LATHE New

Shri Yashwantrao Bhonsale Education Society’s
YASHWANTRAO BHONSALE POLYTECHNIC

DTE CODE 3470
MSBTE CODE 1742
Approved by AICTE, DTE, & Affiliated to MSBTE Mumbai
FUNDAMENTAL OF MACHINING AND MACHINING Mechanism of chip formation

OPERATION In machining, As the cutting edge penetrates into the work piece, a layer of
Machining material get plastically deformed and slides off along the rake face of the
cutting edge. This is called chip formation
Machining is the process of cutting, shaping, or removing material
from a workpiece using a machine tool.
Element of machining
1) Work piece – it is material that undergoes machining operation on it

2) Cutting tool- it has specific geometry and it is made up material with
higher hardness than work material.
Selection of cutting tool material and Geometry depends on material
of work piece, feed, speed, and thickness of chip, material removal
Types of chip
rate & motions in machining operation
3) Motion of Tool and workpiece – during machining operation, work Depending on the workpiece material and the cutting conditions, the
piece or tool or both allow to move in specific direction to remove following mechanisms of chip formation
material in specific direction ( example In turning operation • Continuous chip formation

workpiece rotates continuously and tool moves parallel to axis of
• Lamellar chip formation
rotation )
• Discontinuous chip formation.
1|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

DTE CODE 3470
MSBTE CODE 1742
Continuous chip formation Discontinuous chip
In continuous chip formation the chip Discontinuous chip formation occurs

slides off along the rake face at a if the ductility of the workpiece
constant speed in a stationary flow. Material is very low and material
structure is not homogeneous.
For Continuous chip formation, a
uniform, fine-grained structure and
high ductility of the workpiece
material, positive rake angles are necessary.
Continuous chip with built-up edges formation,
Built-up edges are formed when particles of the workpiece material get
Lamellar chip formation adhere on the rake face and on the cutting edge. These particles have been
subject to high deformation and have been strain-hardened. They are much
Lamellar chip formation is a continuous, periodic chip formation process
harder than the base workpiece material.
similar to pure continuous chip
formation. Built-up edges only occur if
The lamellae are produced due to
• The workpiece material promotes strain hardening,
thermal or elasto-mechanical
vibration with a high frequency • The chip formation is stable and largely stationary,
within the kHz range. • There is a stagnant zone in the material flow in front of the cutting edge,
• The temperatures in the chip formation zone are sufficiently low and do not
allow for recrystallization.

DTE CODE 3470
MSBTE CODE 1742
3) Milling
Milling involves feeding the workpiece pass a rotating cutter with
cutting edges on its side or end or both
Machine used in milling are horizontal and vertical milling machine,
universal milling machine.
4) Grinding
Used to produce a good accurate surface finish..
Machine used in grinding are Surface grinder, cylindrical grinder.
5) Shaping –
Used to produce flat surfaces by reciprocating tool motion.
Classification/ Methods of machining process
Machine used are shaper machine, slotting machine
1) Drilling – 6) Planing
Drilling is the production of holes by using rotating tool. Used to produce flat surfaces by reciprocating Workpiece motion..
Machine used in drilling are senetive drill machine, radial drill Machine used in planning are planning machine, planomiller
machine, bench drill machine. 7) Saws
2) Turning – Saws are used to cut short lengths of long sections.
The workpiece is rotated around its axis and a cutting tool is fed Machine used in sawing are band saw, power hack saw.
parallel to the axis to create a cylinder or at right angles to the axis to
create a face
Machine used in turning are Center lathe, capstan and turret lathe, cnc
lathe

DTE CODE 3470
MSBTE CODE 1742
LATHE Centre lathe parts
It is versatile machine, which consist removing of metal of rotating work Centre lathe named for it because work piece is rotated between two centres.
piece with help of non-revolving tool.
In lathe operation, cutting tool is always fixed to its position and allow to feed
in rotating work piece.
Classification of Lathe
Depending on design and construction, there are different types of lathe for
machining operation
Some basic types of lathe that used are
1) Speed lathe
2) Engine lathe
3) Bench lathe
4) Tool room lathe
5) Capstan and turret lathe Basic parts of centre lathe
Special purpose lathe
1) Bed
a) Wheel lathe 2) Headstock
b) Gap bed lathe 3) Tail stock
c) T lathe 4) Carriage
d) Duplicating lathe 5) Feed mechanism
e) Automatic lathe 6) Screw cutting mechanism
f) CNC lathe 7) Drive unit

