Chapter 3 Turning with the center lathe GDW LZ 280 S:

Practical Session Production Technique | Manual Machining Techniques 25

3.2 Center lathe GDW LZ 280 S

Figure 12 Parts and control panels of GDW LZ 280S

Practical Session Production Technique | Manual Machining Techniques 29

Explanation of parts and control buttons of the GDW LZ 280 S
center lathe, see figure 12:

A RPM display (When V constant is used, this expires and can be seen on the digital
display)
B Rotary knob preset RPM; for single work high RPM setting A or for double work of low
RPM setting B.
C Rotary knob for basic onset with settings: E - F - G - H.
D Rotary knob for the multiplied base with settings: K - L - M.
E Rotary knob for switching the movement of the longitudinal and transverse carriage
from the left to the right or to the center of the work piece or away from it.
M Hexagon for clamping of the longitudinal carriage on the bed of the machine.
O Switch for activating the automatic turn and turn direction. Also, this switch is for
turning on nut lock when cutting a screw-thread.
P Selector dial for adjusting the feed force.
Q Hexagonal nut for clamping the tool slide on the bed of the cross slide.
R Switch for clamping of the spindle sleeve in the tailstock.
S Switch for clamping of the tailstock on the machine's frame.
T Manual chuck for quick clamping device (not standard available on the machine)
U Screw to move the tailstock in transverse direction.
V Push button for the "central lubrication pump".
X Hand wheel to move the "cross slide".
Z Hand wheel to move the "longitudinal slide".
Zo Hand wheel to move to "tool slide".

1 Main switch.
2 Illuminated push button for electrically switching on the machine.
3 Push button for electrically switching off the machine.
5 Switch for turning the coolant pump on or off.
6 Switch to turn on the main spindle with the positions:
clockwise rotation - stop - counterclockwise rotation.
7 Rotary knob for adjusting the RPM of the main spindle.
8 Selector switch for brake 'on - off'.
10 Illuminated push button for "open clamping device" (if present).
11 Illuminated push button for "closed clamping device" (if present).
12 Emergency stop.
13 Start button for quick clamping device if present.
14 Selector switch for turning on end switch device setup at the screw threading (if any).
16 Switch for turning on the machine lights like these if this has no switch.

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3.3 Instruction manual for the digital read-out on the GDW LZ 280 S

Figure 13 Screen of digital read-out Np-20T-V2

Below is a short description of the display unit which is present at the GDW center lathes.
In the field of the X the position of the transverse carriage is displayed.
In the field of the Z the position of the longitudinal slide and the tool slide is displayed. The
digital readout also keeps track of the displacement of the tool slide and sums this
displacement up with the displacement of the longitudinal carriage. Thus, the display in the
field with the Z consists of long slide displacement added together with any movement of the
tool slide. In the field where S is shown, the actual measured RPM is displayed. Also, the
adjusted RPM can be displayed, the actual cutting speed or the adjusted maximum speed.
In the field where T is shown, the current tool is displayed with associated technological
details.
A value is always entered in the field or . The value can be entered in the field
where the LED is lighted. This area remains active until another field is chosen.

On the next page all buttons of the digital read-out are discussed. Furthermore, the most
popular features of the digital read-out are discussed. For matters that are not discussed, ask
the laboratory manager for the comprehensive manual on the display unit.

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3.4 Buttons of the digital read-out (see figure 13)

Saves X value (diameter).

Saves Z value for tools.
Enters work piece zero point in Z direction. (zero shift).
Saves RPM1 for the tool.
Switches indication between given RPM1 ( LED on), actual RPM1 ( LED
off) and actual cutting speed1 ( LED off and point in display).

Switches between mm and inch indication.

Switches between diameter and radius indication.
Switches between normal and positioned spindle stop.
Switches between RPM and constant cutting speed.
Entries and indication of maximum RPM.
Led burns when maximum RPM is reached.

Displays parameters.
Switches between absolute- and incremental measurement read-out.
Led burns with incremental measurements.
Activates a tool and the saved RPM of the cutting speed. Takes over the
actual RPM that is set, at a spinning spindle, or saves it for that tool.
Deletes the entries or the error.
Terminates the entries without change.
Saves the entries or the actual angle of the spindle.

On = constant cutting speed.

Off = RPM display

On the next page will be discussed how the various issues can be set on the digital read-out.
Amongst others, the following is discussed:

 Switching and reference points call.

 Radius or diameter display.
 MM or Inch indication.
 Constant RPM.
 Maximum RPM.
 Constant cutting speed.
 Zero shift.
 Etc.

