Experiment No.
1
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Objective : Study of lathe machine, lathe tools cutting speed, feed and depth of cut. 1.1 WORKING PRINCIPLE
The lathe is a machine tool which holds the workpiece between two rigid and strong supports called centers or in a chuck or face plate which revolves. The cutting tool is rigidly held and supported in a tool post which is fed against the revolving work. The normal cutting operations are performed with the cutting tool fed either parallel or at right angles to the axis of the [Link] cutting tool may also be fed at an angle relative to the axis of work for machining tapers and angles.
Fig. 1.1 Working principLE of lathe machine
1.2
TYPES OF LATHE
Lathes are manufactured in a variety of types and sizes, from very small bench lathes used for precision work to huge lathes used for turning large steel shafts. But the principle of operation and function of all types of lathes is same. The different types of lathes are: 1. Speed lathe (a) Wood working (b) Spinning (c) Centering (d) Polishing 2. Centre or engine lathe (a) Belt drive (b) Individual motor drive (c) Gear head lathe 3. Bench lathe 4. Tool room Lathe
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5. Capstan and Turret 1athe 6. Special purpose lathe (a) Whee1 lathe (b) Gap bed lathe (c) Dup1icating lathe (d) T-lathe 7. Automatic lathe
1.2.1 Speed Lathe
Speed lathe is simplest of all types of lathes in construction and operation. The important parts of speed lathe are following(1) Bed (2) Headstock (3) Tailstock, and (4) Tool post mounted on an adjustable slide. It has no feed box, 1eadscrew or conventional type of carriage. The tool is mounted on the adjustable slide and is fed into the work by hand contro1. The speed lathe finds applications where cutting force is least such as in wood working, spinning, centering, polishing, winding, buffing [Link] lathe has been so named because of the very high speed of the headstock spindle.
1.2.2 Centre Lathe or Engine Lathe
The term engine is associated with this lathe due to the fact that in the very early days of its development it was driven by steam engine. This lathe is the important member of the lathe family and is the most widely used. Similar to the speed lathe, the engine lathe has all the basic parts, e.g., bed, headstock, and tailstock. But its headstock is much more robust in construction and contains additional mechanism for driving the lathe spindle at multiple speeds. An engine lathe is shown in Fig. 1.2. Unlike the speed lathe, the engine lathe can feed the cutting tool both in cross and longitudinal direction with reference to the lathe axis with the help of a carriage, feed rod and lead screw. Centre lathes or engine lathes are classified according to methods of transmitting power to the machine. The power may be transmitted by means of belt, electric motor or through gears.
Fig. 1.2 Principal components of a central lathe
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1.2.3 Bench Lathe
This is a small lathe usually mounted on a bench. It has practically all the parts of an engine lathe or speed lathe and it performs almost all the operations. This is used for small and precision work.
1.2.4 Tool Room Lathe
This lathe has features similar to an engine lathe but it is much more accurately [Link] has a wide range of spindle speeds ranging from a very low to a quite high speed up to 2500 rpm. This lathe is mainly used for precision work on tools, dies, gauges and in machining work where accuracy is needed.
1.2.5 Capstan and Turret Lathe
The development of these 1athes results from the technological advancement of the engine lathe and these are vastly used for mass production work. The distinguishing feature of this type of lathe is that the tailstock of an engine lathe is replaced by a hexagonal turret, on the face of which multiple tools may be fitted and fed into the work in proper sequence. Due to this arrangement, several different types of operations can be done on a job without re-setting of work or tools, and a number of identical parts can be produced in the minimum time.
1.2.6 Special Purpose Lathes
These lathes are constructed for special purposes and for jobs, which cannot be accommodated or conveniently machined on a standard lathe. The wheel lathe is made for finishing the journals and turning the tread on railroad car and locomotive wheels. The gap bed lathe, in which a section of the bed adjacent to the headstock is removable, is used to swing extra-large-diameter pieces. The T-lathe is used for machining of rotors for jet engines. The bed of this lathe has T-shape. Duplicating lathe is one for duplicating the shape of a flat or round template on to the job.
1.2.7 Automatic Lathes
These lathes are so designed that all the working and job handling movements of the complete manufacturing process for a job are done automatically. These are high speed, heavy duty, mass production lathes with complete automatic control.
1.3
CONSTRUCTION
The main parts of the lathe are the bed, headstock, quick changing gear box, carriage and tailstock. 1. Bed: The bed is a heavy, rugged casting in which are mounted the working parts of the lathe. It carries the headstock and tail stock for supporting the workpiece and provides a base for the movement of carriage assembly which carries the tool.
