Metal Cutting and Machine Tools

Unit - II
Objective:
 To familarize with the working principles of different types of Lathe Machines.
 To impart knowledge on attachments and accessoried used on Lathe Machines.
Syllabus:
Engine lathe – principle of working - specification of lathe – types of lathe – work holders, tool
holders – lathe operations. Turret and capstan lathes – collet chucks – other work holders – tool
holding devices – box tools and tool layout. Principal features of automatic lathes – classification
– single spindle and multi-spindle automatic lathes.
Learning Outcomes:
Student will be able to
 Know the working principle of lathe machine
 List the different types of lathe machines
 Specify the lathe machine
 Select appropriate work holder to hold the different worksurfaces.
 Identify suitable operations performed on lathe machine to produce variety of components
 Differentiate engine lathe and capstan and turret lathes.
 Know the principal features of Automatic lathe machines.
1.0 Introduction
Machining is accomplished with the use of machines known as “Machine tools”. For production
of variety of mahcined surfaces different types of machine tools have been developed. The kind of
surface produced depends upon the shape of cutting, the path of the tool as it passes through the
material or both. Depending on them metal cutting processes are called either turning or planning
or boring or other operations performed by the machine tools like lithe, shaper, planer, drill,
miller, grinder etc. as illustrated schematically in Figure.

Machine tools are the kind of machines on which the metal cutting or metal forming processes
are carried out. They employ cutting tools to remove excess material from the given job.
The functions of a machine tool are:

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(i) To hold the tool;
(ii) To move the tool or the workpiece or both relative to each other;
(iii)To supply energy required to cause the metal cutting.
Classification of machine tools
The machine tools are classified as follows:
1. General purpose:
(i) Lathe (ii) Drilling machine
(iii)Shaping machine (iv) Planning machine
(v) Milling machine (vi) Sawing machine.
2. Special purpose:
(i) Special lathes like capstan, turret and copying lathes
(ii) Boring machine (iii) Broaching machine
(iv) Production milling machine (v) Production drilling machine.
3. Automatic Machine tools
These machinetools, also called Automatic screw cutting machines (or simply auto-mata), are
used for mass production of essentially small parts using a set of pre-designed and job-
specific cams.
4. Computer numerical control (CNC) machine tools:
Under CNC machine tools, we have CNC turning centre, which does all the work of a
lathe and CNC machining centre which does milling, drilling etc., with provision for
automatic tool changing and tool wear correction built into it.
Elements of machine tools
Various elements of machine tools are:
1. Structure-formed by bed, column and frame.
2. Slides and tool structure.
3. Spindles and spindle bearing.
4. Kinematics of machine tool drives.
5. Work holding, and tool holding elements.
1.1 Lathe Machine
The history of invention, design and manufacture of a useful form of Lathe dates back to
Eighteenth Century. Still it was in a crude form. The first useful form of Lathe, incorporating the
essential features, was made by H. Maudslay, a Britisher, in 1800. Later developments and
researches led to a number of amendments, as years passed, and the result is what we see today.
Lathe was actually the first Machine Tool which came into being as a useful machine for metal
cutting. Thus, it formed the basis of production of all the other Machine Tools which are the
results of later developments.
Although we find a large number of modern Machine Tools, most of them Automatic too,
still the Lathe maintains its existence as an indispensable
Machine tools even today. It still proves to be a vital necessity in all modern Tool rooms,
Repair shops and Training workshops. Its main significance lies in the variety of its applications
in the production of different types of jobs. As an alternative, a single job will need a number of
other machine tools for performing the various operations required in its production. The utility of
Lathe, even in modern advanced industry, can, therefore, be easily recognised.

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1.2 Principle of Working:

 The Lathe can be defined as a Machine tool which holds the work between two rigid and
strong supports, called Centres, or in a Chuck or Face plate while the latter revolves.
 The chuck or the face plate is mounted on the projected end of the machne spindle.
 The cutting tool is rigidly held and supported in a Tool post and is fed against the revolving
work.
 While the work revolved about its own axis the tool is made to move eigher parallel to or at an
inclination with this axis to cut the desired material.
 In doing so it produces a Cylindrical surface, if it is fed parallel to the axis or will produce a
tapered surface if it is fed at an inclination.
1.3 Types of Lathe:
According to the construction and design, lathes are broadly classified as follows:
1. Bench Lathe
2. Speed Lathe
3. Engine Lathe
4. Tool Room Lathe
5. Capstone and turret Lathe
6. Automatic Lathe
7. Special – Purpose Lathe
Bench Lathe:
 It is very small lathe and is mounted on a separately prepared bench or cabinet.
 It is used for small and precision work since it very accurate.
 It is usually provided with all attachments, which a larger lathe carries.
 It is capable of performing almost all the operations which a larger lathe can do.
Speed Lathe:
 These lathe may be of bench type or they may have the supporting legs cast and fitted to the
bed.
 These lathes have most of the attachments which the other type of lathes carry but no
provision for power feed.
 They have no gear box, carriage and 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.
 They are named so because of the very high speed at which their spindle rotates

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Engine Lathe:
 It is probably the most widely used type of lathe.
 It carries a great historical significance that in very early days of its development it was driven
by a steam engine.
 Its headstock is bigger in size and more robust, incorporating suitable mechanism forproviding
multiple speeds to the lathe spindle.
 The headstock spindle may receive power from a lathe shaft or an individual motor, through
belts.
 It is having a cone pulley with back gears in the headstock to provide different speeds.
 It receives its power from a constant speed motor and for providing different speeds to the
spindle.
 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 headstock.
Tool Room Lathe:
 It is nothing but the same engine lathe but equipped with some extra attachments to make it
suitable for relatively more accurate and precision type of work carried out in a tool room.
 It carries a much wide range 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 1350 to 1800 mm.
Capstan and Turret Lathe:
 These lathe form a very important and useful group and are vastly used in mass production.
 These machines are accurately of some automatic type and very wide range of operations can
be performed on them.
 In operating these machines, a very little skill is required of the operator.
 They carry special mechanisms for indexing of their tool heads.
Automatic Lathes:
 These lathes help a long way in enhancing the quality as well as the quantity of production.
 They are also designed that, all the working and job handling movements of the complete
manufacturing process for a job are done automatically.
 No participation of the operator is required during the operation.
 The semi-automatic lathes, in which the mounting and removing of the work is done by the
operator whereas all the operations are performed by the machine automatically.
 Automatic lathes are available having single or multi-spindles.
 They fall in the category of heavy duty, high speed, lathes mainly employed in mass
production.
Special Purpose Lathes;
 A large number of lathes are designed to suit a definite class of work and to perform certain
specified operations only.
 These are more efficient and effective than the common engine lathe so far as to specified
class of work is concerned.

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According to the height of centers
 Small lathes : having height of centers up to 150 mm.
 Medium- size lathes : having height of centers from 150 to 300mm.
Heavy duty lathes : having height of centers above 300 mm
According to the type of drive the lathes can be grouped as
 Lathes Having step cone pulley drive and the back gears to provide various speeds to the
work.
 This type of drives calls for the use of counter shaft which carries a similar cone pulley to that
provided on the lathe spindle.
 This counter shaft in addition to the step pulley, carries two clutch pulleys also, which are
connected to the main shaft through the belts.
 One of these pulleys carries an open belt and the other a cross belt, to rotate the machine
spindle in opposite directions.
 Lathes Having step-cone pulley drive as usual and the back gears but having
individual motor drives, thus eliminating the use of main shaft.
 This type of drives is conveyed from the motor to the counter shaft and then to the machine
spindle.
 Lathes having single pulley constant speed or geared head drive.
 In this a single pulley is driven by means of ‘V’ belts by the motor and the internal mechanism
of the head stock.
 It is designed to have various speed gears, enables a wide range of speeds of the spindle.
 The quick change gears provides power feed to the carriage.
1.4 Specifications of Lathe:

The size or specifications are expressed by the following items:

1. The height of the centers measured from the lathe bed.
2. The swing diameter over bed i.e., the largest diameter of work that will revolve with out
touching the bed and is twice the height of the center measured from the bed of the lathe.
3. The length between centers. This is the maximum length of the work that can be mounted
between the lathe centers.

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4. The swing diameter over carriage. This is the largest diameter of the work that will revolve
over the lathe saddle, and is always less than the swing diameter over the bed.
5. The maximum bar diameter. This is the maximum diameter the bar stock that will pass
through pass through hole of the headstock spindle.
6. The length of the bed. This indicates the approximate floor space occupied by the lathe

A : length of the bed

B : length between centers
C : swing diameter over bed
D : maximum bar diameter
• height of the centers
• swing diameter over carriage
1.5 Parts of a Lathe
The lathe carries the following main parts, as illustrated by a block diagram in Figure. The main
parts of a Lathe are :
 Bed
 Headstock
 Tailstock
 Carriage
 Legs
 Feed mechanism
Bed:
 The bed of a Lathe acts as the base on which the different fixed and operating parts of the
Lathe are mounted.
 This faciliatates the correct relative location of the fixed parts and at the same time provides
ways for a well guided and controlled movement of the operating part (Carriage).
 Also it has to with-stand various forces exerted on the Cutting tool during the operation. It
must, therefore, be of a very rigid and robust construction.
 Lathe beds are usually made as single piece casting of semi-steel (i.e., toughened cast iron),
with the addition of small quantity of steel scrap to the cast iron during melting; the material
‘Cast Iron’ facilitating as easy sliding action.
 However, in case of extremely large machines, the bed may be in two or more pieces, bolted
together to form the desired length.

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 Bed castings are usually made to have a box section incorporating cross ribs as shown in
Figure.