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3.5 Switch on and reference points call
The digital read-out is switched on using the main switch of the machine. After start-up of the
software, the software version is shown for a short time.
Hereafter the LED burns on and .

First the tool slide (Z) must be moved over the reference point, after switching on, then the
longitudinal slide (Z) and finally the transverse carriage (X). When a reference point is
present, it is in the middle of the range of the axis which is tilted. At a fixed reference point
the slide may only be moved 15-20 mm.
The reference points should be approached in the following order:
1. Chisel slide reached reference point.
2. Longitudinal slide if the reference point is reached, the position will be indicated.
3. Transverse slide if the reference point is reached, the position will be indicated.

If the reference points are approached, the preset tools and the last preset work piece zero
point are active again.

With the button the approach of the reference can be skipped. The preset tools and the
zero point are unusable after disabling.

When the button is pressed later and is lighted, the reference point approach can be
repeated. After turning on the RPM and tool number must always be entered.

Radius or diameter read-out:

The digital read-out may indicate positions in the X-axis as a radius or diameter. Turned work
pieces are usually dimensioned as diameter dimension.

The button changes the display:

LED burns: radius read-out

LED does not burn: diameter read-out

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Millimeter or Inch sizes:

It is possible with the digital read-out to indicate sizes in millimeters or inches. The selected
unit of measure applies to all axes.
The conversion factor is: 1 inch = 25.4 mm

The switches between mm and inches.

LED burns: sizes in inch

LED does not burn: sizes in millimeters

The chosen unit remains set after turning off.

The capabilities of the main spindle:

The main spindle can rotate at a constant speed or at a speed which is constantly adapting
to the diameter of the work piece (constant cutting speed).

Constant speed of the main spindle:

This mode applies when the LED in the button is not lighted. Press the button until the
LED is off.

Push on 1000 sets the speed to 1000 rev/min.

The designation S in the display is switched with the S button as shown in the table above.
With the potentiometer (see page 30 number 7) on the machine one can set the RPM to
slower or faster. The range of the engine speed lies between the minimum rotational speed
of the gearbox and the entered speed.

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Entry of maximum RPM:

The speed of the spindle can be limited to a maximum RPM.

2500 sets a maximum RPM of 2500 rev/min.

When the maximum RPM is reached the LED in button will burn. By pressing the button
, the maximum RPM will be shown in the display. By pressing the button again, the
actual RPM will be shown again.

For working without maximum RPM, enter the maximum RPM of the machine with .

Constant cutting speed:

This mode applies when the LED of button is on.

Press this button until the LED lights. The RPM

depends on the indicated diameter. To do this, the tool
must be measured. In the middle the RPM gets infinitely high.
Here is turned with the maximum set RPM.

150 sets the cutting speed on 150 m/min.

The indication on the display S is switched by pressing button as shown in the table
above. With the potentiometer on the machine, the current cutting speed can be adjusted
accurately. The range of cutting speed is between the minimum RPM of the gearbox and the
entered cutting speed.

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Zero point shift:

Sets the zero point of the work piece. The work piece zero point is the reference point of the
position indicated on the display.

The zero point shift for the Z axis:

1. Touch the surface that has to be Z 0.000 with the tip of the tool.

2. 0 set the zero point, the indicator on the display shows 0.000.

One can enter another value instead of 0. The indication on the display is then set to the
entered value. When you have approached the reference points when you start the machine,
the work piece zero point is retained even after switching off the machine.

The tool memory:

For 99 tools the tool correction can be saved in X, Z axis and the RPM or the cutting speed.
The tools must first be strained in a tool holder. When a preset tool is going to be activated
the read-out indicates the position of the cutting edge in the X and Z axis, and the main
spindle is set to the saved RPM or the preset cutting speed.

Activating tools:

There are two ways to activate a tool:

01 or activates tool1 with the saved RPM or

1 cutting speed.

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Measuring tools:

To save different tools with different lengths on X axis and Z axis in the digital read-out, the
different tools need to be measured.
Measuring tools on the machine can be done as follows:

Activate a measured tool (reference tool). Thereby flatten the head surface
1.
and put the work piece zero point on the Z axis to 0.

2. Place a new tool in the holder, activate tool correction.

Touch the tool with the new tool on the X axis and take over the value with
3.
the push button T of the tool memory.
Hit the front face with this tool and then take over the value Z = 0 with push
4.
button T of the tool memory.

