MACHINING PROCESS –I

Lecture 6

Engr Muhammad Mahboob

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Lathe Accessories

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Lathe Accessories
• Divided into two categories
• Work-holding, -supporting, and –driving
devices
• Lathe centers, chucks, faceplates
• Mandrels, steady and follower rests
• Lathe dogs, drive plates
• Cutting-tool-holding devices
• Straight and offset toolholders
• Threading toolholders, boring bars
• Turret-type toolposts
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Lathe Centers
• Work to be turned between centers must
have center hole drilled in each end
• Provides bearing surface
• Support during cutting
• Most common have
solid Morse taper shank
60º centers, steel with carbide tips
• Care to adjust and lubricate occasionally
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Lathe Centers

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Revolving Tailstock Centers
• Replaced solid dead centers for most
machining operations
• Used to support work held in chuck or
when work is being machined between
centers
• Contains antifriction bearings which allow
center to revolve with workpiece
• No lubrication required between center and
work
• Types: revolving dead center, long point
center, and changeable point center
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Revolving Tailstock Centers

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Microset Adjustable Center
• Fits into tailstock spindle
• Provides means of aligning lathe
centers or producing slight tapers on
work machined between centers
• Eccentric slide (dovetail) allows
center to be adjusted limited amount
to each side of center

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Microset Adjustable Center

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Self-Driving Live Center
• Mounted in headstock spindle
• Used when entire length of workpiece is being
machined in one operation
• Chuck or lathe dog could not be used to drive work
• Grooves ground around circumference of lathe
center point provide drive
• Work usually soft material such as aluminum

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Self-Driving Live Center

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Chucks
• Used extensively for holding work for
lathe machining operations
• Work large or unusual shape
• Most commonly used lathe chucks
• Three-jaw universal
• Four-jaw independent
• Collet chuck

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Three-jaw Universal Chuck

• Holds round and hexagonal work

• Grasps work quickly and accurate within
few thousandths/inch
• Three jaws move simultaneously when
adjusted by chuck wrench
• Caused by scroll plate into which all three
jaws fit
• Two sets of jaw: outside chucking and
inside chucking
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Three-jaw Universal Chuck

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Four-Jaw Independent
Chuck
• Used to hold round, square,
hexagonal, and irregularly shaped
workpieces
• Has four jaws
• Each can be adjusted independently by
chuck wrench
• Jaws can be reversed to hold work by
inside diameter

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Four-Jaw Independent
Chucks

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Headstock Spindle Types
1. Threaded spindle nose
• Screws on in a clockwise direction
2. Tapered spindle nose
• Held by lock nut that tightens on chuck
3. Cam-lock spindle nose
• Held by tightening cam-locks using T-
wrench
• Chuck aligned by taper on spindle nose

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Threaded Spindle Nose

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Tapered Spindle Nose

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Cam Lock Spindle Nose

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Collet Chucks
• Most accurate chuck
• Used for high-precision work
• Spring collets available to hold round,
square, or hexagon-shaped
workpieces
• Each collet has range of only few
thousandths of an inch over or under
size stamped on collet
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Spring Collet Chucks
• Spring-collet chuck
• One form: Handwheel draws collet into
tapered adapter
• Another form: Uses chuck wrench to
tighten collet on workpiece
• Can hold larger work than draw-in type

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Spring Collet Chucks

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Spring Collet Chucks

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Jacobs Collet Chuck
• Jacobs collet chuck
• Utilizes impact-tightening handwheel to
close collets
• Wider range than spring-collet chuck

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Jacobs Collet Chuck

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Magnetic Chucks
• Used to hold iron or steel parts that are
too thin or may be damaged if held in
conventional chuck
• Fitted to an adapter mounted on
headstock spindle
• Used only for light cuts and for special
grinding applications

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Magnetic Chucks

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Faceplates
• Used to hold work too large or shaped so
it cannot be held in chuck or between
centers
• Usually equipped with several slots to
permit use of bolts to secure work
• Angle plate used so axis of workpiece may be
aligned with lathe centers
• Counterbalance fastened to faceplate
when work mounted off center
• Prevent imbalance and resultant vibrations
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Faceplates

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Faceplates

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Steadyrest
• Used to support long work held in chuck
or between lathe centers
• Prevent springing
• Located on and aligned by ways of the
lathe
• Positioned at any point along lathe bed
• Three jaws tipped with plastic, bronze or
rollers may be adjusted to support any
work diameter with steadyrest capacity
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Steadyrest

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Follower Rest
• Mounted on saddle
• Travels with carriage to prevent work
from springing up and away from
cutting tool
• Cutting tool generally positioned just
ahead of follower rest
• Provide smooth bearing surface for two
jaws of follower rest

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Follower Rest

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Mandrel
• Holds internally machined workpiece
between centers so further machining
operations are concentric with bore
• Several types, but most common
• Plain mandrel
• Expanding mandrel
• Gang mandrel
• Stub mandrel