DTE CODE 3470
MSBTE CODE 1742
1) Bed 4) Carriage
Lathe bed is act base for machine component It is mounted on lathe bed. It can be slide on it
It mounted on foundation and support other part relative to it It carries part like tool post, compound slide, cross slide,
The head stock and tailstock are mounted at two ends of bed Half nut, saddle and apron mechanism
A carriage is rest on it and slides during operation
5) Feed mechanism
2) Head stock This mechanism used to powered carriage feeds
Headstock is mounted on left side of foundation and bed This mechanism initiates longitudinal feed and cross feed
It act as housing for drive unit (gear or belt drive) In longitudinal feed tool moves parallel to axis of spindle
It also provide support for spindle which carry heavy chuck on it And in cross feed, cross slide carry tool at right angle to spindle axis.
It supports change gear set on other side of spindle to vary speed of This mechanism receive power from motion of lead screw.
lead screw
6) Screw cutting mechanism
3) Tail stock It arrange in carriage and linked to lead screw
It located on right end of bed Motion during thread cutting controlled by half nut and thread dial.
It can slide on bed and can be clamped any position on bed way
It carry hollow barrel with hand wheel. 7) Main drive
Barrel is used to support centres and drill chuck, reamers, tap. Power unit carry an electric motor
Tailstock is mostly used for support long work piece during turning Different speed ratio of spindle can be obtained through all gear drive
between centres or belt drive.

DTE CODE 3470
MSBTE CODE 1742
Lathe Machine Fixture This type of chuck is particularly used in setting up heavy and irregular
Three jaw chuck shaped work.
it is also called as universal or self-centring chuck.

It consist of a scroll disc, three pinions and adjustable jaws.
A spiral groove is cut on the face of the scroll disc, which meshes with the
jaw teeth
The pinion meshes with the teeth cut on the other face of scroll disc
Magnetic chuck
It consist powerful magnets in
side housing body.
During on condition magnetic
Four jaw chuck flux passes through housing
It four jaw chuck is also called as independent chuck. body and grabs the ferrous
It has four jaw workpiece on it firmly
Each jaw can be adjusted independent by rotating the screw which meshes Magnetic force used as
with the teeth cut on the side of jaw clamping force to hold job
During off condition magnetic flux line cuts away from job and loses it
from chuck face
DTE CODE 3470
MSBTE CODE 1742
Face plates- It is used for driving work with the help of projecting pin, with the dog
It is a cast iron circular disc having threaded hole at its centre or carrier clamp to work while turning work between centre
It can screwed on threaded nose of spindle
There are number of slots and holes are provided on face of plate
It is used to hold the work which cannot be held between the centres or
chuck
The work get hold on face with help of camping plate and bolt
Angle plate-
It is L shaped cast iron
plate
Two faces of the plates
are at right angle and
having slots for
Driving plate or catch plate
clamping face plate on
It is cast iron or steel circular disc
its surface
It has centre boss and catch pin projecting from it
It is used for moving for
It is screw on the threaded nose of head stock spindle
holding work, which is not possible to mount directly on the faceplate.

DTE CODE 3470
MSBTE CODE 1742
Mandrel
Mandrel is the device used for holding and rotating a hollow workpiece
that has been previously drilled or bored
It is solid shaft made of high carbon steel
It is mounted between the centres and work revolves with it
Collar mandrel
It is driven by driven by plate and carrier
It is used to hold large diameter workpiece
Types of mandrel
Collar are provide on mandrel to hold workpiece
1) Plain mandrel
Every workpiece with different internal diameter different mandrel
2) collar mandrel
required
3) cone mandrel
4) expansion mandrel
1) Plain mandrel
The body of the plain mandrel is slightly tapered.
This taper is provided for proper gripping of the workpiece
It is mostly used for standard size work and repeated jobs
Cone mandrel
Every workpiece with different internal diameter different mandrel
Cone mandrel has two cone one is fixed and other is sliding type which
required
can be adjusted by threaded nut provided at threaded end.
It used to hold workpiece with higher diameter with various dimensions

DTE CODE 3470
MSBTE CODE 1742
Stepped mandrel
It is stepped in various diameter
Expansion mandrel Workpiece mounted on these steps of specific diameter
Expansion mandrel is used to hold workpiece of various diameters
Expansion mandrel consist split sleeve which mounted on inner mandrel
This sleeve tapered and parallel outside
The work is mounted on the sleeve which expand within the certain limit
when inner mandrel is pushed through it
This type of mandrel used also for holes odd size.