5. For more tools repeat steps 2,3,4.

Practical Session Production Technique | Manual Machining Techniques 37

 3.6 Turning
Turning is a machining process, where the work piece is rotating and the cutting tool moves
along the work piece and removes material.

In figure 12 page 29 and 30 the components and controls by name of the GDW LZ 280 S
center lathe can be found.

3.7 General guidelines on turning

On turning some issues are important and need to be checked and set carefully.

1 The chisel should be sharp

2 The chisel must be exert in a way that the main cutting side takes the correct position
compared to the heart line of the work piece, so turning can be done longitudinally
and/or transversely (see figure 14).

Figure 14 Position of main cutting edge relative to the heart line of the work piece

3 Setting the chisel on center height (see figure 15). This can be done in the following
manners:
1 Put the chisel point exactly even with the center point of the swiveling center in the
loose head.
2 Put the chisel point even with the heart (center) of an already flat turned front face.
3 Measure the chisel point height with a caliper and adjust this precisely on the
center of the material.

Figure 15 Setting the chisel on center height

Practical Session Production Technique | Manual Machining Techniques 38

4 The chisel may not protrude further than 1, 5 to 2 times the size of the shaft of the
chisel, relative to the front of the chisel holder. When the protruding length of the
chisel is too long, there is a risk the chisel will vibrate because of the chisel forces
that occur during machining

Figure 16 Protruding length chisel

5 Vibrating of the chisel may also occur when the tool slide protrudes too much, we can
avoid protruding length too short, there is a risk that the chisel holder damages the
work piece or the clamping tool of the machine.

Figure 17 Front chisel slide even with transverse slide

Practical Session Production Technique | Manual Machining Techniques 39

Notes:

Practical Session Production Technique | Manual Machining Techniques 40

3.8 Actions before the machine can be set

1 Make sure the automatic infeed is switched off in the longitudinal or transverse
direction. You can do this by turning the hand wheels for the longitudinal or the cross
slide. If one of the hand wheel is not turning, then the automatic feed motion could be
activated, or the nut slot for cutting threads is enabled.

2 Set the right RPM or the right cutting speed. The RPM can be determined in two
ways:

1. having the formula: v = π x d x n (v = cutting speed in m / min, d = diameter work

piece in meters, n = RPM in rev/min). See table 2 page 42 for cutting speeds of
various materials.

2. by using the RPM nomogram. (See page 43)

The setting of the constant cutting speed should be done at the digital read-out, refer to the
manual page 35.

3 Set the automatic feed rate on the machine using table 4 on page 46.
n = Vc  1000
π d

3.9 Sequence of switching on the lathe:

1. Switching on the main spindle causes the work piece to rotate.

2. Enable automatic infeed.

3.10 Sequence to switching off the lathe:

1. Disable automatic infeed.

2. Turning off the main spindle, causes the work piece to stop.

Practical Session Production Technique | Manual Machining Techniques 41

3.11 Table with cutting speeds for various materials:

Table 2 Cutting speeds for various materials

Practical Session Production Technique | Manual Machining Techniques 42

3.12 RPM nomogram of center lathe GDW LZ 280 S

Table 3 RPM nomogram of center lathe GDW LZ 280S

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3.13 The use of the RPM nomogram
1. Search the cutting speed table which cutting speed belongs to the work piece material.
The cutting speed depends, among other things, on:

a the type of material to be machined

b the material from which the tool is manufactured

2. Measure the diameter of the work piece with the caliper

Example of the use of the RPM nomogram of the GDW LZ 280 S center lathe.

Data: Cutting speed V = 100 m/min.

Work piece diameter 20 mm.

The solution according RPM nomogram: n = 1600 rev/min.

Practical Session Production Technique | Manual Machining Techniques 44

Automatic feed rates at the GDW LZ 280 S center lathe

On a center lathe, it is possible to carry out the movement of the tool in two ways:

 Moving the chisel by hand happens by means of turning one of the hand wheels.
Hand wheel of the longitudinal carriage for the Z-axis, and the hand wheel of the
transverse carriage for moving in the X-axis.
 By use of the automatic starter that is present on the machine. The speed with which
the slides of the machine moves is constant so that a surface can be obtained with
high quality. The speed in the table is always indicated in mm/rev.

Use automatic starter on the GDW LZ 280 S:

On the GDW LZ 280 S it is possible to use the automatic feed motion. First, determine what
speed you want per revolution (see table 4 page 46). Set this speed with the several rotary
knobs on the machine. If this happens, you can turn on the machine and make a choice for
the longitudinal slide (Z-axis) or the cross slide (X-axis). If the choice is made, you switch on
the motion and the slide will automatically move.