The guide ways are of two types: (a) Flat guideways (b) inverted Vee guideways. Generally, the
combination of both the flat and inverted Vee guideways is used as shown below.

 All-flat ways are not vbery popular now, although it is easy to produce them.
 The Prismatic, or Inverted ‘V’ ways are now preferred over the flat ways for the reason that
their construction totally disallows the entry of chips and dirt, etc. between the saddle and the
bed, thus preventing the contact surfaces from being spoined due to scratching.
 Also, they provide very efficient duiding surfaces and the wear of the bed does not have any
appreciable effect on the overall alignment to the lathe.
 Most of the countries adopt a combination of the falt and prismatic shapes of bed ways. In
this, the flat wyas act as supports, i.e., taking the maximum portion of the load and stresses,
whereas the prismatic shapes act as guide-ways.
 Tail stock is usually guided along the bed by a combination of one prismatic and one falt way.
Headstock:
 It is permanently fastened to the innerways at the left hand end of the bed.
 It serves to support the spindle and driving arrangements.
 All lathes receive their power throught the headstock, which may be equipped with a step-
cone pulleys or a gear head drive (the modern lathes are provided with all geared type head
stock to get large variations of spindle speeds).
 In order to allow the long bar or work holding devices to pass through, the headstock spindle
is made hollow. A tapered sleeve fits into the tapered spindle hole.
It consist of the following main parts:
1. Cone pulley 2. Backgears and backgear lever,
3. Main spindle or Head stock spindle 4. Live centre, and
5. Feed reverse lever.

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 Tailstock :
It is situated at the right hand end of the bed.
 It is used for supporting the right end of the work.
 It is also used for hodling and feeding the tools such as drills, reamers, taps etc.

Carriage:

 The carriage controls and supports the cutting tool.

 The carriage has the following five major parts :
(i) Saddle. It is a H-shaped casting fitted over the bed. It moves along the guide ways.
(ii) Cross-slide. It carries the compound slide and tool post; can be moved by power or by hand.
(iii) Compound rest. It is marked in degrees; used during taper turning to set the tool for angular
cuts.
(iv) Tool post. The tool is clamped on the tool post.
(v) Apron. It is attached to the saddle and hangs in front of the bed. It has gears, levers and
clutches for moving the carriage with the lead screw for thread cutting.
Feed mechanism:
 It is employed for imparting various feeds (longitudinal), cross and angular) to the cutting
tool.
 It consists of feed reverse lever, tumbler reversing mechanism, change gears, feed gear box,
quick change gear box, lead screw, fed rod, apron mechanism and hald ntu mechanism.

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1.6 Lathe Accessories or Work Holding Devices and Tool Holding Devices:
The devices employed for handling and supporting the work and the tool on the lathe are called
its accessories. The various accessories are enumerated below :
1. Chucks
2. Face plate
3. Angle plate
4. Driving plate
5. Lathe carriers or dogs
6. Lathe centres
7. Lathe mandrels
8. Rests
9. Jigs and fixures.
Chucks:
 A chuck is one of the most important devices for holding and rotating workpieces in a lathe.
 Workpiece of short length and large diameter or of irregular shape which cannot be
conveniently mounted between centers are held quickly and rigidly in a chuck.
 A chuck is attached to the lathe spindle by means of bolts with the back plate or screwed on
the spindle nose.
 There are different kinds of chucks:
1. Four jaw independent chuck
2. Three jaw universal chuck
3. Air or hydraulic operated chuck
4. Magnetic chucks
5. Collet chuck
6. Combination chuck
7. Drill chuck
Three Jaw Self Centering Chuck:

 A three jaw chuck is used for gripping cylindrical workpieces when the machined surface is
concentric with the work surfaces.
 The jaws have a series of teeth that mesh with spiral grooves on a circular plate within the
chuck.
 This plate can be rotated by the key inserted in the square socket, resulting in simultaneous
radial motion of the jaws.
 Since the jaws maintain an equal distance from the chuck axis, cylindrical workpieces are
automatically centered when gripped.

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Four jaw independent chuck:

 This chuck has four jaws which may be made to slide within the slots provided in the body of
the chuck for gripping different sizes of work piece.
 Each jaw may be moved independently by rotating the screw which meshes with the teeth cut
on the under side of the jaw.
 Each jaw is made of tough steel has three inner and one outer gripping surfaces.
 The outer gripping surface is used for holding larger sizes of the work piece by
reversing the jaw.
 Although accurate mounting of a workpiece can be time consuming, a four-jaw chuck is often
necessary for non-cylindrical workpieces.
Combination Chuck:
 As the name implies, a combination chuck, may be used both as a self centering and an
independent chuck to take advantage of both the types.
 The jaws may be opened individually by separate screws or simultaneously by the scroll disk.
Magnetic Chuck
 It implies the use of Electric Current for developing a strong Electromagnet which holds the
job centrally in the chuck.
 Although many designs of these chucks are prevalent, still the Rotary type is in common use.
 One notable feature of this type of chuck is that it is not capable of withstanding heaby cuts on
the job it grips and also that the job to be held in his chuck should be of iron or steel.
 They are also known as Electro-magnetic Chucks.

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Air or Hydraulic Chuck
 In these chucks, Air or Hydraulic Pressure is used for pressing the jaws against the job.
 The pressure is provided by a cylinder and piston mechanism, fitted at the rear of the Head
Stock, and is controlled by a Valve by the operator.
 Threes chucks are very quick acting and provide a very firm grip. Their use is, however,
largely confined to those machines engaged in mass production.
Collect:
 It is another useful type of chuck which provides very firm grip, but ist use is confined to
small jobs only.
 Draw-in type Collects are in common use. Their front portion is splittedf which provides a
springy action and hence the grip.
Face plate:

 It is usually a circular cast iron disc, having a threaded hole at its centre so that it can be
screwed to the threaded nose of the spindle.
 It consists of a number of holes and slots by means of which the work can be secured to it. A
number of other things like bolts, nuts, washers, clamping plates and metallic packing pieces,
etc., are required for hodling the work properly on a face plate.
Angle Plate:

 It is employed for hodling work in conjuction with a Face plate.

 When the size or shape of the work is such that it is not possible to mount the work directly on
the face plate, the Angle plate is secured to the Face plate and work mounted on it.
 It is almost an indispensable attachment for most of the operations in Face plate work.
 A useful form of Angle plate is shown in Figure.
Driving Plate
 It is a cast iron circular disc having a projected Boss at its rear.
 The Boss carries internal threads, so that it can be screwed on to the spindle nose.

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 It also carries a hole to accommodate a pin which engages with the tail of Lathe dog or Carrier
when the job is held in the latter.

Lathe Carriers or Dogs:

As stated above, they are used in conjuction with the
Driving plate. The two common forms, known as
Stright tail and Bent tail, are shown in Figure. Tthe
work to be held is inserted in the ‘V’ shaped hole of the
Carrier and them firmly secured in position by means
of the set screw. It may, however, be noted that the
capacity of threes carriers is limited to hold a certain
range of diameters only and very big jobs are eigher
held in Chucks or Face plates.
Centres:
 They form a very important group of Lathe Accessories and are made in various designs.
 They act as solid bearings to support the work during the operation. Cast steel or High grade
tool steel is the common material used for their manufacture.
 They are then hardened and ground to correct angle. Sometimes, when very high speeds are to
be employed, tips made of some other hard materials like cemetned carbide or high spped
steel are used which are fitted into usual types of shanks.
 These shanks are machined to have standard taper to fit in the corresponding tapered holes in
the Spindle or Tail stock sleeve. Tip of the Centre is usually made to have an included angle
of 60°.

 The common forms of Dead Centres are shown in Figure.

 The ordinary type or Standard Centre is most commonly employed.

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 In case of the Half centre, about half of its front cone is removed by filing to give the shape
shown. Its specific use is in facing operation.
 A Cup Centre or Reverse Centre is employed ehwn a work of small diameter is to be turned
which has a conical end, ie., ends in a sharp point.
 Yet another type of Dead Centre used in high speed machining is a Carbide tipped centre,
shown in Figure.
Lathe mandrels :

 A “mandrel” can be described as a solid steel shaft or spindle which is used for holding bored
parts for machining their outside surfaces on lathe. They are also known as arbors.
 Mandrels are usually employed for those jobs (relatively small) which have a finished hole
which is concentric with the outer surface that is to be machined.
 The common types of mandrels are: Solid or plain, collar, stepped, expanding and double cone
mandrels.
Rests:

 When a very long job is to be turned between centres on a lathe, due to its own weight it
provides a springing action and carries a lot of bending moment. The result is that the turning
tool is spoiled very soon and may even break sometimes. To aboid this, such jobs are always
supported on an attachment known as ‘steady rest or centre rest’

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 Sometimes, when the job is too flexible, it becomes necessary to support the job very close to
the cutting edge of the tool throughout the operation. In such cases a ‘follower rest’, is used
instead of the steady rest. It is attached to the saddle of the lathe carriage and thus travels
along with the tool throughout the operation.
Jigs and fixtures:
 Jigs and fixtures are used in conduction with the face plate on a lathe for supporting and
holding odd shaped and eccentric jobs during the operation.
 This specific use is in the mass production of identical parts otherwise, if only a single item is
to be made, the cost of production of the jigs or fixtures itself will be too high, preventing
their use.
1.6.1 Tool holding devices:

 Tool posts are the devices used on various machines for holding the tools in position and
providing a rigid support to them during the operation.
 Common types of Tool posts used on Lathes are shown in Figure.
 The American type single tool post shown in Figure(a) is used for holding as single Tool
holder or a Solid forged tool only. It is commonly used in light work. It consists of a vertical
body having a Slot to accommodate the tool shank and a Flange at its bottom. The Collar
carries a spherical groove in which the Rocket is placed. This rocker can be tilted to adjust the
height of the cutting edge of the tool. This adjustment wil, obviously, change the effective
rake and clearance angles of the tool.
 A better form of Single tool post, called the Open side Tool post, is shown in Figure(b).