DTE CODE 3470
MSBTE CODE 1742
Rests – Follower rest

Rest is device, which is used to support longer jobs at an intermediate point It is also called as traveling rest
to prevent from bending due to own weight and vibration due to cutting This rest moves along tool during
forces. turning
Common type of rests It has two adjustable jaw
Steady rest The jaw can be adjusted to support the
It is also called as centre rest work between them and turning tool
This rest remain stationary with respect to tool The frame is attached to the saddle of
It consist cast iron frame with three carriage and travel along with tool
adjustable jaws during cutting.
The frame is divided in two part which

are hinged at one end to give facility of Lathe machine operation
easy setting and removing of job 1) Turing ( straight turning ,step turning , taper turning )
Rest body can clamped on bed at any 2) Facing
position where support required 3) Thread cutting

4) Knurling
All three jaw can be adjusted radially by 5) Drilling
using setscrew on job 6) Boring
All three jaw can be adjusted radially by using setscrew on job 7) Parting
The tip of jaw provide bearing surface on job and support it 8) Grooving
9) chamfering
10 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

DTE CODE 3470
MSBTE CODE 1742
TURNING Taper turning
Straight turning This operation is used to produce tapered part or conical part on cylindrical
work piece
It involves removal material from work piece in order to reduce its diameter
along its length. Following methods are used for taper turning
In this tool feed is parallel to axis of 1) swivelling of compound rest

spindle 2) setting over tailstock centre
3) by using broad nose form tool
4) by taper turning attachment
Step turning
It also called shoulder turning Swivelling of compound rest

In this work piece is turned in In this compound slide is set at half taper angle. Then tool is feed towards
different diameter up to certain work piece in half taper angle line.
length, which looks likes steps
It is used when taper Length is small
For this tool feed is parallel to
And tool is allow to feed in workpiece with help of hand wheel of compound
axis of spindle
slide, during this carriage and cross slide is stationary

DTE CODE 3470
MSBTE CODE 1742
By tailstock set over method
In this method, the tailstock set offset from its centre position so that action
of rotation is inclined by half taper angle.
The feed to the tool is given in the parallel to the guide ways and conical
surface is generated.

DTE CODE 3470
MSBTE CODE 1742
Facing
It used to finish the ends of a work piece

to make it flat and smooth Work is held in
chuck and tool feed is feed in right angle
to axis of spindle.
Threading
Taper By Using Broad Nose Tool
Threading operation includes
In some special operation taper turning is done with special form tool
formation of thread of different size
In this tool is feed directly toward and type with different pitches.
work piece without setting of
In this thread are created on
compound slide
cylindrical surface of work piece by
Tool feed direction is right angle engaging carriage slide to lead screw
to axis of spindle through half nut.
This type of taper turning is used for short length taper. Tool feed to work piece in direction parallel to axis of spindle.

DTE CODE 3470
MSBTE CODE 1742
Knurling Boring
It is operation of creating knurled surface on work piece. Work piece hole diameter increases through internally in operation. For this
work piece is drilled with specific size
It may diamond or straight
drill then boring tool insert through the
knurling
hole.
Knurled surface increase
Tool is feed is parallel to axis of spindle
grip over work piece
.Hole may be get straight, taper through
In tool feeding direction is boring operation
parallel to axis of spindle
Parting
Drilling
In Parting workpiece is made to cut down in two section along its cross
It is process of making hole in work piece. section by using cut-off tool
In this drill bit is held in chuck fitted on tailstock. Parting tool feed is right angle to axis
This drill is get feed to work piece of spindle
along axis of spindle by turning hand Since parting tool cut material from
wheel. its both side (left and right), so tool
During drilling on lathe, work piece should be well position on axis of
is revolving and drill bit is stationary. rotation and must have proper clearance and cutting angle

DTE CODE 3470
MSBTE CODE 1742
Grooving-
Grooving (necking) is process turning

grooves on cylindrical surface of work
piece.
Grooving tool is designed as per of type

and size of groove required
Tool feed direction is right angle to axis

of spindle
Grooves may of type square groove, round or v shaped.
Orthogonal cutting tool Oblique cutting tool
Chamfering Tool cutting edge angle makes 900 Tool cutting edge angle makes
With line or path of movement of other than 900With line or path
It is operation in which sharp edges of
tool of movement of tool
work piece get bevelled.
Tool life is short Tool life is more
Chamfering is done for external diameter
or bored hole also Analysis of orthogonal cutting is Analysis of oblque cutting is
simple complex
For chamfering tool is feed is right angle
and parallel to axis of spindle.

DTE CODE 3470
MSBTE CODE 1742
three mutually perpendicular

Two mutually perpendicular cutting
cutting forces act on the work
forces act on the work piece
piece
More heat generated for same Less heat generated for same
amount of work amount of work
It has limited application It has wide application
It removes more metal in its life

It removes less metal in its life as compare to orthogonal cutting
tool.
Cutting Tool Nomenclature
Taper and Taper Angle
Taper is a uniform increase or decrease in diameter of a work piece
Measured along its length such that the tapered surface when extended forms
a cone.
Taper turning involves production of conical surface internally or externally

on cylindrical work piece.