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Plain Mandrel

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Expanding Mandrel

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Gang Mandrel

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Stub Mandrel

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Lathe Dogs
• 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 driveplate
and provides drive to workpiece
• Made in variety of sizes and types to
suit various workpieces
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Standard bent-tail lathe
dog
• Most commonly used for
round workpieces
• Available with square-head
setscrews of headless
setscrews

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Standard bent-tail lathe
dog
• Bent tail engages in slot on
drive plate

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Straight-tail lathe dog
• Driven by stud in driveplate
• Used in precision turning

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Safety clamp lathe dog
• Used to hold variety of work
• Wide range of adjustment

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Heavy Duty Lathe Dog
• Wider range than others
• Used on all shapes

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Cutting-Tool-Holding
Devices
• Available in three styles
• Left-hand offset
• Right-hand offset
• Straight
• Each has square hole to accommodate
square toolbit held in place by setscrew
• Angle of approximately 15º to 30º to base
of toolholder

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Left-Hand Offset Toolholder
• Offset to the right
• Designed for machining work close to
chuck or faceplate and cutting right to left
• Designated by letter L

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Right-Hand Offset
Toolholder
• Offset to the left
• Designed for machining work close to the
tailstock and cutting left to right
• Also for facing operations
• Designated by letter R

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Straight Toolholder
• General-purpose type
• Used for taking cuts in either direction
and for general machining operations
• Designated by letter S

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Carbide Toolholder
• Has square hole parallel to base of
toolholder to accommodate carbide-tipped
toolbits
• Holds toolbit with little or no back rake
• Designated by letter C

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Cutting-Off (Parting) Tools
• Used when work must be grooved or
parted off
• Long, thin cutting-off blade locked
securely in toolholder by either cam
lock or locking nut
• Three types of parting toolholders
• Left-hand
• Right-hand
• Straight

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Threading Toolholder
• Designed to hold special form-relieved
thread-cutting tool
• Has accurately ground 60º angle
• Maintained throughout life of tool
• Only top of cutting surface sharpened
when becomes dull

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Styles of Boring Toolholders
• Held in standard toolpost
• Light boring toolholder
• Used for small holes and light cuts
• Medium boring toolholder
• Suitable for heavier cuts
• May be held at 45º or 90º to axis of bar
• Mounted on compound rest of lathe
• Heavy-duty boring bar holder
• Three bars of different diameters
• May be held at 45º or 90º to axis of bar
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Compound Rest
Tooling Systems
• Standard, or round, toolpost
• Generally supplied with conventional
engine lathe
• Fits into T-slot of compound rest
• Provides means of holding and adjusting
type of toolholder or cutting tool required
• Concave ring and the wedge or rocker
provide for adjustment of cutting-tool
height

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Conventional ToolPosts

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Modular
(Quick-Change) Tooling
• Initially developed for CNC machine
tools to improve accuracy, reduce tool-
change time and increase productivity
• Benefits realized on conventional lathes
with systems designed for these machines
• Modular tooling system must be rigid,
accurate and have quick-change
capabilities
• Basic clamping unit or turret can hold
variety of cutting tool modules
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Modular
(Quick-Change) Tooling
• Initially developed for CNC machine
tools to improve accuracy, reduce tool-
change time and increase productivity
• Benefits realized on conventional lathes
with systems designed for these machines
• Modular tooling system must be rigid,
accurate and have quick-change
capabilities
• Basic clamping unit or turret can hold
variety of cutting tool modules
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Modular Tooling System
• Principal function is to reduce cost of
keeping large tool inventory
• Tools can be specifically mounted to suit
characteristics of workpiece
• More common systems available
• The Super Quick-Change Toolpost
• The Quadra* Index Toolpost
• The Super-Six Index Turret
• The Vertical Index Turret

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Super Quick-Change
Toolpost
• Provides fast, accurate, and reliable
method of quickly changing and setting
various toolholders for different
operations
• Locking system has two sliding gibs
forced out against toolholder
• Handle pulled into lock position
• Provides rigid, positive lock with zero
backlash
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Super Quick-Change
Toolpost

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Quadr* Index Toolpost
• Allows four tools to be mounted on
turret at same time
• Each tool locked independently
• Provides flexibility to use from one to four
tools simultaneously
• Unique indexing system of turret
allows it to be set in 24 positions
(every 15º)

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Super-Six Index Turret
• Designed to simplify and increase
machining productivity on engine lathes
when multi-operation jobs require use of
more than one tool
• Up to six tools for external and internal
machining operations
• Allows height adjustment for each tool
• Tool changes can be made in less than
1 sec
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Vertical Index Turret (VIT)
• Designed to give highest accuracy,
fastest tool change and greatest
rigidity of any tool system available for
engine lathes
• Same concept as indexing turrets on
CNC lathes
• Can hold up to six or eight tools
• Closest to performance of CNC lathes

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