ME-101

WORKSHOP TECHNOLOGY

Lathe Machine
fundamentals

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 Safety
 Respect the machines

 Common Sense

• Wear safety glasses

• Avoid loose clothing
• Restrain long hair
• Never wear gloves
• Never wear shorts or sandals
• Remove Necktie
• Stay alert

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 Lathe - Introduction

The Basics
• The lathe is one of the most common
machines found in today’s modern machine
shop. Used primarily to produce cylindrical
workpieces.

• Different from a mill in that it produces a

round diameter on a part by rotating a
workpiece against a non-rotating single-point
tool, as Figure 1. shows.

• The lathe, operated manually, changes the

size, shape, and finish of a workpiece with a Fig. 1
variety of cutting tools.

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 Lathe - Introduction

 Types Of Lathes
 The three types of lathes you
may find in a machine shop today
are:
• Engine Lathe
• The original lathe is the engine lathe, shown in
Fig. 1.
• This type of lathe positions and holds a
workpiece on a desired centerline, while the
spindle rotates the workpiece.
• As the workpiece spins, the cutting tool Fig. 1
gradually passes along the surface of the
workpiece, and a layer of material is removed.
• Engine lathes are the most frequently used
manual lathes.

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 Lathe - Introduction
 Types Of Lathes
 Turret Lathe & CNC Machining
Centers
• The turret holds multiple cutting tools that
rotate into position when needed. Each time
the turret lever is activated, the turret spins
and positions the next tool in the sequence. It
is then ready to carry out different machining
operations.
• Because the turret holds multiple tools, the
machinist does not have to change tools each
and every time a different tool is needed.
There are automated versions of these lathes
that are computer controlled and are called
CNC Machining Centers.

Turret CNC Machining Center

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 Lathe - Introduction
 Types Of Lathes
 CNC – Lathes
• Today, many shops use CNC
lathes, like the one in Fig. 1.
• A CNC lathe is a type of lathe
that uses computer numerical
controls (CNC) to operate the
lathe. These machines use
single bit tooling.

Fig. 1

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 Basic Lathe Terminology
Compound Rest

Headstock Tool Post Tailstock

Chuck
Cross Slide
Ways

Bed

Feed Gear Box

Carriage
Lead screw

Brake –
Emergency
(E) Stop

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 Basic Lathe Terminology
 Parts Of A Lathe
• The bed is the base and backbone of the lathe. The bed is a heavy, rigid
frame made of cast iron on which all other components of the lathe are
mounted and/or move.

• The ways are parallel, longitudinal rails located on the bed. There are
two sets of inner and outer ways. The ways guide other components on
the lathe, such as the tailstock.

• The headstock is mounted on the inner ways and provides the power to
rotate the workpiece. It consists of a hollow spindle and a set of gears
that rotate the spindle at a range of speeds that are operator adjustable

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 Basic Lathe Terminology
 Parts Of A Lathe
• The spindle is mounted in the headstock and carries the work
holding devices, i.e. – chuck. The spindle has a hole extending
through its length, through which a long bar stock can be fed. The
size of this hole determines the maximum diameter of bar stock
that can be machined when the materials must be fed through the
spindle.

• The tailstock is located opposite of the headstock and supports

the end of longer workpieces. The tailstock typically contains a
center that holds the other end of the workpiece in place, but it can
also hold a cutting tool, by way of a drill chuck.

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 Basic Lathe Terminology
 Parts Of A Lathe

• The carriage is the section of the lathe that slides along the ways
and supports the cross-slide and cutting tool. The carriage contains
the compound rest, which permits angular adjustment of the cutting
tool. The compound rest can rotate with respect to the cross-slide,
which permits further positioning of the tool being used.

• The leadscrew powers the carriage assembly. The leadscrew is a

large, threaded rod that is located below and parallel to the ways.

