MACHINE TOOLS AND

MACHINING OPERATIONS

Module 2
 Conventional machining
1. Metal cutting

Single point cutting tool Multi point cutting tool

 Turning  Drilling
 Boring  Milling
 Threading  Tapping
 Shaping  Broaching
 Planning  Hobbing
 Slotting
2. Grinding process
 Surface grinding
 Cylindrical grinding
 Centerless grinding

3. Finishing process
 Lapping
 Hobing
 Super finishing
 Types of machining processes
1. Turning
2. Drilling
3. Shaping and Slotting
4. Planning
5. Milling
6. Grinding
7. Honing
8. Boring
9. Gear Manufacturing
10. Finishing operations
1. TURNING Operation
Lathe
BASIC WORKING PRINCIPLE OF LATHE
• Lathe removes undesired material from a rotating work piece in the form
of chips with the help of a tool which is traversed across the work and can
be fed deep in work.

• The tool material should be harder than the work piece and the latter
held securely and rigidly on the machine.

• The tool may be given linear motion in any direction. A lathe is used
principally to produce cylindrical surfaces and plane surface, at right
angles to the axis of rotation.

• It can also produce tapers and bellows etc. Operation of turning is done
on parts as small as those used by watches to huge parts weighing several
tons.
 Main Parts of a lathe
1. Bed
2. Head stoke
3. Tail stoke
4. Carriage
5. Saddle
6. Compound rest
7. Tool post
8. Lead screw
9. Feed mechanism
10. Apron mechanism
Main Parts of a lathe
 Components of Lathe
• A lathe basically consists of a bed to provide support, a headstock and
tailstock , a cross slide to traverse the tool, a tool post mounted on the
cross slide.

• The spindle is driven by a motor through a gear box to obtain a range

of speeds.

• The carriage moves over the bed guide ways parallel to the work piece.

• The cross slide provides the transverse motion.

• A feed shaft and lead screw are also provided to power the carriage
and for cutting the threads respectively.
 Types of lathes
• Speed lathe
• Engine/Centre lathe
• Bench lathe
• Special purpose lathe
• Tool room lathe
• Capstan and turret lathe
• Automatic lathe/ NC lathe
• CNC lathe
Speed Lathe

• These lathes may be of bench type or they may have the supporting legs
cast and fitted to the bed.

• They have no gear box, carriage and the lead screw. With the result, the
tool is fed and actuated by hand.

• Usually the tool is either mounted on a tool post or supported on a T-

shaped support.

• Such lathes are usually employed for wood turning, polishing, centering
and metal spinning etc. 
 Center lathe

• Its headstock is bigger in size and more robust, incorporating suitable

mechanism for providing multiple speeds to the lathe spindle.

• The headstock spindle may receive power, from a lathe shaft or an

individual motor, through belts.

• It carries a combination of gears, instead of the cone pulley and back

gears combination, the lathe is known as geared head lathe and the
headstock as all geared head stock.
Bench lathe

• It is a very small lathe and is mounted on a separately prepared

bench or cabinet.

• It is used for small and precision work since it is very accurate.

• It is usually provided with all the attachments, which a larger lathe

carries, and is capable of performing almost all the operations which
a larger lathe can do.
Special purpose lathe
• A large number of lathes are designed to suit a definite class of
work and to perform certain specified operations only.
• They prove to be more efficient and effective as compared to the
common engine lathe so far as this specified class of work is
concerned.
Special purpose lathe
1. Turret and Capstan Lathes

2. Tool room lathe

3. Duplicating lathe

4. Gap bed lathe

5. Blog lathe
Turret and Capstan Lathes
• Turret and capstan lathes are the natural development of
the engine lathe.

• The tailstock is replaced by an indexable multi-station

tool head called the turret.

• This head carries a selection of standard tool holders and

special attachments.