DTE CODE 3470
MSBTE CODE 1742
4) End cutting edge- it is angle between end cutting edge and line
perpendicular to shank
5) relief angles – these are angles which provided to avoid rubbing of

tool during cutting
6) side relief angle- it is angle between the portion of side flank below
side cutting edge and the line perpendicular to the base of the tool
7) end relief angle- it is angle between the portion of end flank below
end cutting edge and the line perpendicular to the base of the tool
1) Cutting Edge- 8) Back rake angle- the angle between the face of tool and the line
The portion of face of tool which removes chips from work piece. parallel with the base of the tool, measured in perpendicular plane
For lathe tool there are side cutting edge, end cutting edge, nose. through the side cutting edge
2) Nose – it is intersection of side cutting edge and end cutting edge 9) Side rake angle- the angle between the face of tool and the line
3) Side cutting edge angle- it is angle between side cutting edge and parallel with the base of the tool, measured in plane perpendicular to
side of tool shank base of tool.
(Rake angles are used to give specific direction for chip flow)

DTE CODE 3470
MSBTE CODE 1742
Tool Signature
It standardized way to specify tool angles
Tool signature describes that how the tool positioned in relation to work piece
Tool signature represents rake angles, relief angle, cutting edge angles, and
nose radius.
Tool signature (2-7-7-7-15-15-0.8)
It means
2 0 = back rake angle
7 0= side rake angle
7 0=end relief angle
7 0= side relief angle
150 = end cutting edge angle
15 0= side cutting edge angle
0.8 = nose radius in mm

DTE CODE 3470
MSBTE CODE 1742
Cutting Parameter Of Lathe Depth of Cut
Cutting speed – The depth of cut is define as it perpendicular distance from machined surface
to non-machined surface.
For lathe cutting speed peripheral velocity of work piece.
It is express in meters per minute
𝜋𝑑𝑛 Depth of cut t = (d1 – d2)/2

Cutting speed V = 1000 m/min
d1= diameter of the non-machine surface
d= diameter of work in mm
d2 = diameter of machine surface.
n = rpm of spindle
Greater the cutting speed lesser the depth of cut and vice a versa.
Feed-
Machining time calculation-
The feed of cutting tool is distance the tool advances for each revolution of
work. 𝒍
Time taken to complete cut = minutes
𝒔×𝒏
The feed is express in mm/ rev
l= length of work in mm
The feed is depend on shape, size and weight material composition of the
work. s= feed in mm/rev
Greater feed is used for stock removal and fine feed is used for finishing cut. n = rpm of spindle

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Shri Yashwantrao Bhonsale Education Society’s

YASHWANTRAO BHONSALE POLYTECHNIC

FUNDAMENTAL OF MACHINING AND MACHINING Mechanism of chip formation

1) Work piece – it is material that undergoes machining operation on it

material in specific direction ( example In turning operation • Continuous chip formation

1|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

Continuous chip formation Discontinuous chip

In continuous chip formation the chip Discontinuous chip formation occurs

2|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

3|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

LATHE Centre lathe parts

Some basic types of lathe that used are

4|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

5|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

Three jaw chuck shaped work.

it is also called as universal or self-centring chuck.

7|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

8|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

9|Page Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

Rests – Follower rest

adjustable jaws during cutting.

The frame is divided in two part which

Rest body can clamped on bed at any 2) Facing

position where support required 3) Thread cutting

All three jaw can be adjusted radially by 5) Drilling

using setscrew on job 6) Boring

10 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

TURNING Taper turning

In this tool feed is parallel to axis of 1) swivelling of compound rest

It also called shoulder turning Swivelling of compound rest

11 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

By tailstock set over method

12 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

It used to finish the ends of a work piece

13 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

This drill is get feed to work piece of spindle

During drilling on lathe, work piece should be well position on axis of

14 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

Grooving (necking) is process turning

Grooving tool is designed as per of type

Tool feed direction is right angle to axis

Grooves may of type square groove, round or v shaped.

Orthogonal cutting tool Oblique cutting tool

15 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

three mutually perpendicular

It has limited application It has wide application

It removes more metal in its life

Cutting Tool Nomenclature

Taper and Taper Angle

Taper is a uniform increase or decrease in diameter of a work piece

Taper turning involves production of conical surface internally or externally

16 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

5) relief angles – these are angles which provided to avoid rubbing of

17 | P a g e Manufacturing process ( I Scheme SEM 4) Mr Pushkar K Parab

It standardized way to specify tool angles

Tool signature (2-7-7-7-15-15-0.8)

2 0 = back rake angle

7 0= side rake angle

7 0=end relief angle

7 0= side relief angle

150 = end cutting edge angle

15 0= side cutting edge angle

0.8 = nose radius in mm