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 Basic Lathe Terminology
 Tooling
 Collets – Work Holding
• Collets run more true than a chuck
 Drill Chuck – Tool Holding
• Mainly for drill bits
• Mounts on a Morse Taper
arbor (1 thru 4 most common)
• Slides into tailstock Drill Chuck – Tool Holding

Morse Taper
Collets – Work Holding

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 Basic Lathe Terminology
 Tooling

 Center Drill – used first

• Keeps holes accurately positioned

 Twist Drill

 Reamer
• A tool for widening or shaping holes
• Precise hole size

 Boring Bar – Boring Holes

 Lathe Tool Bits – Facing – Turning – Threading - Grooving

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 Basic Lathe Terminology
 Tool Post & Holder

 Tool holders slide down onto tool post

 Twist handle to lock and release tool holders

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 Basic Lathe Terminology

 Work Holding Devices

 3 Jaw Chuck
• The jaws open and close together
automatically centering the workpiece.
Chuck (key) Wrench 3 Jaw – 2 Piece
• This kind of chuck usually has a 2 piece
Reversible
reversible set of jaws, or a complete
other set, one set holds the larger work
while the other set holds rings and small
work.

• These 3 jaw universal chucks when in

good shape center work accurately to
within .002 to .003.
3 Jaw – Solid Jaw (2 Sets)

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 Basic Lathe Terminology
 Work Holding Devices

 4 Jaw Chuck
• The 4 jaw independent chuck has four jaws and each
must be moved separately with a chuck wrench; it is
used mainly to hold work that is not perfectly round.
• It may be used to hold work that is round, square, 4 Jaw – Solid Reversible Jaws
rectangular, or irregular in shape. This chuck is more
accurate since the work can be centered with the use
of a dial indicator.
• The jaws on this kind of chuck are solid reversible;
that is, they can be taken out and put on again in the
opposite direction or a 2 piece reversible jaw. They
have steps so that different sizes of work can be held.
There are also 4 jaw self centering chucks available.

4 Jaw – 2 Piece Reversible

Jaws

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 Basic Lathe Terminology
 Cutting

• Facing
• Turning Parted Necked
Turned
• Boring
• Taper Turning
• Center Drilling
• Parting – Grooving
• Hole Tapping
• Knurling (a small projecting knob or ridge)
• Threading Faced
Tapered

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 Lathe - Operations
Outer Diameter Cutting Operations
• Facing - is the machining of a flat surface on the end, or face,
of a workpiece. Facing is sometimes used to remove uneven,
rough surfaces and burrs from a workpiece.

• Turning - is the machining of the external surface of round

parts. During turning, a part is held at one or both ends while it
rotates against a single-point tool. The cutting edge is forced
against the surface of the workpiece, cutting metal as the tool
is fed along the surface.

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 Lathe - Operations
Outer Diameter Cutting Operations
 Parting - also called cutting off, involves separating a complete
piece from stock. Parting is important because you can ruin the
whole job if the part is not cleanly removed
 OD grooving is a simple machining process during which a
cutting tool is plunged into a workpiece to create a groove or
channel. There are essentially three types of grooves: square-cut
grooves, round-cut grooves, and V-cut grooves.
 OD threading - is a special turning operation that uses a single-
point tool to cut threads down the length of a workpiece. The
lathe has the ability to cut many different types of threads with
the most common being a 60 degree thread.

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 Lathe - Operations
Outer Diameter Cutting Operations
 Knurling – is the process of forming horizontal or diamond
shaped notches or teeth on the circumference of the work to
provide a gripping surface

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 Lathe - Operations
Outer Diameter Cutting Operations
 Taper Turning – Tapering is an increase or decrease in
diameter at a uniform rate
There are five principle methods of machining tapers on the
lathe
Method Advantage / Disadvantage Information Required
1 Compound rest Length of taper limited. Both Must know the taper angle
external and internal threads

2 Offset tail stock External taper only Taper per inch or taper per
foot
3 Taper attachment Best method to use Angle or taper per inch

4 Tool bit Very short taper Taper angle

5 Reaming Internal only Taper number

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 Lathe - Operations
Inner Diameter Cutting Operations
• Drilling simply creates a hole in the workpiece. A drilled hole is the
least accurate type of hole made.

• Boring enlarges the inner diameter of a preexisting hole. This

process improves the accuracy of the hole and makes it more round.

• Reaming smoothes the internal surface of a hole. It uses a special

multi-point tool to remove metal from inside a hole.

