Manufacturing Process-II

UNIT-I
LATHE MACHINES

Subject: Manufacturing Process-II

Class: B.Tech –Mechanical
 Lathe operations
Many different kind of operations are carried out on lathe
(i) Straight Turning (x) Grooving
(ii) Facing (xi) Eccentric turning
(iii) Taper turning (xii) Spring winding
(iv) Parting (xiii) Spinning
(xiv) Polishing
(v) Boring
(xv) Drilling
(vi) Threading (xvi) Reaming
(vii) Knurling (xvii) Internal thread cutting
(Viii) Profile turning (xviii) Tapping
(ix) Chamfering (xix) Counterboring
(xx)Taperboring
 Lathe Operations
 Turning: to remove material from the outside diameter of a workpiece to

obtain a finished surface.

 Facing: to produce a flat surface at the end of the workpiece or for
making face grooves.
 Boring: to enlarge a hole or cylindrical cavity made by a previous
process or to produce circular internal grooves.
 Drilling: to produce a hole on the work piece.

 Reaming: to finishing the drilled hole.

 Threading: to produce external or internal threads on the work piece.

 Knurling: to produce a regularly shaped roughness on the workpiece.

Lathe Operations
 Turning ..
Cylindrical job
Operations on Lathe ..
 Turning ..
Operations on Lathe ..

 Excess Material is removed to reduce Diameter

Cutting Tool: Turning Tool

Work is held in either chuck or between centers.

Longitudinal feed is given to the tool either by

hand or power.
 Facing
Flat Surface/Reduce length
Operations on Lathe ..
 Facing ..

 machine end of job  Flat surface or to Reduce Length of

Operations on Lathe ..

Job
 Turning Tool

 Feed: in direction perpendicular to workpiece axis

Length of Tool Travel = radius of workpiece

 Depth of Cut: in direction parallel to workpiece axis

 Knurling
Operations on Lathe ..

Produce rough textured surface

For Decorative and/or Functional Purpose

Knurling Tool

 A Forming Process

MRR~0
Operations on Lathe ..
Knurling
 Grooving
Operations on Lathe ..

 Produces a Groove on workpiece

 Shape of tool  shape of groove

 Carried out using Grooving Tool  A form tool
 Also called Form Turning
Operations on Lathe .. Grooving ..
Operations on Lathe ..
Parting
Cutting work piece into Two
Similar to grooving
Parting Tool
Tool rides over – at slow feed
Coolant use
Operations on Lathe ..
Parting
Operations on Lathe ..
Chamfering
Operations on Lathe ..
Chamfering
 Beveling sharp machined edges
 Similar to form turning
 Chamfering tool – 45°
 To
 Avoid Sharp Edges
 Make Assembly Easier
 Improve Aesthetics
 Drilling
Drill – cutting tool – held in TS – feed from TS
Operations on Lathe ..
 Hole making operations - Lathe

 Holemaking methods: drilling,

reaming, counterboring and
countersinking, boring, internal
shouldering
 Cut internal threads with taps,
external with threading die
Drilling a hole with a Morse taper-shank
drill held directly in the lathe tailstock .
 Reaming
Reaming is the surface finish operation where very

high dimensional accuracy is needed.

Cutting tool- reamer cutting tool ( multi cutting edge)

Held on the tailstock spindle through a drill chuck

 Using the tailstock for alignment to tap a
hole on the lathe.

Cutting external threads with a threading

die on the lathe. The face of a tailstock
mounted chuck or the tailstock quill will
help keep the die square.
 Boring operation

 Boring: Boring means enlarging an existing hole.

 After the hole has been drilled to required depth, the drill is

withdrawn. This hole can then be enlarged in diameter by

using a boring tool.
 Boring tool or boring bar fitted with a tool bit has to be

smaller than the hole in the work piece.

 The Boring operation is really an internal turning operation
Boring operation
 Threading
 Threading is an operation of cutting helical grooves on the

external cylindrical surface of the work piece.

 The workpiece is held in a chuck and the threading tool is fed

longitudinally to the revolving work. The longitudinal feed is

equal in the pitch of the thread to be cut.
Spinning
 Spinning
 Spinning is a metal forming process in which an axially symmetric part

is gradually shaped over a mandrel by means of a rounded tool or

roller
 In spinning operation, flat circular blanks are often formed into hollow

shapes such as photographic reflectors.

 In a lathe, tool is forced again a rotating disk, gradually forcing the

metal over the chuck to conform to its shape.

 Chucks and follow blocks are usually made of wood for this

operation
 Taper
The amount of taper in work piece is usually specified by
the ratio of the difference of the taper to its length.
K= D-d/l
Where K is termed as conicity
 Taper Turning
D1  D2
tan  
Operations on Lathe ..

2L
 Taper Turning methods

By swiveling the compound rest

By Setting over the tailstock center

By a taper turning attachment

By Nose form tool

By combing longitudinal and cross feed in a special

lathe.
 Taper Turning ..
by form tool
Operations on Lathe ..
 Taper Turning ,,
by compound rest
Operations on Lathe ..
Taper Turning attachement
Problem 1
Determine the angle at which the compound rest would be
swiveled for cutting a taper on a work piece having a
length of 150 mm and outside diameter 80 mm. The
smallest diameter on the tapered end of the rod should be
50 mm and the required length of the tapered portion is
80 mm.
Solution
Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm

tan ᾳ = (80-50) / 2*80 or ᾳ = 10.620

The compound rest should be swiveled at 10.62o

Problem 2
A taper pin of length 90mm has taper length of 50
mm. The larger diameter of taper is 95mm and the
smaller diameter is 85 mm. Determine
Taper in degrees
The angle to which the compound rest should be setup
up
The tailstock setting over.