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Fig. 1.3 Principal components of a lathe
2. Legs: The legs carry the entire load of machine and are firmly secured to floor by foundation bolts. 3. Headstock: The headstock is clamped on the left hand side of the bed and it serves as housing for the driving pulleys, back gears, headstock spindle, live centre and the feed reverse gear. The headstock spindle is a hollow cylindrical shaft that provides a drive from the motor to work holding devices. 4. Gear Box: The quick-change gear-box is placed below the headstock and contains a number of different sized gears. 5. Carriage: The carriage is located between the headstock and tailstock and serves the purpose of supporting, guiding and feeding the tool against the job during operation. The main parts of carriage are: a). The saddle is an H-shaped casting mounted on the top of lathe ways. It provides support to cross-slide, compound rest and tool post. b). The cross slide is mounted on the top of saddle, and it provides a mounted or automatic cross movement for the cutting tool. c). The compound rest is fitted on the top of cross slide and is used to support the tool post and the cutting tool.
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d). The tool post is mounted on the compound rest, and it rigidly clamps the cutting tool or tool holder at the proper height relative to the work centre line. e). The apron is fastened to the saddle and it houses the gears, clutches and levers required to move the carriage or cross slide. The engagement of split nut lever and the automatic feed lever at the same time is prevented she carriage along the lathe bed. 6. Tailstock: The tailstock is a movable casting located opposite the headstock on the ways of the bed. The tailstock can slide along the bed to accommodate different lengths of workpiece between the centers. A tailstock clamp is provided to lock the tailstock at any desired position. The tailstock spindle has an internal taper to hold the dead centre and the tapered shank tools such as reamers and drills.
1.4 SPECIFICATION OF LATHE
The size of a lathe is generally specified by the following means: (a) Swing or maximum diameter that can be rotated over the bed ways (b) Maximum length of the job that can be held between head stock and tail stock centres (c) Bed length, which may include head stock length also (d) Maximum diameter of the bar that can pass through spindle or collect chuck of capstan lathe. Fig. 1.4 illustrates the elements involved in specifications of a lathe. The following data also contributes to specify a common lathe machine.
Fig. 1.4 Specifications of a lathe (i) Maximum swing over bed (ii) Maximum swing over carriage (iii) Height of centers over bed (iv) Maximum distance between centers (v) Length of bed
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(vi) Width of bed (vii) Morse taper of center (viii) Diameter of hole through spindle (ix) Face plate diameter (x) Size of tool post (xi) Number of spindle speeds (xii) Lead screw diameter and number of threads per cm. (xiii) Size of electrical motor (xiv) Pitch range of metric and inch threads etc .
1.5 LATHE OPERATIONS
For performing the various machining operations in a lathe, the job is being supported and driven by anyone of the following methods. 1. Job is held and driven by chuck with the other end supported on the tail stock centre. 2. Job is held between centers and driven by carriers and catch plates. 3. Job is held on a mandrel, which is supported between centers and driven by carriers and catch plates. 4. Job is held and driven by a chuck or a faceplate or an angle plate. The above methods for holding the job can be classified under two headings namely job held between centers and job held by a chuck or any other fixture. The various important lathe operations are depicted through Fig. 1.5 (a), (b) and (c). The operations performed in a lathe can be understood by three major categories
Fig. 1.5(a) Lathe operation (a) Operations, which can be performed in a lathe either by holding the workpiece between centers or by a chuck are: 1. Straight turning 2. Shoulder turning 3. Taper turning 4. Chamfering 5. Eccentric turning 6. Thread cutting 7. Facing 8. Forming 9. Filing 10. Polishing
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11. Grooving 13. Spinning
12. Knurling 14. Spring winding
(b) Operations which are performed by holding the work by a chuck or a faceplate or an angle plate are: 1. Undercutting 2. Parting-off 3. Internal thread cutting 4. Drilling 5. Reaming 6. Boring 7. Counter boring 8. Taper boring 9. Tapping
Fig. 1.5(b) Lathe operations
(c) Operations which are performed by using special lathe attachments are: 1. Milling 2. Grinding
Fig. 1.5(C) Lathe operations
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1.6 CUTTING SPEED
Cutting speed for lathe work may be defined as the rate in meters per minute at which the surface of the job moves past the cutting tool. Machining at a correct cutting speed is highly important for good tool life and efficient cutting. Too slow cutting speeds reduce productivity and increase manufacturing costs whereas too high cutting speeds result in overheating of the tool and premature failure of the cutting edge of the tool. The following factors affect the cutting speed: (i) Kind of material being cut, (ii) Cutting tool material, (iii) Shape of cutting tool, (iv) Rigidity of machine tool and the job piece and (v) Type of cutting fluid being used.
Calculation of cutting speed Cs, in meters per minute Cs = ((22/7) D N)) /1000 Where D is diameter of job in mm. N is in RPM
1.7 FEED
Feed is defined as the distance that a tool advances into the work during one revolution of the headstock spindle. It is usually given as a linear movement per revolution of the spindle or job. During turning a job on the center lathe, the saddle and the tool post move along the bed of the lathe for a particular feed for cutting along the length of the rotating job.
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