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 The main Clamping bolt is used for securing the Tool post and the adjusting screws for
gripping the tool in position. Height of the tool is adjusted by using flat packing pieces under
the tool. This form of tool post is also used as a Rear tool post on lathes.
 Another useful form of Tool post, usually employed on heavy duty Lathes, is shown in
Figure(c).
 It is provided with four bolts, each carrying a coiled spring. Two tools can be simultaneously
mounted on it. The tools are held between the base and Clamping bars and gripped firmly by
tightening the bolts. The Springs help in keeping the bars in position when the tools havbe
been withdrawn.
 A Square tool post, vastly used in mass production, is shown in Figure(d).
 It can accommodate four tools at a time. It is also called a Turret Tool Post. It facilitates
mounting of 4 different tools prior to starting the operation and bringing them to the desired
position, one after the other, by rotating the handle. Such arrangement ia an asset and a vital
necessity in repetition work because it saves a lot of time in tool setting.
1.7 Lathe Operations
 Operations which are performed in a lathe either by holding the work piece between centres or
by a chuck are:
1. Facing 2. Turning 3. Taper turning
4. Drilling 5. Reaming 6. Boring
7. Undercutting or grooving 7. Threading
8. Knurling 9. Forming
1.7.1 Centering:
 Centering is the operation of producing conical holes in the work piece.
 Where the work is required to be turned between centres or between a chuck and a centre,
conical shaped holes must be provided at the ends of the work piece to provide bearing
surface for the lathe centres.
 The centre may be located by any one of the following equipments :
 Using centre head and steel rule of a combination set.
 Using a hermaphrodite caliper.
 Using a divider and surface plate.
 Using a surface gauge.
 Using a bell center punch.
1.7.2 Facing:
 Facing is an operation of machining the ends of a
workpiece to produce a flat surface square with the axis.
It is also used to cut the work to the required length.
 The operation involves feeding the tool perpendicular to
the axis of rotation of the workpiece.
 A properly ground facing tool is mounted in the tool
post. A regular turning tool may also be used for facing
a large workpiece. The cutting edge should be set at the
same height as the centre of the workpiece.

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1.7.3 Turning
 Turning is the most commonly used operation in Lathe.
 Turning in a lathe is to remove excess material from the work piece to produce a cylindrical or
a cone shaped surface.
 Normally the work piece is rotated on a spindle and the tool is fed into it radially, axially, or
both ways simultaneously, to give the required surface.
 The term ‘turning’, in the general sense, refers to the generation of any cylindrical surface
with a single point tool.
 The common types of turning are:
 Plain turning
 Step turning
 rough turning
 finish turning
 shoulder turning and
 taper turning.
1. Plain turning:
 It is an operation of removing excess material from
the surface of the cylindrical workpiece.
 In this operation, the work is held eigher in the
chuck or between centres and the longitudinal feed is
given to the tool either by hand or power.

2. Step turning:

 In this type of lathe operation various steps of different diameters in the workpiece are
produced.
 It is carried out in the similar way as plain turning.
3. Rough Turning:

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 Rough Turning is the term used for the process of heavy stock removal in order to save
machining time.
 In this process, deeper cut is taken and heavier feed is employed. However, rigidity of the
machine should be considered before deciding upon the feed rate and depth of cut. The
surface produced will, obviously, be rough.
 A sharp edged heavy turning tool with a strong cutting dege is employed in this operation so
that it is strong enough to take deep cuts and is capable of bearing the heavy cutting forces.

4. Finish Turning:

 Once the larger part of the excess material has been removed through Rough Turning, it is
followed by Finish Turning Operation in order to bring the job to correct size and provide a
fine surface finish on it.
 The amount of excess material to be removed through this operation is very less and therefore,
lighter feed and smaller depth of cut are used the heavier tool is replaced by a finish turning
tool.
5. Shoulder Turning:

 Shoulder is that part of a component where its two different diameters meet each other,
forming a step.
 This can have several forms, such as square, bevelled, undercut or having a radius.
 The first three are automatically formed while turning the smaller diameter, if a tool of
properly shaped cutting edge is used.
 The undercut shoulder can be formed by feeding a parting tool into the larger diameter closer
and parallel to the surface of the smaller diameter.

6. Taper Turning:
 A taper may be defined as a uniform increase or decrease in diameter of a work piece
measured along its length.

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Taper Elements:

Where, D = Large diameter of taper in mm.

d = small diameter of taper in mm.
l = length of taper part in mm
2α = full taper angle
α = angle of taper angle or half taper angle.
Refer to Figure, The taper angle α can be found by using the following relationship :

or,

 The amount of taper or conicity of taper in a work piece is specified by ratio of the difference
in diameters of the taper to its length. This is termed as conicity and designated by letter K.
The conicity K of a taper is defined as:
K
 In a Lathe taper turning is an operation to produce a conical surface by gradual reduction in
diameter from a cylindrical job.
 Taper turning can be done by the following ways:
1. By a form tool.
2. By setting over the tailstock.
3. By swiveling the compound rest.
4. By taper turning attachment.
5. By compound feed.
Taper Turning by a Form Tool:

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 Taper turning by a form tool uses a tool which is a broad nose tool having straight cutting
edge.
 The tool is set on the work piece at half taper angle, and is fed straight into the work to
generate a tapered angle.
 This method is limited to turn limited length taper only.
 This is due to the reason that the metal is removed by entire cutting edge, and any increase in
length of the taper will necessitate the use of a wider cutting edge.
 This will require excessive cutting pressure, which may distort the work due to vibration and
spoil the work due to vibration and spoil the work surface.
By Setting Over the Tailstock:

 The principle of turning taper by this method is to shift the axis of rotation of the workpiece,
at an angle to the lathe axis, and feeding the tool parallel to the lathe axis.
 The angle at which axis of rotation of the workpiece is shifted is equal to half angle of taper.
 The amount of setover is limited. This method is suitable for turning small taper on long jobs.
 The main disadvantage of this method is that the live and dead centres are not equally stressed
and the wear is not uniform. Moreover, the lathe dog being set at an angle, the angular
velocity is not constant.
From geometry:
BC= Setover
BC=AB sin α
Setover = L sin α
If the angle α, the angle of taper, is very small, for all practical purposes,
Sin α=tan α
Setover = L tan α

Setover =

Setover =

If the taper is turned on the entire length of the workpiece, then 1 = L

Setover =

19
By Swiveling the Compound Rest:

 This method employs the principle of taper turning by rotating the workpiece on the lathe axis
and feeding the tool at an angle to the axis of rotation of the workpiece.
 The tool is mounted on the compound rest, is attached to a circular base, graduated in degrees,
which may be swiveled and clamped at any desired angle.
 Once the compound rest is set at the desired half taper angle, rotation of the compound slide
will cause the tool to be fed at an angle and generate the corresponding taper.
 This method is limited to turn a short but steep taper owing to limited movement of the cross
slide.
 The movement of the tool in this method is controlled by hand, thus this gives low production
rate and poor surface capacity.
By Taper Turning Attachment:

20
  The principle of taper turning by taper turning attachment is to guide the tool in a straight
path set at an angle to the axis of rotation of the workpiece, while the work is being held
by a chuck or between centres aligned to the lathe axis.
 A taper turning attachment consists of a frame or bracket which is attached to the rear end
of the lathe bed and supports a guide bar pivoted at the centre.
 The bar having graduations in degrees may be swiveled on either side of the zero
graduation and is set at any desired angle with the lathe axis.
 When taper turning attachment is used, the cross slide is first made free from the lead
screw by removing the binder screw.
 The rear end of the cross slide is tightened with the guide block by means of bolt.
 When longitudinal feed is engaged, the tool mounted on the cross slide will follow the
angular path, as the guide block will slide on the guide bar set at an angle to the lathe axis.
 Taper turning by this method does not disturb the alignment of the live and dead centre.
 By this process both steep and small taper can be made over any length of the work piece.
Advantages of using a taper turning attachment are :
1. The alignment of live and dead centres being not disturbed; both straight and taper turning
may be performed on a work piece in one setting.
2. Once the taper is set, any length of a piece of work may be turned taper within its limit.
3. Very steep taper on a long work piece may be turned, which cannot be done on any other
method.
4. Accurate taper on large number of work pieces may be turned.
5. Internal tapers can be turned with ease.
By Compound Feed:
 Taper turning by manipulation of both feeds is inaccurate and requires skill on the part of the
operator.
 It is used for sharp tapers only.
1.7.4 Drilling:

 It is an operation of producing a cylindrical hole in a workpiece by the rotating cutting edge of

a cutter known as the drill.
 For this operation, the work is held in a suitable device, such as chuck or face plate, as usual,
and the drill is held in the sleeve or barrel of the tailstock. The drill is fed by hand by rotating
the handwheel of the tailstock.