• Tapping cuts internal threads into a drilled hole.

• ID grooving cuts a single circular channel or groove into a drilled

hole.
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 Cutting Tools
Fig. 1
• The most common cutting tools used are made from
materials such as high-speed tool steels (HSS) and carbide.
(a compound of carbon with metal or other element)

• Most tools made from these steels are single-point tools,

which means they contain a single cutting edge. Single-
point tools, shown in Fig. 1 and in the next slide, are the
most popular cutting tools used on the lathe – hand ground
HSS or the tools shown in Fig. 2 which are Brazed-tipped
cutting tools. Hand Ground HSS Tool Bits

• These tools are made from inexpensive material with a tip

of more expensive cutting material brazed onto the cutting
end. These materials include most commonly a C2 or C6
carbide. Carbide tooling can cut many materials at speeds
up to four times faster than HSS. C2 – used for non-ferrous
metals and C6 used for tougher to machine ferrous metals.
Brazed Tip Carbide Tool Bits
Fig. 2

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 Cutting Tools – Single Point

Cuts Left To Right Cuts Right To Left

Cutting tip

Height Adjustment Left-Hand Thread Cutting 60deg Right Hand

Screw For Tool
Holder & Tool
A cutting tools tip should be set to the centerline of the workpiece

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 Cutting Tools – Carbide Inserting Tooling
• Shops also use replaceable cutting inserts.
• Cutting inserts come in a variety of shapes, as you can see below.
• Inserts are secured in a tool holder and rotated so that there is a new cutting surface
in the same location.

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 Basic Lathe Terminology
 Feeds and Speeds (F/S)

 Spindle Speed:
• Speed (rpm) that the spindle and/or chuck rotates

 Tool Speed:
• [in/min] or [mm/min]: How fast the carriage is moving (Z axis)

 Feed Rate:
• [mm/rev] relative speed of tool and spindle

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CUTTING SPEEDS, FEEDS AND DEPTH OF CUT

 Cutting speed and feed governs the length of time required to

machine the work and the quality of the surface finish
 Cutting speed is the distance the work moves past the cutting
tool in one minute measured on the circumference
 Feed is the distance the cutter moves during one revolution of
the work
 The cutting speeds can be increased 50 percent if a coolant is
used and 300 to 400 percent if a cemented carbide cutting
tool is used.

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DEPTH OF CUT

 Depth of cut refers to the distance the cutter

has been fed into the work surface.
 The depth of cut also varies with the condition
of the lathe, material hardness, speed ,feed
and amount of material removed
 It must be remembered that material is
removed around the periphery of the work and
for a given feed the reduction in diameter will
be twice.
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SELECTION OF CUTTING SPEEDS AND FEED
 Factors that can effect selection of cutting speeds and
feed are
 Material used for the cutting tool
 Kind of material being machined
 Finished desired
 Condition of lathe
 Kind of coolant
 Shape of material
 Depth of cut

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SPEED AND FEED CHART
Material Rough Cut Finishing Cut
Cast Iron 80 FPM 100 FPM
Low Carbon Steel 130 FPM 160 FPM
Medium Carbon Steel 90 FPM 100 FPM
High Carbon Steel 50 FPM 65 FPM
Tool Steel 50 FPM 65 FPM
Brass 160 FPM 220 FPM
Bronze 90 FPM 100 FPM
Aluminum 600 FPM 1000 FPM

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CALCULATING SPEED OF WORK (SPINDLE
SPEED)
 Based on the table in the previous slide RPM
for a given material can be calculated based on
the following formula
CS = RPM * π * D
 Where CS is the recommended cutting speed
 And D is the diameter of the work
 RPM is the spindle speed

 For rough cuts highest speeds and coarsest feeds can be used
 For finished cuts a high spindle speed with a sharp tool and fine feed
are used 30
CUTTING CONDITIONS

 Cutting Speed, Feed, Depth of Cut

Based on these cutting conditions, material
removal rate can be calculated using following
formula
RMR = CS * f * d
Where,
 RMR is material removal rate mm3/s, (in3/s)

 CS is recommended cutting speed mm/s, (in/s)

 f is feed mm, (in)

 d is depth of cut mm, (in)

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