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Lathe - 131903 - MANUFACTURING PROCESS 1
Lathe - 131903 - MANUFACTURING PROCESS 1
The Lathe
Section 11
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Parts of the Lathe
Headstock
Tailstock
Quick Bed
Change
Gearbox
Carriage
Spring-ball clutch
will slip when too
much strain is
applied to feed rod
Lathe Accessories
Unit 46
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
46-16
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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46-17
Chucks
• Used extensively for holding work for
machining operations
– Work large or unusual shape
• Most commonly used lathe chucks
– Three-jaw universal
– Four-jaw independent
– Collet chuck
46-18
Headstock Spindles
Universal and independent chuck fitted to
three types of headstock spindles
1. Threaded spindle nose
– Screws on in a
clockwise direction
2. Tapered spindle nose
– Held by lock nut
that tightens on chuck
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46-21
Headstock Spindles
3. Cam-lock spindle nose
• Held by tightening cam-locks using T-wrench
• Chuck aligned by taper
on spindle nose
Collet Chuck
• 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
46-23
Collet Chuck
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46-24
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46-25
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46-27
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46-28
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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46-29
Threading Toolholder
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PowerPoint to accompany
Cutting Speed
• Rate at which point on work circumference
travels past cutting tool
• Always expressed in feet per minute (ft/min)
or meters per minute (m/min)
• Important to use correct speed for material
– Too high: cutting-tool breaks down rapidly
– Too low: time lost, low production rates
47-35
Example:
Calculate r/min required to rough-turn 2 in. diameter
piece of machine steel (CS 90):
CS x 4
r/min
D
90 x 4
r/min 180
2
CS x 320
Metric Formula r/min
D
47-38
Lathe Feed
Depth of Cut
• Depth of chip taken by cutting tool and one-
half total amount removed from workpiece
in one cut
• Only one roughing and one finishing cut
– Roughing cut should be deep as possible to
reduce diameter to within .030 to .040 in. (0.76
to 1 mm) of size required
– Finishing cut should not be less than .005 in.
47-42
Inch System
• Circumference of crossfeed and compound
rest screw collars divided into 100-125 equal
divisions
– Each has value of .001 in.
• Turn crossfeed screw clockwise 10 graduations,
cutting tool moved .010 in. toward work
• Lathe revolves, so .010 depth of cut taken from
entire work circumference reducing diameter .020 in.
• Check machine for its' graduations
47-45
Lathe Safety
Unit 48
Safety
• Be aware of safety requirements in any area
of shop
• Always attempt to observe safety rules
• Failure results in:
– Serious injury
– Resultant loss of time and pay
– Loss of production to company
48-52
Safety Precautions
• Lathe hazardous if not operated properly
• Important to keep machine and surrounding
area clean and tidy
• Accidents usually caused by carelessness
48-53
Safety Precautions
• Always wear approved safety glasses
• Rollup sleeves, remove tie and tuck in loose
clothing
• Never wear ring or watch
48-54
Safety Precautions
• Do not operate lathe until understand controls
• Never operate machine if safety guards
removed
• Stop lathe before measure work or clean, oil
or adjust machine
• Do not use rag to clean work or machine
when in operation
– Rag can get caught and drag in hand
48-55
Safety Precautions
• Never attempt to stop a lathe chuck or
driveplate by hand
• Be sure chuck or faceplate mounted securely
before starting
– If loose, becomes dangerous missile
• Always remove chuck wrench after use
– Fly out and injure someone
– Become jammed, damaging wrench or lathe
48-56
Safety Precautions
• Move carriage to farthest position of cut and
revolve lathe spindle one turn by hand
– Ensure all parts clear without jamming
– Prevent accident and damage to lathe
• Keep floor around machine free from grease,
oil, metal cuttings, tools and workpieces
– Oil and grease can cause falls
– Objects on floor become tripping hazards
48-57
Safety Precautions
• Avoid horseplay at all times
• Always remove chips with brush
– Chips can cause cuts if use hands
– Chips become embedded if use cloths
• Always remove sharp toolbit from
toolholder when polishing, filing, cleaning,
or making adjustments
PowerPoint to accompany
Objectives
Lathe Centers
• Work machined between centers turned for
some portion of length, then reversed, and
other end finished
• Critical when machining work between
centers that live center be absolutely true
– Concentric work
49-61
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49-64
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49-65
To Align Centers by
Trial-Cut Method
1. Take a light cut (~.005 in.) to true
diameter from section A at tailstock end
for .250 in. long
2. Stop feed and note reading on graduated
collar of crossfeed handle
3. Move cutting tool away from work with
crossfeed handle
4. Bring cutting tool close to headstock end
49-67
To Align Centers by
Trial-Cut Method
To Align Centers by
Trial-Cut Method
8. If both diameters not same size, adjust
tailstock either toward or away from
cutting tool ½ difference of two readings
9. Take another light cut at A and B at same
crossfeed graduated collar setting.