21
1.7.5 Reaming:

 Reaming is the operation which usually follows the earlier operation of drilling and boring in
case of those holes in which a very high grade of surface finish and dimensional accuracy is
needed.
 The tool used is called the reamer, which has multiple cutting edges. The reamer is is held on
the tailstock spindle, either direct or through a drill chuck and is held stationary while the
work is revolved at very slow speed. The feed varies from 0.5 to 2 mm per revolution.
 For reaming tapered holes, taper reamers are used.
1.7.6 Boring:

 It is the operation of enlarging and turning a hole produced by drilling, punching, casting or
forging.
 In this operation, as shown in Figure, a boring tool or a bit mounted on a rigid bar is held in
the tool post and fed into the work by hand or power in the similar way as for turning.
 Boring cannot originate a hole.
1.7.7 Undercutting/grooving:
 It is the process of reducing the diameter of a
workpiece over a very narrow surface. It is often done
at the end of a thread or adjacent to a shoulder to leave
a small margin.
 The work is revolved at half the speed of turning and a
grooving tool of required shape is fed straight into the
work by rotating the cross-slide screw.
1.7.8 Threading:
 Threading is an operation of cutting helical grooves on
the external cylindrical surface of the workpiece.
 In this operation, as shown in Fig.9.21, the work is held in
a chuck or between centres 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.

22
1.7.9 Knurling:

 It is an operation of embossing a diamond shaped pattern on the surface of a workpiece.

 The purpose of knurling is to provide an effective gripping surface on a workpiece to prevent
it from slipping when operated by hand.
 The operation is performed by a special knurling tool which consists of 1 set of hardened steel
rollers in a holder with the teeth cut on their surface in a definite pattern. The tool is held
rigidly on the tool post and the rollers are pressed against the revolving workpiece to squeeze
the metal against the multiple cutting edges, producing depressions in a regular pattern on the
surface of the workpiece.
 Knurling is done at the slowest speed available in a lathe. Usually the speed is reduced to ¼th
of that of turning, and plenty of oil is flowed on the tool and workpiece.
1.7.10 Forming:
 It is an operation of turning a convex, concave or any irregular shape.
 Form-turning may be accomplished by the following methods: (i) Using a forming tool, (ii)
Combining cross and longitudinal feed, (iii) Tracing or copying a template.

1.8 Speed, Feed and Depth of Cut

 Cutting speed of the tool is directly proportional to the Surface or Peripheral speed of the
work.
 It is the distance travelled per minute by a point on the circumference of the work in a
direction parallel to the direction of the feed of the tool. It is expressed in meters per minute
and is given by the formula.

Where V= Cutting speed in meters per minute

D= Diameter of the work surface in mm.
and N= Speed of the work in rpm.
 The Cutting speed to be employed for a particular work depends upon a number of factors.

23
 The main factors which influence the selection of a proper cutting speed are the following:
 Material of the cutting tool.  Shape of the tool.
 Hardness and machinability of the metal to be
 Depth of cut.
machined.
 Quality of heat treatment, if it is a H.S.S. steel tool.  Feed to be given to the tool.
 Whether machining is to be done with or without the use
 Rigidly of the machine.
of a coolant.
 Rigidly of the tool and the work.
Feed of the tool, which denotes the advancement of the tool for each revolution of the work. The
tool can be moved in three directions with respect to the axis of the work and the corresponding
feeds are named after these directions of the tool movement as described below.
1. Longitudinal Feed: Tool moves parallel to the axis of the work; such as in Plain turning, Step
turning, Threading, etc.
2. Cross Feed: Tool moves normal to the axis of the work; such as in Facing, Undercutting,
Parting off, etc.
3. Angular Feed: Tool moves at an inclination to the axis of the work; such as in Taper turning.
 When a job is turned on lathe, a certain amount of material is removed continuously by the
tool, in a cut, in the form of chips.
 The total thickness of the material to be removed depends upon the amount of machining
allowance provided on the job and the final dimensions required.
 Thickness of the metal removed in a cut by the tool is known as Depth of cut. In other words,
‘depth of cut’ as the distance, measured normal to the work axis, by which the point of the
tool penetrates into the job surface in a cut. It will, obviously, be equal to half the difference of
two diameters of the job. It will be expressed thus :

1.9 Estimating Machine Time

The Total Time required in completing a job by machining will include many factors-such
as actual time taken in machining (cutting time), time required in setting of job, time required in
setting of tool or tools and Handling time, etc. The method of computing the actual machining or
cutting time is given below.
Suppose the work is to be turned through a length of 1 mm,
l1 = Distance required for feeding the tool cross-wise, to increase the depth of cut, in mm
l2 = Over travel of the tool in mm at the end of each cut.
t = Depth of cut in mm. f1 = Feed in mm per revolution.
N = Speed in rpm of the work.
n = Total number of cuts taken for obtaining the required diameter or the number of passes.
L1 = Total distance, in mm that the tool travels in the direction of the feed.
Now, the Distance travelled by the tool in the direction of the feed in a single cut,
= l+l1+l2 = L (say)
Therefore, the total distance L1 is given by : L1 = L×n mm
Also the amount of feed (f) per minute will be given by f = f1×N mm
The time T, in minutes, required for the tool to move through the complete length L 1 mm will be
computed by the formula:

24
1.10 Capstan and Turret Lathes
 Although centre/engine lathe is very useful and versatile yet it is not suitable for batch and
mass production since the time taken for changing and setting the tools and time required for
making measurements on the workpiece is quite large.
 Moreover, a skilled machinist is required to run to the centre lathe.
 This increased rate of production can be obtained by saving the time lost in changing and
setting of tools for new operations.
 In other words, we can say that if the required quantity of production of identical parts can be
obtained throught a single setting of tools the rate of production of these items will be quicker
and economical.
 The above rate can be further enhanced by the application of more than one tool
simultaneously.
 This demand of increased production is fulfilled by the use of Capstan and Turret lathes,
which provide both these facilities.
 That is, the complete job can be finished in a single setting of tools and more than one tool can
be employed simultaneously.
 When the operations are repeated several times with the same setting, the desired results are
easily obtained.
Difference between Turret Lathe and Centre Lathe:
S.No Aspects Turret lathe Centre lathe
Primarily used for
Adapted to quantity production
Nature of production miscellaneous jobbing, tool
1 work; classed as a production
work room or single operation
machine tool.
work.
Hexagonal turret tailstock),
upon which are bolted various
Constructional difference
2 tool holders for knew turning, It has a tailstock
(Turret head or tailstock)
roller box turning, drill and
recessing.
Can hold a number of cutting
No. of tools that can be tools at a time; the tools can
3 One tool cuts at a time.
handled at a time operate on the job
simultaneously.
Tools may be permanently set-
No such provision is
4 Set-up of tools up in the turret in the sequence
available in a centre lathe.
in which they need be used.
Provision of rigidity in
Extreme rigidity to permit No special provision
5 the holding of work and
multiple and combined cuts. available.
tools

Use of turret lathe can often

Consumes more time
Machining time and cut machining time by 25 to
6 comparatively.
handling time 75% and handling time by
25% to 50%.

25
 Thread cutting is generally Always provided on a
performed by tops and die centre lathe to enable
7 Lead screw
heads. Hence no lead screw is thread cutting by a single
provided for thread cutting. point tool.
8 Degree of automation Semi-automatic Very normal
9 Rate of production Higher Lower.
Lower, because after tools and
Higher, because of the
machine setting the operations
10 Labour cost requirement of highly
can be performed by unskilled
skilled workers.
or semi-skilled operators only.
Higher than the centre lathe
because of higher initial
11 Overhead charges investment, more consumption Lower comparatively.
of power and higher
maintenance cost.

1.11 Main Parts of a Turret or Capstan Lathe

The main operating parts of a Capstan and a Turret lathe are illustrated in block diagrams. The
former presents the front and the latter top view.

Main Parts of a Capstan Lathe

Main Parts of Turret Lathe

26
The main parts are:
 Headstock  Carriage or chaser saddle
 Turret saddle  Bed
 Legs

1. Headstock
 A turret or Capstan lathe carries a similar type of head stock as a centre lathe, but is
comparatively larger in size and heavier in construction in order to provide a wider range of
speeds (between 30 to 2000 rpm).
 The Headstock, as usual, carries a hollow spindle with screwed nose to accommodate the
chuck. Alternatively, the spindle may have a flange at its front for holding the chuck.
The following types of headstocks are commonly used :
(i) Cone pulley type
(ii) Direct motor driven headstock
(iii) All geared headstock
(iv) Preoptive type headstock.
 One of the chief characteristics of turret headstock is the provision for rapid stopping, starting
and speed changing in order that the maximum advantage is taken by the operator of the most
advantageous cutting speed for any job and at the same time to minimize the loss of time in
speed changing, stopping and starting.
2. Carriage or chaser saddle.
 It carries a cross-slide over it, on which are mounted two tool posts, one at the front and the
other at the rear.
 Both these tool posts are usually square tool posts in which each is capable of holding four
tools at a time. Tools in the rear tool post are mounted in an inverted position.
 Both hand and power feed can be employed to the saddle as well as the cross-slide, but the
common practice is to use hand feed for the cross-slide until and unless a very heavy job is to
be machined.
 When power feeds are in operation, stops and trip dogs are used for controlling the
longitudinal and cross feeds of the saddle and cross-slide respectively. These stops and trip
dogs make the power feed to disengage as soon as the required tool travel is complete.
The cross-slide carriage is of following two types;
(i) Reach over (or bridge) type: Its construction is more rigid and allows a second tool holder to
be mounted at the rear.
(ii) Slide hung type: This type of carriage is generally fitted with heavy duty turret lathe where the
saddle rides on the top and bottom guideways on the front of the lathe bed.
3. Turret saddle.
 It is mounted directly on the lathe bed on the same side as a tailstock in the centre lathe.
 The turret head mounted on the slide or the saddle, as the case may be, is usually hexagonal in
turret lathes and circular or hexagonal in capstan lathes, having six holes, one each on each
flat face or equi-spaced along the periphery of the circular head.
 The indexing of the tools is in a clockwise direction. After indexing, the automatic feed can be
engaged.

