressed
in meter/min. or mm/min.
 Cutting speed (V) = π DN/60 × 1000 mm/min
 Where, D = diameter of the work piece (mm)
 N = rpm of the work
Cutting speed depends upon the following factors:
 i. Tool material.
 ii. Work material.
 iii. Depth of cut.
 iv. Tool geometry.
 v. Type of machine tool.

2.9.2 Feed (f):

 It is the relative motion of tool in one revolution of workpiece. It is expressed in mm/rev.

2.9.3 Depth of Cut (t):

 It is the total amount of metal removed per pass of the cutting tool. It is expressed in mm. It can
vary and depending upon the type of tool and work material. Mathematically, it is half of difference
of diameters.
Depth of cut (t) = D-d/2 mm
where, D = outer diameter, (mm)
d = Inner diameter (mm)

2.10 Reference
1) R.K.Rajput,”Manufacturing Technology”,Lakshmi publication (P) Ltd.
2) B.S.Raghuvanshi, “Workshop Technology (Vol.ll)”,Dhanpat Rai & Co.
3) Serope Kalpakjian, Steven R. Schmid,”Manufacturing Engineering and Technology”,6th Edition,
Prentice Hall, New York
4) Rajender Singh, “Introduction to Basic Manufacturing Process and Workshop Technology”, New
Age International Publishers.

Mr. Ankur N Tank, Department of Mechanical Engineering

Manufacturing Process (3141908) 2.27
Unit – 2 Metal Cutting Lathes