Measure diameters and adjust tailstock.
49-69
Grinding Lathe
Cutting Tools
Unit 50
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50-74
To Grind a
General-Purpose Toolbit
1. Dress face of grinding wheel
2. Grip toolbit firmly, supporting hands on grinder
toolrest
3. Hold toolbit at proper
angel to grind cutting
edge angle
• Tilt bottom of toolbit
toward wheel and
grind 10º side relief
or clearance angle
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50-75
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50-76
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50-78
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50-79
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50-80
Machining
Between Centers
Unit 52
Rough Turning
• Removes as much metal as possible in
shortest length of time
• Accuracy and surface finish are not
important in this operation
– .020- to .030-in. feed recommended
• Work rough-turned to
– Within .030 in. of finished size when
removing up to .500 in. diameter
– Within .060 in. when removing > .500 in.
52-92
Finish Turning
• Follows rough turning
• Produces smooth surface finish and cuts
work to an accurate size
• Factors affecting type of surface finish
– Condition of cutting tool
– Rigidity of machine and work
– Lathe speeds and feeds
52-95
Filing in a Lathe
• Only to remove small amount of stock,
remove burrs, or round off sharp corners
• Work should be turned to within .002 to .003
in. of size
• For safety, file with left hand so arms and
hands kept clear of revolving chuck
• Remove toolbit from toolholder before filing
• Cover lathe bed with paper before filing
52-98
6. Start lathe
7. Grasp file handle in left hand and support
file point with fingers of right hand
Procedure for
Polishing in a Lathe
1. Select correct type and grade of abrasive
cloth for finish desired
• Piece about 6 – 8 in. long and 1 in. wide
• Use aluminum oxide abrasive cloth for
ferrous metals
• Use silicon carbide abrasive cloth should be
used for nonferrous metals
2. Set lathe to run at high speed
3. Disengage feed rod and lead screw
52-102
Shoulder
• Shoulder: the change in diameters, or step,
when turning more than one diameter on a
piece of work
• Three common types of shoulders
– Square
– Filleted
– Angular or Tapered
Knurling, Grooving,
and Form Turning
Unit 53
Knurling
• Process if impressing a diamond-shaped or
straight-line patter into the surface of the
workpiece
– Improve its appearance
– Provide better gripping surface
– Increase workpiece diameter when press fit
required
53-107
Knurling
• Diamond- and
straight-pattern
rolls available in
three styles
– Fine
– Medium
– Course
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53-108
Knurling Tool
• Toolpost-type toolholder on which pair of
hardened-steel rolls mounted
Knurling tool with
one set of rolls in
self-centering head
Grooving
• Done at end of thread to
permit full travel of nut up
to a shoulder or at edge of
Square
shoulder for proper fit
• Also called recessing,
undercutting, or necking
• Rounded grooves used Round
where there is strain on
part
V-shaped
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53-115
Threads
• Used for hundreds of years for holding parts
together, making adjustments, and
transmitting power and motion
• Art of producing threads continually
improved
• Massed-produced by taps, dies, thread
rolling, thread milling, and grinding
55-120
Threads
• Thread
– Helical ridge of uniform section formed on
inside or outside of cylinder or cone
• Used for several purposes:
– Fasten devices such as screws, bolts, studs, and
nuts
– Provide accurate measurement, as in micrometer
– Transmit motion
– Increase force
55-121
Thread
Terminology
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Permission required for reproduction or display.