• A square or hexagonal turret is mounted on the cross

slide in place of the usual compound rest in engine lathe.
Operating principles of capstan
and turret lathe
HEXAGONAL TURRET
HEXAGONAL TURRET
• The hexagonal turret is carried on a saddle and is
intended for holding and bringing the tools in a forward
feed movement.

• On the turret-type, each face is provided with four tapped

holes to accommodate screws for holding flanged holders
and attachments in which tools are clamped.

• On capstan lathes, the turret may be circular; it has also

six holes for accommodating shanked tool holders that
are normally used for small works that do not need to be
held in a flat face.
Advantages
The main advantages of turret and capstan lathes
include the following:
1. multiple tool holders that enable the setting up
of all the tools necessary to produce a certain job
2. Less-skilled operators are needed, as compared
with center lathes
3. No need to change tooling or move the work to
another machine, as many operations can be
performed without the need to change tooling
layout.
 DIFFERENCE BETWEEN CAPSTAN AND TURRET
LATHES
• Capstan lathes are mainly used for bar work, whereas
turret lathes are applicable for large work in the form of
castings and forgings.

• In a capstan or ram-type lathe, the hexagon turret is

mounted on a slide that moves longitudinally in a
stationary saddle.

• In the turret- or saddle-type lathe, the turret is mounted

directly upon a movable saddle, furnished with both
hand and power longitudinal feed
Capstan lathe
Turrent lathe
Tool room lathe
• It is nothing but the same engine lathe but equipped with some extra
attachments to make it suitable for a relatively more accurate angle of
speeds and feeds.
• The usual attachments provided on a tool room lathe are taper turning
attachment, follower rest, collets, chucks, etc.
• This lathe is made to have a comparatively smaller bed length than the
usual engine lathe. The most commonly used lengths are 135 to 180 cm.
Tool room Lathe
• It is similar to center lathe, but more accurately built
and is equipped with various attachments.

• The extra attachments includes :-

1. Taper turning attachment
2. Thread chasing dial
3. Coolant pump
4. Turret tool post , follower rest, collets and chucks

It is used for precision work on tool, dies gauges etc.

3. Duplicating lathe
• It is used for duplicating the shape of a template on to the
workpiece.

• It is for duplicating the shape of a flat or round template

on to the work piece.

• Mechanical, air or hydraulic devices are all used for

coordinating the movement of the tool to reproduce
accurately the shape of the template.

• T- lathe and Gap lathe are examples.

Gap Bed lathe
Vertical lathe
Blog lathe
NC lathe
 NC Machines
• Numerical control is defined as the form of
programmable automation, in which the process is
controlled by the number, letters, and symbols.

• In case of the machine tools this programmable

automation is used for the operation of the machines.

• The part program is a sequence of instructions,

which describe the work, which has to be done on
a part, in the form required by a computer under the
control of a numerical control computer program.
CNC lathe
 CNC Machine
• CNC Machining is a process used in the manufacturing
sector that involves the use of computers to
control machine tools.
• Tools that can be controlled in this manner
include lathes, mills, routers and grinders. ...
• Under CNC Machining, machine tools function through
numerical control.
• CNC stands for Computer numerical control is an
automation of machine tools.
• Automation of machine is done by computers executing
programmed sequence of machine control commands.
• In CNC system manufacturing program of machine is
highly automated.
Comparison Between NC and CNC Machine
• NC stands for Numerical Control whereas CNC stands for
Computer Numerical Control.

• In NC Machine the programs are fed into the punch cards. Punch
card. Early method of data storage used with early computers.

• Punch cards also known as Hollerith cards and IBM cards are paper
cards containing several punched or perforated holes that were
punched by hand or machine to represent data.