27
4. Bed. The bed is a box shaped gray iron casting with a system of well developed internal
stiffening ribs. The turret saddle and cros-slide travel along the ways on the top of the bed.
5. Legs. In each lathe there are two legs, one below each end of the bed. These legs are hollow
castings which bear entire load of the bed, of the sliding and stationary parts mounted over the
bed and also of the tooling and work holding devices or mechanisms.
1.12 Difference between Turret and Capstan Lathe:
Features of turret lathe that make it a quantity production machine:
1. Rigidity in holding work and tools is built into the machine to permit multiple and combined
cuts.
2. Tools may be set-up in the turret in the proper sequence for the operation.
3. Each station is provided with a feed stop of feed trip so that each cut of a tool is the same as
its previous cut.
4. Multiple cuts can be take from the same station at the same time, such as two or more turning
and/or boring cuts.
5. Combined cuts can be made; that is, tools on the cross slide can be used at the same time that
tools on the turret are cutting.
6. Turret lathes may be fitted with attachments for taper turning, thread chasing, and
dupulicating, and can be tape controlled.
A capstan lathe is a lathe designed to use a number of cutting tools mounted in a rotating turret
or capstan and arranged to perform turning operations successively.
 This machine is similar both in appearance and operation to a turret lathe, but is used on
smaller work.

Mounting the Capstan Head Mounting the Turret Head

S.No Aspects Turret lathe Capstan lathe

Turret is mounted on an auxiliary
Turret (head) is mounted
1 Turret position slide, which moves on the guide
directly on the saddle.
ways provided on the saddle.
The saddle is fixed at a convenient
For feeding the tools entire
2 Feeding of tools distance from the work and the
saddle is moved.
tools are fed by moving the slide.

28
 Because of the overhung of the
Very high rigidity because
slide or ram, the tool support unit
3 Extent of rigidity all the cutting forces are
is subjected to bending and
transferred to the lathe bed.
deflection, resulting in vibrations.
Can handle heavier jobs (as Since this type of lathe cannot
a consequence of No.3) withstand heavy cutting loads,
Capability to handle
4 involving heavy cutting therefore its use is confined to
jobs
forces and severe cutting relatively lighter and smaller jobs
conditions and precision work.
Maximum bar size
5 Upto 200 mm diameter Upto 60 mm diameter.
that can be handled
Almost full length of the
Limited tool travel (since the tool
bed (since the turret saddle
6 Tool travel feeding is done by the traverse of
directly rides over the bed
the slide).
way).
Relatively slower and as The tool traverse is faster and
7 Rate of tool feeding such provides more fatigue offers less fatigue to the operator’s
to the operator’s hands. hands.
Usually equipped with the reach-
over type only since it is employed
for relatively smaller jobs and
Reach-over type or side
8 Type of carriage therefore, does not require a large
hung type.
owing over bed; moreover this
type of carriage provides better
rigidity.
 Heavier designs are
usually provided with
pneumatic or hydraulic
chucks to ensure a
firmer grip over heavy
jobs These lathes do not have such
9 Other provisions
 Provision for cross provisions.
feeding of the
hexagonal turret (in
some designs) to enable
cross feeding of turret
head tools.

1.13 Types of Turret Lathes

Turret lathes may be classified as follows:
1. Horizontal turret lathe
(i) Ram type
(ii) Saddle type
2. Vertical turret lathes
3. Numerically-Controlled (NC) turret lathes.

29
1. Horizontal turret lathe. These lathes are made in two general designs and are known as ram
and saddle.
(i) Ram-type turret lathe :
 It is so named because of the way the turret is
mounted.
 The turret is placed on a slide or ram, which moves
back and forth on a saddle clamped to the lathe bed.
 This arrangement permits quick movement of the
turret.
 Speeds may be from 50 to 1000 r.p.m. depending on
the size of lathe.
 Larger lathes have lower speeds of the turret at any
predetermined point.
 Ram type machines do not require the rigidity of
chucking machines, because bar tools can be made
to support the work.
 It is recommended for bar and light-duty chucking
work.
(ii) Saddle-type turret lathe:
 Here the turret is mounted directly on a saddle that
moves back and forth with the turret.
 Since chucking tools overhang and are unconnected
with the work through some sort of support; greater
strain on both work and tool support results.
Chucking tools must have rigidity.
 The stroke is longer, which is an advantage in long
turning and boring cuts, and saddle mounts assist the
rigidity.
 Speed may be from 20 to 1500 rpm depending upon
the size of the machine.
 It is used for chucking work.
2. Vertical turret lathe:
 Vertical turret lathe resembles vertical boring mill,
but it has the characteristic turret arrangement for
holding the tools.
 It consists of a rotating chuck or table in the
horizontal position with the turret mounted above on
a cross rail.
 In addition, there is at least one side head provided
with a square turret for holding tools.
 All tools mounted on the turret or side head have
their respective stops set so that the length of cuts
can be the same in successive machining cycles.
 A Vertical lathe, shown in figure, is provided with two curter heads: The swiveling main
turret head and the side head. The turret and side heads function in the same manner as the
hexagonal and square turrets on a horizontal lathe.

30
 To provide for angle cuts both the ram and turret heads may be swiveled 30° right or left of
centre.
 It consists of a rotating chuck or table in the horizontal position with the turret mounted above
on a cross rail. In addition, there is at least one side head provided with a square turret for
holding tools.
 All tools mounted on the turret or side head have their respective stops set so that the length of
cuts can be the same in successive machining cycles.
 A Vertical lathe, shown in Fig.9.43, is provided with two curter heads: The swiveling main
turret head and the side head. Another side head is possible. The turret and side heads function
in the same manner as the hexagonal and square turrets on a horizontal lathe.
 To provide for angle cuts both the ram and turret heads may be swiveled 30° right or left of
centre.
 The side head has rapid traverse and feed independent of the turret and, without interference,
provides for simultaneous machining adjacent to operations performed by the turret.
 The ram provides another tool station on the machine, which can be operated separately or in
conjunction with the other two.
 Vertical lathes are utilised solely for complex chucking work, particularly for boring
operations, and are not adapted to bar work.
3. Numerically-controlled (NC) turret lathes. A numerically-controlled lathe is designed
especially for heavy-duty production. Such lathes are now available in considerable variety
and have proven to be for more productive than manually operated machines.
1.14 Size and Specifications of Turret Lathe
The size of a turret lathe can be specified by:
1. Miximum diameter of the bar tht can be passed through the machine spindle.
2. Swing diameter of the workpiece.
3. Spindle speeds
4. Feeds.
5. Chuck size.
6. Capacity of the drive motor.
7. Cost etc.
Specifications of capstan lathe:
- Either, the total length of the bed, and height of the spindle centre above the bed. Or
- The working length of bed, and the swing.
1.15 Common Tools and Attachments Used on Turret and Capstan Lathes
A large number of Tools and Attachments are used interchangeably on common Turret
and Capstan lathes. However, there are some attachments which are exclusively used on Turret
lathes only.
The tools which are common to both the Turret as well as Capstan lathe are the following:
 Work stops or Bar stops  Centring and chamfering tools
 Drill and feamer holders  Turning tools
 Tap and die holders  Box tools
 Boring tools  Reaming tools
 Knurling tools  Centres and supports
 Attachments used on cross-slide 

31
Work Stops or Bar Stops

 When mass production of identical parts is to be carried out, it is necessary that the same
length of the bar stock should project outside the Chuck each time it is pushed forward.
 Obviously, it will not only be a difficult job to adjust the required length every time, through
actual measurement, but simultaneously a lot of time will also be wasted on account of the
same.
 To prevent this wastage the Work Stops are used which enable the setting of same length of
bar in the beginning of the operations for each new job.
 The Bar stop is mounted on the Turret head in the same way as other tools and is normally the
first tool to come into the operating position.
The different forms of stops are:
 Plain Stop
 Adjustable Stop
 Micrometer Stop
Centering and Chamfering Tools
 A large variety of centering tools is in commercial use.
 The simplest form is a Flat centering tool, which consists of a solid Shank provided with a flat
Drill as its front.
 The shank is held in a Bush fitted in the hole of the Turret or Capstan head and, when fed
forward, gives a true centre.
 A more sensitive type of Centring tool is the Roller steady Centring tool, shown in Figure.
 It consists of the main Body having the shank at its back. On its front are fitted three
adjustable Roller steadies, as shown.
 It can be employed for jobs of different diameters as the rollers can be easily adjusted at the
desired positions.
 During the operation the rollers act as steady supports to keep the job concentric with the lathe
spindle and the centring tool, provided at the centre, is then fed against the job face.
 It is chiefly employed on those machines which run at very high speeds.

32
 Another useful form of such a tool is the Combined Bar Stop and Centring Tool shown in
Figure. It consists of a cast body having the shank at its rear and carrying an adjustable drill at
its centre.
 This drill can be operated by the Lever, shown in the diagram. The flat portion, hinged at the
top, is used as a stop.
 In operation, the drill is withdrawn by means of the lever and the stop brought in position.
After the use of stop is over, it is swung out of position and the centring drill fed forward by
means of the lever.
 This tool, thus, serves a dual purpose and is reckoned as a very important attachment of these
machines.
 There are some other useful forms of Centring tools in which a single tool can perform both
the centring and facing operations.
 Out of various designs available the most popular is the Double Cutter type centring and
facing tool, shown in Figure.
 It carries two cutters and a flat drill at its front, as shown.
 They can be adjusted as desired. In operation, first the centre hole is drilled on the job face,
followed by facing by the two cutters.