Turning the infeed on and off and the nut lock for thread cutting:

To enable the automatic starting we use the O lever (see page 29 figure 12) on the
longitudinal carriage. The choice between longitudinal or cross feed is made by pressing the
lever or pulling it out. The choice of the infeed direction is only possible when the automatic
infeed is switched-off. When the lever is pulled out, the automatic longitudinal onset (z-axis)
is active when the lever is pushed, the automatic cross feed (x-axis) is active. By moving the
lever to the left, after the choice for automatic infeed direction, the selected slide will start
move (see figure 18).
If you move the lever O to the right, the nut lock will be turned on, the carriage will now start
to move in the longitudinal direction with the preset RPM of the thread.
The direction of movement of the selected carriage is preset with the turning knob E on the
machine. For controls and levers that are named, see page 29 and page 30 lathe GDW LZ
280 S.

Figure 18 Handle for switching on

automatic feed and nut lock for cutting
screw thread

Practical Session Production Technique | Manual Machining Techniques 45

In below table the automatic feed rate of the GDW LZ 280 S is shown.

Table 4 Automatic feed rate of the GDW LZ 280S

Practical Session Production Technique | Manual Machining Techniques 46

3.14 Chisel shapes with various applications

Figure 19 Chisel shapes and their applications

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Designations and applications of turning tools (see figure 19)

Chisels can be divided into applications for:

 Extern turning.
 Intern turning.

Chisels for extern turning:

1 Parting is used for the insertion of narrow grooves, for example run out groove with
screw thread, as well as for lighting of twisted work pieces.
2 Turning tool, due to the big nose angle, this chisel is very suitable for quick
machining (turning) in the longitudinal direction of the work piece.
3 Knife chisel is used for the front- and end turning of work pieces in the longitudinal
direction, but by slightly inclining the main cutting edge, this tool can also be used for
finishing of end faces through which in one operation with the same tool, both the end
face and the diameter (the longitudinal direction) can be turned accordingly.
4 Bend Roughing tool, by its form, this tool is suitable for rotated turning as well as the
turning of end faces which can also provide the work piece with a bevel edge.
5 External thread chisel, for the external cutting of screw thread on the lathe, provided
with a top angle of 55° or 60°.
9 Chisel is used for stabbing grooves.
10 V-groove bit is used for stabbing V-grooves for V-belts.
11 Facing tool, due to the big nose angle this chisel is very suitable for rapidly
machining (for turning) in the radial direction of the work piece.
13 Left knife chisel is used for the front- and end turning of work pieces in the
longitudinal direction.
14 Chisel profile, if a special desired profile needs to be applied at one time.
15 Facing tool, is used for finishing in the radial direction, surfacing.

Turning chisel for internal turning:

6 Inner thread chisel, for internally cutting a thread on the lathe, provided with a top
angle of 55° or 60°.
7 Blind drill bit is used for the internal front- and end rotating of blind or stepped holes.
8 Through drill bit is used for the internal front and end rotating of through-holes.
12 Room chisel is used for internal turning of grooves or walls e.g. undercut
groove of internal screw thread.
16 Boring bar, clipped with a left long boring bar. This boring bar is used to rotate a wall
of a deep and big hole.

Practical Session Production Technique | Manual Machining Techniques 48

Left or right version of a chisel:

To recognize a chisel to be left or tight, one looks at the head of the chisel (see figure 20). If
the main cutting edge is right, then the chisel is named right. If the main cutting edge is on
the left side, one speaks of a left chisel.

Figure 20 Right and left chisel

Practical Session Production Technique | Manual Machining Techniques 49

3.15 The clamping of work pieces on a center lathe
To clamp a work piece in a center lathe there are several clamping tools:

 Chucks.
 Set Plates.
 Jigs.
 Centers and cleats.
 Glasses.

Chucks

There are several types of chucks:

• A self-centering three-jaw chuck which is suitable for clamping round, triangular- and
hexagonal material. For a three-claw see figure 21.
• A self-centering four-jaw chuck which is suitable for tensioning round- and square material.
For a four-claw, see figure 22.
• An independent four-claw which is suitable for clamping of round, square and rectangular
material (see figure24). Working with this chuck needs some practice. This is because each
"claw" should be set separately to clamp the work piece properly. For an independent four-
claw see figure 23.