• But in CNC machine the programs are fed directly into the computer
with the help of a small keyboard similar to our traditional keyboard.
 Specifications of a lathe
1. Height of centers
2. Length b/w centers
3. Swing diameter over bed
4. Swing diameter over carriage
5. Maximum diameter of bar
6. Length of bed
7. Power of motor
8. Drive used
Specifications of a lathe
 Lathe accessories
Work holding devices
1. Chuck
2. Centers
3. Face plate
4. Angle plate
5. Mandrels
6. Steady rest
7. Follow rest
8. Lathe dog
9. Catch plate and carriers
10. Collets
CHUCK
Types of chucks

1. Four jaw / Independent chuck

2. Three jaw / Self centering chuck

3. Collet chuck

4. Magnetic chuck
 Lathe Centers

• Lathe centers acts as support for the work piece.

• It takes up the thrust due to metal cutting.

• It is usually held on tail stock.

Holding the Work Between Centers

Figure (a) mounting the work between centers using a "dog”

 Lathe centers

1. Ordinary center
2. Ball center
3. Rotating center
4. Friction center
5. Half center
6. Brazed tip
Rotating Centers
 Steady Rest
• It is used when a long piece is machined or
drilled at its end by holding the job in a chuck.

• It avoids the undue deflection of the job at the

other end.
Steady rest
FACE PLATE
• Mounting work on a face plate provides an ideal
way of supporting certain types of works.

• Flat plates can be screwed on head stock for

operations like facing, drilling, boring etc.
Face plate
 Mandrel
• It is a hardened piece of round bar with centers
and flats at each end.
• It is used for holding and obtaining hollow piece
of work piece.
• It is made of high carbon steel to avoid
distortion and wear.
• It is tapered to 0.5mm so that work can be
forced on it with press fit and then removed after
machining.
 Types of Mandrels

1. Plain (one size bore)

2. Stepped ( different dia. )
3. Collar (helps in reducing weights)
4. Screwed (internal thread)
5. Cone (different diameter)
6. Gang
7. Expansion
8. Taper shank
Types of mandrels
Mandrel-of-Decoiler-and-Coiler
Expandable mandrel
• A lathe dog, also known as a lathe carrier, is a device that
clamps around the workpiece and allows the rotary motion of the
machine's spindle to be transmitted to the workpiece.
Lathe dog
Chuck

Figure (b) three‑jaw chuck

Collet

Figure (c) collet

Face Plate

Figure 22.8 (d) face plate for non‑cylindrical workparts

Tool post accessories
Operations performed in lathe
1. Facing and Centering
2. Straight turning
3. Shoulder turning
4. Chamfering
5. Thread cutting
6. Filing
7. Taper turning
8. Eccentric turning
9. Grooving
10. Polishing
 Facing
• It is done to produce flat end surface on the work
piece.
• Tool is fed perpendicular to axis of job rotation.
 Centering
• Conical shaped hole must be provided at the
ends of the work piece to provide bearing surface
for lathe centers.

• Center holes are produced by using a counter-

sink tool which is held on tail stock.
 Turning

• Turning is a machining process to produce parts round

in shape by a single point tool on lathes.

• The tool is fed either linearly in the direction parallel or

perpendicular to the axis of rotation of the workpiece, or
along a specified path to produce complex rotational
shapes.

• The primary motion(drive motion) of cutting in turning

is the rotation of the workpiece, and the secondary
motion of cutting is the feed motion.
Straight turning
Turning Operations
Chamfering

Cutting edge cuts an

angle on the corner of
the cylinder, forming
a "chamfer"
Operation performed by attaching tools in
tailstock.
Taper Turning
Thread cutting
External thread cutting
Internal thread cutting
 ISE 316 -
Manufacturing
Processes Engineering

Boring
• Difference between boring and turning:
▫ Boring is performed on the inside diameter of
an existing hole
▫ Turning is performed on the outside diameter
of an existing cylinder
• In effect, boring is an internal turning
operation
• Boring machines
▫ Horizontal or vertical - refers to the orientation
of the axis of rotation of machine spindle
Blog lathe
 Conclusion
 Machining is a material removal process.

 Material removal is effected by the relative motion b/w

the tool and work piece.

 Tool material should be harder than the work piece.

 Excess material is been removed in the form of chips.

 The basic elements of machining are workpiece, tool and

chips.
Thank you