 A common form of tool used for Chamfering the ends of bars is shown if Figure. It consists of
a cast Body, fitted with a conical bush and a cutter, as shown.
 The bar end, as the tool advances, is supported on the tapered inside surface of the bush
enabling the application of heavy feeds.

Chamfering Tool
Drill and Reamer Holders
 Various types of Drill and Reamer Holders are employed in Turret and Capstan lathe work.
 The simplest form, known as Plain drill holder consists of a hollow cylindrical body and a
shank at the rear.

33
 Drill or Reamer is fitted in the hollow portion and tightened by means of a set screw provided
on the Holder.
 The Floating holder is made in two pieces so as to enable slight adjustment in the drill or
reamer position to make it concentric with the work.

Self-Centring Drill Chuck

 An improved and easily operated type is the Self-centring Drill Chuck.
 It automatically brings the drill or reamer in required alignment with the work and ensures a
firm grip.
 A typical design of this is shown in Figure.
Turning Tools

 The most commonly used Turning Tool is the Knee type Tool.
 It can be employed with equal advantage for bar work as well as individual items like
Castings and Forgings.
 The plain type of knee tool has its use confined to small machines only.
 The popular design is the Adjustable Type, shown in Figure.
 It consists of a vertical Body, provided with the shank at its rear.
 A vertical slot is provided in the body, along which the tool can be adjusted in a vertical
direction at any desired height. The Turning tool is fitted in a vertical direction.

Knee Tool Holder with Micrometer adjustment

34
 The latest development in the design of knee tool holders is the provision of Micrometer
adjustment.
 In this, a vertical screwed spindle is fitted in the corresponding tapped hole in the body of the
holder. This spindle carries a graduated disc at its top and a collar just below that.
 A corresponding groove is made in the body of the cutting tool to accommodate the collar, as
shown in Figure.
 A datum mark is provided on the top of the tool. With the help of this mark and the
graduations on the disc the height of the tool can be adjusted just mechanically, calling for no
appreciable amount of skill on the part of the operator.
 This enables a positive control of the tool height and therefore the job can be easily turned to
close limits. Adjustments up to 0.01mm can easily be made.
Tap and Die Holders
 Different designs of Tap and Die Holders are available commercially.
 The sensitive Tap holder, used for holding small Taps up to 8mm diameter, consists of a
shank, as usual, and a Revolving head.
 The head carries graduations and the shank a corresponding datum marks to indicate the depth
to which the Tap has been fed during the operation.
 While Tapping, the Head is held firmly in hand and released as soon as the required depth of
the hole has been tapped. The Head, together with the Apt, revolves along with the job.
 The spindle is then revolved in a reverse direction and the Head held in hand, as usual, to
withdraw the Tap.
 For larger taps, the self-releasing type of Tap Holder is used, which facilitates an automatic
engagement and disengagement of the Head with the shank at the appropriate time.

 Just as case of Tap holders, the Self-opening type of Die Heads (shown in Figure) are
preferred over the Solid non-adjustable type.
 It is obviously a very useful and commonly used attachment for cutting external threads on
jobs.
 The Die head accommodates the dies which can be adjusted by means of the screws.
 The shank is fitted in the turret or capstan head and fed onto the job.
 When the required thread length is obtained, further feeding of the head is stopped and the
dies open out automatically, to be clear of the job. The Head is then withdrawn in the usual
manner.

35
Box Tools
 The first operation to be performed in a capstan or turret lathe engaged in bar work is to turn
different diameters of the work from the end of the workpiece.
 A box tool fitted on the turret face is employed for this purpose.
 As the tool, mounted on the tool holder, is fed into the work from the unsupported end, some
sort of support is supplied by the holder on to the work to prevent any deflection or vibration
set up by the heavy cutting action of the tool.
 The holders containing the tool and the support practically enclose the work as the metal
cutting progresses.
 Hence this class of tool holders is named as box tool holders and the tools as box tools.

Balanced tool holder:

 Its name is derived from the fact that the tools mounted on the holder are so arranged that the
cutting thrust exerted by one the tools on the work is balanced by the cutting thrust developed
by the other tool fitted on the holder.
 This prevents any bending of the work and obviates the use of any other work support.
 The tools may be set radially or tangentially at the opposite ends of the work, the position of
one being slightly advanced than the other along the axial-length.
 Both the tools may take full depth of cut and the depth of cut may be divided.
 Figure illustrates a balanced tool holder.
V-Steady tool holder:

36
 The V-steady box tool holders are used for lending support to the workpiece while cutting
action progresses from the end of a bar stock.
 Both the tool and V-steady are mounted on the adjustable slide in order to set the required
diameter of the machines part and to position the tool relative to the V-steady.
 The tool is set slightly in advance than the V-steady. The two faces of the V-steady are so
arranged that the top face is parallel to the shank and the bottom face is perpendicular to the
tool axis allowing it to take both the up and side thrust of the tool.
 The steady block is provided with another size of V on the other end and the block may be
reversed for supporting different diameter of work.
 The V-steady tool holder is mainly used in brass work. Figure illustrates a V-steady tool
holder.
Roller steady box tool holder:

 This type of tool holder illustrated in figure, is commonly used in bar work for turning steel
rods.
 In construction, it replaces V-steady and in its place two rollers are used to provide support to
the work. The tool may be mounted radial or tangential to the workpiece.
Bar ending tool holder:

 These holders are used for finishing the ends of bolts, pins, rods, etc. the rollers are set slightly
in advance to the tool cutting edge, which centre the work and take up cutting pressure.
 Different types of tools are fitted on the holder for shaping different types of bar ends. The
box tool may be adjustable or of one unit type. Figure illustrates a bar ending tool holder.

37
Reaming Tools
 Machine Reamers used on Centre lathe work can be employed on Turret and Capstan lathes
also, but a more useful form is the Collapsible Reamer which gives an excellent surface finish
and is easy in operation.
 Usually this tool consists of a cylindrical body fitted with two diametrically opposite, floating
type, Reamer Blades.
 These blades can be made to collapse by means of rotating a collar provided on the body,
immediately after the operation is over, and the tool becomes free of the internal surface of the
job while returning back.
 This prevents the scoring of the job surface by the tool and, thus, results in a fine surface
finish.
Knurling Tool:

 Knurling tools used on Turret and Capstan lathes are available in various designs.
 They are held either in Turret or Capstan head or in the Tool post on Cross-slide.
 Adjustable type knurling tools are commonly employed. The most useful, and easy to operate,
tool is the Concentric knurling tool.
 In construction and operation, it is similar to a Self-opening Die head and carries three knurls
instead of the jaws of die-head.
 All the three knurls can be adjusted radially by means of the Hand lever and they always
remain equidistant from the centre of the circular head.
 This adjustment enables the application of the same tool on various different diameters.
1.16 Job Holding Devices
 The common devices used for holding the jobs on Turret and Capstan lathes are chucks,
Arbors, Colletx and specially designed Fixtures.
 The Chucks used on these lathes may have three or two jaws and may be operated either
mechanically or by air or hydraulic pressure.
 Electrically operated Magnetic chucks are also employed.
 All these chucks provide an automatic true centering for the job and ensure enough rigidity.
Also, they are quick and easy in operation.
A Collect Chuck
 The mechanism of a Collet Chuck is shown in Figure. It can be used with equal advantage of a
Centre lathe, Capstan lathe or Turret lathe for producing items from bar stock.

38
 It consists of the main Body having a tapered inside surface which corresponds to the outside
tapered surface of the Collet.
 A disc is incorporated in the chuck which carries inside threads to receive the rear threaded
end of the collet.
 On the outside surface of this disc, teeth are cut to form a Bevel wheel which meshed with the
Bevel pinion, operated by hand by means of a key.
 Usually an Adaptor bush is fitted to the rear side of the chuck, which carries internal threads.
The assembly is then screwed on to the nose of the Lathe spindle.
 In operation, when the key is rotated the
disc rotates and, in doing so, it either draws
in or pushes out the collet, depending upon
the direction of its rotation when the collet
is drawn in its splitted body is pressed
against the tapered inside surface of the
chuck, making a firm grip over the bar.
 Against this, when the collet is pushed out
the pressure on its body is relieved and it
opens out releasing the grip on the bar
which can be then fed forward.
Collets
Several designs of Collets are available commercially, but their main classifications are:
1. Draw in type: Which exerts the grip over the bar when it is drawn in.
2. Push out type: Which exerts the grip over the bar when it is pushed outwards.
Depending upon the above two types the direction of taper on the surface of the collets will differ.
The former type will have the taper from the front towards the rear and vice versa.
1.17 Turret Tooling Lay Out
In order to perform any work in a capstan or turret lathe, proper planning for systematic
operations should be carried out in advance before setting the work on the lathe. The following
procedures should be adopted to plan and execute a work.
1. For effective planning and control, for each capstan or turret lathe, an upto-date capacity chart
is an essential requirement. The chart supplied by the manufacturers contains every working
details of the machine such as the maximum and minimum diameter of the work that can be
mounted, maximum length of stroke of the turret and saddle, maximum length of cross-slide
movement, tools available, swing diameter over the carriage, bore diameter on the turret face,
bore diameter of the spindle, and the maximum size of the collet chuck that can be mounted on
the machine, number of spindle speeds and feeds available, h.p. input, etc.
2. For tooling layout, a drawing of the finished part is also needed.
3. The proper tool selection for different operations should be made from the available tools and
tool holders. Standard tools are preferred for a small number of works. Where large number of
identical pieces are to be manufactured, special tools and tool-holders may be designed for
reducing setting and machining time.
4. Once the proper tool selection is made, the finished drawing of the workpiece is superimposed
on the capacity chart supplied and the tools to be used are drawn out at the respective positions
on the turret face and on the cross-slide tool posts in a regular sequence. The length of travel of