Figure 21 Self centering four cutter Figure 22 Self centering three cutter

Figure 23 Independent
Figure 24 Independent four cutter
with clamped rectangular material

Practical Session Production Technique | Manual Machining Techniques 50

Face plates

A face plate is used for attaching irregular shaped work pieces which cannot be clamped with
a chew plate because of their form. If you want to clamp a work piece on a face plate, you
should use clamping bolts and clamping plates to fix the work piece to the faceplate. Also, a
counterweight is often mounted to the face plate to evenly distribute the load on the main
spindle which extends the life of the main spindle. For a face plate see figure 25.

Figure 25 Set plate with clamped work piece

Collets

Collets could be used for tensioning rod material that is pulled "blank". Because the material
is pulled "blank", it meets a big size and shape accuracy. This accuracy one has been
needed if one wants to stretch with a collet because the range of a collet is small. For each
measure of material one has to purchase a collet. Jigs are available in many shapes like
round, hexagonal, square etc. For a collet see figure 26.
There are also special collets for clamping rings that have to be processed in- and externally.
For the internal machining of rings, we use a "kiting". For a kiting see figure 27.
For external machining of rings we use a "tower tang". For a tower tang see figure 28.

Figure 26 Collet Figure 27 Komag Figure 28 Tormenting

Practical Session Production Technique | Manual Machining Techniques 51

Centers and cleats

When the turned cylinders of a work piece must be put in a line, clamping centers are used
(see figure 29), in combination with a cleat.
We strain the fixed center (see figure 31) with an over tube in the main spindle of the center
lathe, for this we need to remove the chuck of the main spindle. In the spindle sleeve of the
tailstock a rotating center is placed (see figure 30). The cleat is attached on the work piece
(see figure 32). The rotary motion of the main spindle is transmitted onto the work piece
through the cleat and the drive plate (see figure 32).

Figure 29 Turning between centers with drive plate and carrier

Figure 31 Fixed center with half point Figure 30 Rotating center

Figure 32 Drive plate

Practical Session Production Technique | Manual Machining Techniques 52

Glasses
Glasses are used on the center lathe in the following cases:

 If the dimensions of the work piece are in such a way that during processing of the
work piece there is a risk of deflection and/or the occurrence of vibration, which may
cause the surface condition and form accuracy to not meet the requirements of the
drawing anymore.
 To support a slender shaft which will deflect due to occurring cutting forces.

There are two types of glasses:

 Fixed glasses (see figure 33).

 Moving glasses.

Figure 33 Support of a long work piece using fixed glasses

Practical Session Production Technique | Manual Machining Techniques 53

 Assignment for turning: the pen holder.

On the next page you will find the assignments that we have to make for the subject
turning.

The pen holder consist of six elements:

1. Holder.
2. Sleeve.
3. Foot.
4. Plastic cap.
5. Compression spring.
6. Allen screw.

There are a number of manufactured parts of the items listed above: holder, bus and foot.
The other parts are purchased and are called buying parts. These are: plastic shell,
compression spring and allen screw.
Of the manufactured part, the holder and the sleeve are made on a center lathe. The
base of the pen holder is made on a milling machine.

Assignment for turning:

Write a work preparation for turning the holder and a work preparation for turning the
sleeve.

Data of the holder: for drawing, see page 57

Material : AI Ø 20 mm long 87 mm.

Tools to be used : -Collet.
-Knife chisel.
-Drill Ø 12 mm.
-Profile chisel 3 mm.
-Center drill Ø 3.15 mm.
-Convex bevel chisel in two parts.

Data of the sleeve: see drawing page 58

Material : Brass slw. 24 mm long 27 mm.

Tools to be used : -Knife chisel.
-Center drill Ø 3.15 mm.
-Drill Ø 15 mm.
-Boring tool with an angle of 45°

Practical Session Production Technique | Manual Machining Techniques 54

The work preparation:

A work preparation is a document wherein exactly is written how one can make a work
piece step by step. In a work preparation is listed: Order of processing, clamping tools, to
be used tools, adjusting RPM, feed rates, etc. For an example see page 56.

In a work preparation should be included:

 A sketch of the clamping including the chisel.

 The name of the operation.
 The tool to be used.
 The RPM (theoretically preset)

Practical Session Production Technique | Manual Machining Techniques 55

 Example work preparation:

Practical Session Production Technique | Manual Machining Techniques 56

Practical Session Production Technique | Manual Machining Techniques 57
Practical Session Production Technique | Manual Machining Techniques 58