55-122
Thread Terminology
• Screw thread
– Helical ridge of uniform section formed on
inside or outside of cylinder or cone
• External thread
– Cut on external surface or cone
• Internal thread
– Produced on inside of cylinder or cone
55-123
• Major diameter
– Largest diameter of external or internal thread
• Minor diameter
– Smallest diameter of external or internal thread
• Pitch diameter
– Diameter of imaginary cylinder that passes
through thread at point where groove and thread
widths are equal
– Equal to major diameter minus single depth of
thread
– Tolerance and allowances given at pitch
diameter line
55-124
• Root
– Bottom surface joining sides of two adjacent
threads
– External thread on minor diameter
– Internal thread on major diameter
• Crest
– Top surface joining two sides of thread
– External thread on major diameter
– Internal thread on minor diameter
• Flank
– Thread surface that connects crest with root
55-126
• Depth of thread
– Distance between crest and root measured
perpendicular to axis
• Angle of thread
– Included angle between sides of thread
measured in axial plane
• Helix angle
– Angle that thread makes with plane
perpendicular to thread axis
55-127
• Right-hand thread
– Helical ridge of uniform cross section onto
which nut is threaded in clockwise direction
– When cut on lathe, toolbit
advanced from right to left
• Left-hand thread
– Helical ridge of uniform cross section onto
which nut is threaded in counterclockwise
direction
– When cut on lathe, toolbit
advanced from left to right
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Permission required for reproduction or display.
55-128
Thread Forms
• April, 1975 ISO came to an agreement
covering standard metric thread profile
– Specifies sizes and pitches for various threads
in new ISO Metric Thread Standard
– Has 25 thread sizes, range in diameter from 1.6
to 100 mm
– Identified by letter M, nominal diameter, and
pitch M 5 X 0.8
55-129
Unified Thread
• Developed by U.S., Britain, and Canada for
standardized thread system
• Combination of British Standard Whitworth and
American National Standard Thread
.6134
D (external thread) .6134 x P or
N
.5413
D (internal thread) .5413 x P or
N
.125
F (external thread) .125 x P or
N
.250
F (internal thread) .250 x P or
N
D = .6866P
F = .335P
C = .310P
Square Thread
• Being replaced by Acme thread because of
difficulty in cutting it
D = .500P
• Often found on vises F = .500P
and jack screws C = .500P + .002
Allowance
• Permissible difference between largest
external thread and smallest internal thread
• Difference produces tightest fit acceptable
for any given classification
The allowance for a 1 in.—8 UNC Class 2A and 2B fit is:
Minimum pitch diameter of the
internal thread (2B) = .9188 in.
Maximum pitch diameter of the
external thread (2A) = .9168 in.
Allowance = .002 in.
55-139
Tolerance
• Variation permitted in part size
• May be expressed as plus, minus, or both
• Total tolerance is sum of plus and minus tolerances
• In Unified and National systems, tolerance is plus
on external threads and minus on internal threads
The tolerance for a 1 in.—8 UNC Class 2A thread is:
Maximum pitch diameter of the
external thread (2A) = .9168 in.
Minimum pitch diameter of the
external thread (2A) = .9100 in.
Tolerance = .0068 in.
55-140
Limits
• Maximum and minimum dimensions of part
The limits for a 1 in.—8 UNC Class 2A thread are:
Thread-Chasing dial
• Lathe spindle and
lead screw must be
in same relative
position for each cut
– Thread-chasing dial
attached to carriage for
this purpose
• Dial has eight divisions
– Even threads use any division
– Odd threads either numbered
or unnumbered: not both
Thread Cutting
• Produces a helical ridge of uniform section
on workpiece
• Performed by taking successive cuts with
threading toolbit of same shape as thread
form required
• Work may be held between centers or in
chuck
55-148
Thread-Cutting Operation
Procedure to cut a 60º thread
1. Check major diameter of work for size
2. Start lathe and chamfer end of workpiece
with side of threading tool to just below
minor diameter of thread
3. Mark length to be threaded by cutting
light groove at this point with threading
tool while lathe revolving
55-151