39
tools for each turret face is now calculated from the chart and position of stops decided. Any
difficulty in setting and operation is worked out on the paper.
5. The proper spindle speed, feed and depth of the cut are now worked out for each operation.
6. The work and the tools are then set on the machine according to the planned chart.
The planning production of a hexagonal bolt is given below:

1. The capacity chart of the machine is made available.

2. The drawing of the finished hexagonal bolt is taken into consideration. (see Figure)
3. The tools and equipment such as bar stop, roller steady turning tool holder, roller steady bar
ending tool holder, self opening die head, chamfering tool, parting tool are collected.
4. The sketch of the work and tools are superimposed on the capacity chart to decide the length of
travel of the tool and the position of stops.
5. Proper speeds and feeds for each operation are next calculated.
6. Setting and machining operations are performed in the following order:
(a) Setting of the bar stops: The bar stop is set at a distance of 70mm from the collet face by
using a slip gauge. An extra length of 10mm than the bolt length is allowed, 4mm for parting off
and 6mm for clearance off the collet face so that the parting off tool may penetrate deep into the
work without any interference (See Figure)

40
(b) Setting of the roller steady box turning tool: The roller steady box turning tool is set on
the next turret face for turning a diameter of 16mm. The stop for turning the tool is set 20mm
from the colt face by a slip guage. The rollers are set slightly behind the cutting edges,
approximately 1.5mm. (See Figure)

(c) Setting of bar ending tool: The bar ending tool is set on the next turret face and is brought
into operation after turning the bar. The stop is adjusted in the position by using a slip gauge (See
Figure)

(d) Setting of self opening die head: The self opening die head is mounted on the next face of
the turret and the dies are fitted into it to cut a thread of 16mm diameter. The stop is adjusted in a
position keeping in view the pulling out length of the die head for self releasing. (See Figure)

41
(e) Setting of chamfering tool: the chamfering tool is mounted on the four station turret on
the cross-slide and the extreme longitudinal position of the saddle is adjusted by a stop. The cross
feed movement of the cross-slide is adjusted by a stop (See Figure)

(f) Setting of parting off tool: The parting off tool is set on the rear tool post on the cross-slide
and the longitudinal position of the parting off tool is adjusted by the stop set at a distance of 6mm
from the turret face (See Figure)

1.18 Automatic Lathes

 Automatic lathes are machine tools in which the components are machined automatically.
 The working cycle is fully automatic that is repeated to produce duplicate parts without
participation of the operator.
 All the working and idle operations are performed in a definite sequence by the control system
adopted in the automatic which is set up to suit a given work.
 Strictly speaking the machine is not fully automatic since operator is required to load the
machine for a batch of parts and start each cycle.

42
 These machines are used when production requirements are too high for turret lathes to
produce economically.
 Their use results in the following advantages:
1. Greater production over a given period.
2. More economy in floor space.
3. More consistently accurate work than turrets.
4. More constant flow of production.
5. Scrap loss is reduced by eliminating operator error.
6. During the automatic machining operation, the operator is free to operate another
machine or inspect the completed parts.
Semi automatics. Semi-automatic machines are usually turning machines adapted to chuck work.
In these machines, although the movements of workpiece or tools are automatically controlled,
but the workpiece has to be loaded into and removed from the chuck at the beginning and end of
each cycle of operations. The machining cycle is automated, but the direct participation of the
operator is required to start each subsequent cycle, i.e., to machine each subsequent workpiece.
Automatics and semi-automatics are chiefly designed to perform the following machining
operation: centring, cylindrical turning, tapered and formed surfaces, drilling, boring, reaming,
spot facing, knurling, cutting threads, facing milling, broaching, grinding and cut off. Additional
operations such as slotting and cross drilling etc. can also be performed on these machines with
the help of special attachments.
1.19 Classification of Automatic Machines
These are various ways to classifying the automatic lathes, depending upon the type of work
machined, these machines are classified as:
1. Magzine loaded Automatics: These machines are used for producing components from accurate
separate blanks. These machines are also called ‘Automatic chucking machines’.
2. Automatic bar Machines: Automatic bar machines are designed for machining components
from bar or pipe stock. These machines are chiefly used for the manufacture of high quality
fasteners (screws, nuts and studs), bushings, shafts, rings, rollers, handled and other parts, usually
made of bar or pipe stock, and recently of separate blanks as well.
Depending upon the number of work spindles, the automatic lathes can be classified as:
Single spindle automatics and Mutispindle automatics.
Automatics can also be classified according to: purpose and arrangement of the spindle.
According to purpose, automatics are classified into: general and single purpose machines.
According to the arrangement of the spindle, automatics are classified into horizontal and vertical
machines.
Automaticity:
In automatic machines, the automaticity is achieved by mechanical means using cam drives. The
operating cycle is automatically controlled with the help of a camshaft carrying cams which are
linked to the operative mechanisms (slides, feeding and clamping mechanisms) through a system
of levers gears etc,. When the camshaft rotates, the cams actuate the various operative units. In the
figure shown aAccording to their forms the cams are classified as plate cams and cylinder cams.
In accordance with their cycle control, the automatics may be grouped into three categories:

43
1. In the first category, automatics have a single camshaft which rotates at a constant speed or the
given set up and which controls both working and idle motions. The speed of the camshaft
corresponds to slow working motion and since the idle motions should be completed a shortest
possible time, considerable time will be wasted for these motions for the machines of this
category, however, due to its simplicity, this category is justified for small automatics with only
few idle motions.
2. Automatics of the second category have also only one camshaft but is has two speeds of
rotation : slow of working motions and fast for idle motions. However, the camshaft has quite a
large moments of inertia (due to whole set of working and ilde cams) and due to this, the
changeover mechanisms will experience impact loads when switching over from one speed to the
other. Thus, it is rather impossible to obtain any significant difference between the two speeds of
rotation.
3. The third group of automatics have one camshaft for working motion which rotates at slow
speed and a high speed auxiliary camshaft for actuating the idle motions. This group finds
applications for machining complex shaped work-pieces where many auxiliary motions are
required.
Automaticity can also be obtained by Hydraulic, Pneumatic, Electric and combined
systems and also by punch tapes, punched cards, magnetic tapes or by a drum.
1.19 Types of Single Spindle Automatics:
1. Automatic cutting off machines.

These machines produce short workpieces of simple form by means of cross-sliding tools. The
machines are simple in design. The head stock with the spindle is mounted on the bed. Two cross
slides are located on the bed at the front end of the spindle. Cams on a camshaft actuate the
movements of the cross-slides through a system of levers.

44
The principle of operation of such a machine is explained below with the help of Figure. The
required length of work (stock) is fed out with a cam mechanism, upto the stock stop which is
automatically advanced in line with the spindle axis, at the end of each cycle. The stock is held in
the collect chuck of the rotating spindle. The machining is done by tools held in slides operating
only in the cross-wise direction. Special attachments can be employed if holes or threads are
required on the simple parts.
2. Single Spindle Automatic Screw Machine

This machine was originally used for producing small screws, but has long since graduated to the
production of all sorts of small turned parts. These machines are essentially wholly automatic bar
type turret lathes. They differ from the horizontal turret lathe in that the turret revolves about a
horizontal pivot pin instead of about a vertical axis. They are designed for machining complex
internal and external surface on parts made of bar stock or of separate blanks. Upto ten different
cutting tools may be employed at one time in the tooling of such a screw machine. The tools are
fixed in indexing turret and in cross-slides. The turret carries six tools. Two cross-slides (front and
rear) are employed for cross-feeding tools. A vertical slide for parting off operation may aso be
provided. I t is installed above the work spindle. The head stock is stationary and houses the
spindle which rotates in either direction . the bar stock is held in a collet chuck and advanced by a
feed finger after each piece is finished and cut off. All movements of the machine units are
actuated by cams mounted on the camshaft. These machines are made in several sizes for bar
work from 12.7mm to 60mm diameter.
3. Swiss type Automatic Screw Machine.

45
 The machine is also known as ‘Sliding head screw machine’ or movable headstock machine’
because the head stock is movable and the tools are fixed.
 These machines are used for machining long accurate parts of small diameter (2to25mm).
 The stock is held by a rotating collect in the head stock and all longitudinal feeds are obtained
by a cam which moves the head stock as a unit.
 The rotating bar stock is fed through a hard bushing in the centre of the tool head.
 The tool head which consists of five single point tools is placed radially around the bushing.
 Most diameters turning is done by two horizontal tool slides while the other three slides are
used principally for such operations as knurling, chamfering, recessing and cutting off.
 The tools are controlled and positioned by cams that bring the tools in as needed to turn, face,
form, and cut off the work-piece from the bar as it emerges from the bushing.
 The cutting action is confined close to the support bushing reducing the overhand to a
minimum. As a result, the work can be machined to very close limits.
 Tolerances of 0.005 to 0.00125 mm are common.
 The machine does step, straight, taper, back, and form cutting. With special attachments,
centering, drilling and reaming operations can also be performed.
 Tools are simple and adjustments easy. All tools can work at once and a piece is finished in
one pass, making the time short for most work.
1.20 Multi Spindle Automatic Machines
 The multi-spindle automatic machines are the fastest type of production machines and are
made in a variety of models with two, four, five, six or eight spindles.
 In contrast to the single spindle machine, where one turret face a t time a working on one
spindle, the multi-spindle machine has all turret faces working on all spindles at the same
time.
 Their production capacity is higher than that of sindle-spindle machines but their machining
accuracy is somewhat lower.
 The rate of production of a multi-spindle machine, however, is less than that of the
corresponding number of single-spindle machines.
 For example, the production capacity of a four spindle machine is not four times only 2½ to 3
times more than that of a single-spindle machine.
1.21 Types of Multi-Spindle Automatic Machines
The multi-spindle automatic machine may be classified in various ways. In accordance with the
type of blank used, these may be classified as :
1. Bar type Machine: The bar type machine operates on bar stock, usually round, but be
hexagonal or any suitable shape. B ar type machines are rated by the largest diameter of stock that
can be fed through the spindles. The size of round bars ranges from about 14.3mm to 19mm
diameter.
2. Magazine-loading type or Chucking-type Machine: The chucking machine identical to bar
type machine and operates in the same manner but handles several individual work-pieces, such
as castings or forgings held in several chucks. The capacity of this machine is the diameter of the
work that can be swing over the tool slides. The common sizes are upto about 250mm diameter.
In accordance with their principles of operation, the multi-spindle automatic machines may be
classified as : (i) Parallel action automatics, and
(ii) Progressive action automatics.

46
(i) Parallel action multi-spindle automatics

 Parallel action multi-spindle automatic machine is also called as ‘multiple-flow’ machine. In

this type of machine, the same operation is performed on each spindle and a work-piece is
finished in each spindle in one working cycle.
 Means that the number of components being machines simultaneously is equal to the number
spindles in the machine.
 The rate of production is thus very high, but the machine can be employed to machine simple
parts only since all the processes are done at one position.
(ii) Progressive-action multi-spindle Automatics

 In this design of multi-spindle automatic machine, the workpiece is machined in states and
progressively in station after station.
 The head stock is mounted at the left end of the base of the machine.
 It contains a spindle carrier which rotates about a horizontal axis through the centre of the
machine.
 The working spindle is mounted on this spindle carrier.
 The spindles carry the collets and bars from which the workpieces are machined.
 The bar stock is fed through each spindle from the rear.
 On the face of the spindle-carrier support are mounted cross-slides which carry tools for
operations such as cut off.

47
 Assignment-Cum-Tutorial Questions
I)
1. What is the working principle of Lathe Machine?
2. Give any two specifications of Lathe Machine.
3. Give applications of Speed Lathe.
4. When do you use Production Lathes?
5. For holding cylindrical work pieces, which type of device is used?
6. What is the function of Tailstock.
7. What is the use of Compound slide?
8. What is the function of Apron?
9. Lathe Mandrels are used for______________
10. Define Taper.
11. Difference between Lead screw and Feed rod.
12. Use of Thread Chasers.
II)
1. Explain, with the help of a neat sketch, the principle of working in a lathe.
2. How is the size of a Lathe determined? Explain the term ‘Swing’.
3. What factors govern the Classification of Lathes? Describe in brief the various types of
Lathes.
4. Give a neat diagram of an Engine Lathe. Describe and mark its Main parts and Controls.
5. Write short notes on the following :
(a) 3-jaw chuck (b) 4-jaw Independent chuck, (c) Combination chuck
(d) Magnetic chuck (e) Air and hydraulic chucks, and (f) Collet chuck.
6. What is a Face Plate? Where will you prefer its use and why? Sketch and describe the
following: (a) Angle Plate, and (b) Lathe Dogs.
7. What are Mandrels and why are they used? Describe the construction and use of different
types of Mandrels.
8. What are the Steady and Follower Rests? Why are they used?
9. Describe the different type of the tool posts used on a lathe.
10. What Machining Operations can be performed on a Centre Lathe?
11. Describe various Taper Turning Processes used for production of Taper work on Lathes and
compare their relative merits.
12. Describe the Taper Turning Attachment of a Lathe. What are its merits and demerits over
other methods of Taper Turning?
13. Explain the procedure of cutting threads on lathe machine.
14. Compare the merits and demerits of Turret and Capstan lathes with an Engine lathe.
15. What are the main parts of Capstan and Turret lathes? Describe in brief with the help of
suitable illustrations.
16. Enumerate the difference between capstan and turret lathe.
17. Describe the attachments used on capstan and turret lathe machines.
18. What are the ‘Box tools’? Describe with sketch a Roller Steady Box Tool for Turning.
19. Describe, with the help of a neat sketch, the working of a collet chuck.
20. Give a broad classification of Automatic machines, mentioning their main features.
21. Describe single spindle automatic lathe machines with a sketch.
22. Explain the working of Progressive action Multi spindle automatic machines.

48
III)
1. The size of a lathe is expressed by
(A) Gross weight of lathe (B) Diameter of chuck
C) Maximum speed of chuck (D) Swing of lathe
(E) Height of centres from ground
2. Lathe bed is made of
(A) Mild steel (B) Cast steel
(C) Pig from (D) Close grain cast iron (E) Alloy steel.
3. The power is transmitted by lead screw to the carriage through
(A) Gear system (B) Pulley drive
(C) Rack and pinion a arrangement (D) Half nut (E) Chain drive.
4. A left hand tool on a lathe cuts most efficiently when
(A) It travels from left to right (B) It travels from right to left
(C) It travels across the bed (D) It is operated by compound slide
(E) Automatic feed is connected.
5. While using HSS tolls on a lathe, cutting speed will be maximum when machining
(A) Cast iron (B) Mild steel
(C) High carbon steel (D) high speed steel (E) Aluminium.
6. In which operation on a work piece on lathe the spindle speed will be least?
(A) Parting off (B) Finishing
(C) Taper turning (D) Thread cutting (E) Plain turning.
7. Steady rest is
(A) An additional support provided for long jobs (B) Used while turning unsymmetrical objects
(C) Used during thread cutting only (D) Used when a lathe is subject to vibrations.
(E) Used when a lathe is not provided with foundations.
8. Which one of the following methods be used for turning internal tapers only?
(A) Compound rest (B) Tailstock offset
(C) Taper attachment (D) Form tool (E) Reamer.
9. The taibstock set over for a job when (Figure)

D=30mm d=22mm L=255mm l=75mm would be

(A) 4mm (B) 8mm
(C) 12mm (D) 13.6mm (E) 24mm.
10. The tail stock set over in turning a taper of 1 in 12 in a piece of 84mm long would be
(A) 2.5mm (B) 3.5mm
C) 5mm (D) 7mm (E) 8.4mm
11. A mandrel is
(A) A slightly tapered hardened steel shaft that supports works which cannot be
supported otherwise.
(B) A tapered gauge used for inspection of tapered holes
(C) Auxiliary chuck used on lathe for holding small loads.
(D) Is used in lathe work to hold castings (E) None of the above.

49
12. In a centre lathe gear box for changing spindle speeds the provision for speeds is made in
(A) Arithmetical progression (B) Geometrical progressions
(C) Square progression (D) Cubical progression
(E) Random members.
13. While machining a brass casting on a lathe, the type of chuck used is
(A) Collect chuck (B) Magnetic chuck
(C) Face plate (D) Three jaw chuck
(E) Four jaw chuck
14. When large number of components are turned and parted off from a bar, the chuck used is
(A) Three jaw chuck (B) Four jaw chuck
(C) Face place (D) Collet chuck (E)Magnetic chuck.
15. Undercutting is
(A) An operation of cutting extra wide threads
(B) An operation of cutting a groove next to a shoulder on a piece of work.
(C) Cutting from the base of a work piece.
(D) An operation of cutting deep grooves.
(E) None of the above.
IV)
1. Calculate the angle at which the compound rest would be swiveled for cutting a taper on a
workpiece having a length of 180mm and outside diameter 90mm. The smallest diameter on
the tapered end of the rod should be 60mm and the required length of the tapered portion is
100mm.
2. A Lathe, having cone pulley drive, carries a 4-stepped Cone pulley. The diameters of the four
steps are 100mm, 140mm, 180mm and 220mm. The Pinions on the spindle and the Back gear
shaft each carry 20 teeth while the meshing gears carry 60 teeth each. If the machine Motor
drives the Countershaft at a speed of 300 r.p.m., calculate the different speeds which can be
obtained for the Lathe Spindle.
3. A taper pin of length 90mm has a taper length of 50mm. the larger diameter of taper is 95mm
and the smaller diameter is 85mm. Determine: (i) Taper in mm metre and in degrees. (ii)
The angle to which the compound rest should be set up. (iii) The tailstock setting over.
4. A workpiece of 300mm diameter and 600mm length is to be turned down to 282mm for the
entire length. The suggested feed is 1.2 mm/revolution and the cutting speed is 162 m/min. the
maximum allowable depth of cut is 4.5 mm.
Calculate the following :
i) Spindle r.p.m. ii) Feed speed. iii) Material removal rate. iv) Cutting time.
Assume tool over travel is 12.0 mm. neglect tool approach.
5. A component having length 120mm and diameter 10mm from a raw material of 120mm
length and 12mm diameter, using a cutting speed of 32m/min and a feed rate of 0.8 mm/rev.
how many times we have to re-sharpen or regrind if 800 workpieces are to be produced?
6. For turning a carbon steel cylinder bar of length 3.6m and diameter 0.24m at a feed rate of 0.7
mm/rev with a HSS tool, one of the two available cutting speeds is to be selected. These two
cutting speeds are 120 m/min and 68 m/min. the tool life corresponding to the speed of 120
/min is known to be 15 minutes with n=0.6. The cost of machining time, set-up time
unproductive time together is Rs.1.50/sec. The cost of one tool resharpening is Rs.25.

50