Module 2

Basic Machine Tools

Contents
• Introduction
• Lathe machine
• Classification of lathe machines
• Working Principle & Specification of lathe machines
• Machining Operations on lathe
• Shaper
• Principal parts of shaper
• Shaping operations
• Advantages and disadvantages
• Planer
• Principal parts of planer
• Difference between Shaper & Planer
• Slotter
• Principal parts of slotter
• Kinematics of slotter
• Slotting applications
General Purpose Machine Tools
1. General classification of machine tools

• Conventional or traditional machine tools like Lathes,

Milling machines, etc. are used more widely for faster
material removal by shearing or brittle fracturing.
• Non-conventional or non-traditional machine tools: like
EDM, ECM, USM, etc. which remove material from exotic
materials slowly by electro-physical, electro-chemical
processes.
• Modern numerical and computer controlled machine
tools: Like CNC lathe, CNC milling
General Purpose Machine Tools cont.….
The basic machine tools which are commonly used for general
purposes are:
1. Lathes
2. Shaping machines
3. Planning machines
4. Slotting machines
5. Boring machines
6. Drilling machines
7. Milling machines
8. Hobbing machines
9. Gear shaping machines
10. Broaching machines
11. Grinding machine
Classification Of Lathes
(a) According to configuration
• Horizontal -Most common for ergonomic conveniences
• Vertical - Occupies less floor space, only some large lathes are
of this type.

(b) According to purpose of use

• General purpose-Very versatile where almost all possible types
of operations are carried out on wide ranges of size, shape and
materials of jobs; example: center lathes
• Single purpose- Only one (occasionally two) type of operation
is done on limited ranges of size and material of jobs; example –
facing lathe, roll turning lathe etc.
• Special purpose- Where a definite number and type of
operations are done repeatedly over long time on a specific type
of blank; example: gear blank machining lathe etc.
Classification Of Lathes cont.…
(c) According to size or capacity
• Small (low duty) - In such light duty lathes (upto 1.1 kW),
only small and medium size jobs of generally soft and easily
machinable materials are machined

• Medium (medium duty) - These lathes of power nearly upto

11 kW are most versatile and commonly used

• Large (heavy duty)

• Mini or micro lathe - These are tiny table-top lathes used for
extremely small size jobs and precision work; example : swiss
type automatic lathe

.
(d) According to degree of automation
• Non-automatic - Almost all the handling operations are done
manually; example: centre lathes

• Semi-automatic - Nearly half of the handling operations,

irrespective of the processing operations, are done
automatically and rest manually; example: capstan lathe,
turret lathe, copying lathe relieving lathe etc.

• Automatic - Almost all the handling operations (and

obviously all the processing operations) are done
automatically; example – single spindle automat (automatic
lathe), swiss type automatic lathe, etc.
Parts of lathe machine
Headstock- The headstock is usually located on the left side of the
lathe and is equipped with gears, spindles, chucks, gear speed control
levers, and feed controllers.

Tailstock- Usually located on the right side of the lathe, the work
piece is supported at the end. Also used to perform the few operations
like: drilling, reaming etc.
Bed- The main parts of the lathe, all parts are bolted to the bed. It
includes the headstock, tailstock, carriage rails and other parts. Made
of Cast Iron.

Carriage- The carriage is located between the headstock and the

tailstock and contains apron, saddle, compound rest, cross slide and
tool post.

Lead Screw- Lead screw is used to move the carriage automatically

during threading.

Feed Rod- It is used to move the carriage from left to right and vice
versa.

Chip Pan- It is present at the bottom of the lathe. Chip pan is used to
collect the chips that are produced during the lathe operation.
 Kinematics System And Working Principle
Of Lathes
• Lathe machines are normally used to produce cylindrical
surfaces.

Working Principle - The job is held in the chuck attached to the

head stock or between the centers provided at the head stock or
tail stock. The tool is held on the compound rest. Job is rotated
at the predetermined speed by the head stock. The tool is moved
relative to the workpiece with the help of carriage, cross slide or
compound rest. Desired quantity of metal is removed in the
form of chip from the work piece.
Specification of a lathe machine
A lathe machine is specified by the following-

 Height of the centers measured from the lathe bed.

 Swing diameter over bed. This the largest diameter of work

piece which will revolve without touching the bed. It is equal
twice the height of centers from the bed.

 Swing diameter over carriage. It is the largest diameter that

can revolve over the cross-slide. This always less than the
swing diameter over the bed.

 Maximum bar diameter. This is the maximum diameter

that will pass through the head stock spindle.

 Length of the bed.

Types of Lathe

Engine Lathe or center lathe

• It is most common type of lathe and is widely used in workshop.
• The speed of the spindle can be widely varied as desired which is
not possible in a speed lathe.

Bench Lathe
• Small lathe which can mounted on the work bench
• It is used to make small precision and light jobs.

Tool room lathe

• It is similar to an engine lathe, designed for obtaining accuracy.
• It is used for manufacturing precision components, dies, tools,
jigs etc. and hence it is called as tool room lathe.
Automatic Lathe
• A lathe in which the work piece is automatically fed and
removed without use of an operator.
• It requires very less attention after the setup has been made and
the machine loaded.

Turret Lathe
• Turret lathe is the adaptation of the engine lathe where the tail
stock is replaced by a turret slide (cylindrical or hexagonal).
• Multiple tools mounted on turret either attached to the tail stock
or cross slide, which allows quick changing in tooling and
cutting operation.

Computer controlled lathe (CNC Lathe)

• A highly automated lathe, where cutting, loading, tool changing
and part unloading are automatically controlled by computer
coding.
Machining Operations Usually Done In Centre
Lathes
• Facing
• Centering
• Rough and finish turning
• Chamfering, Grooving
• Axial drilling and reaming by holding the cutting tool in the
tailstock barrel
• Taper turning by
1. offsetting the tailstock
2. swivelling the compound slide
3. using form tool with taper over short length
4. using taper turning attachment if available
5. combining longitudinal feed and cross feed, if feasible.
Machining Operations Usually Done In Centre
Lathes cont.….
• Boring (internal turning); straight and taper
• Forming; external and internal
• Cutting helical threads; external and internal
• Parting off
• Knurling
Machining Operations Usually Done In Centre
Lathes
Turning- Turing is used
to make (or to reduce)
the external size of the
workpiece.

Facing- Facing is used to make a

flat surface at the end of the work
piece.
Machining Operations Usually Done In Centre
Lathes cont…
Grooving- It is used to make
a groove in workpiece.

Parting- To remove a certain

portion of workpiece.
 Threading- Used to make threads on the surface of workpiece. It
can be external or internal surface.

Drilling- To make a axial hole in workpiece.

Boring- It is used to enlarge a existing hole.

Reaming- It is used to give the finishing touch to existing hole by

removing a small amount of materials.
Tapping is the process of cutting a
thread inside a hole so that a cap
screw or bolt can be threaded in to hole.

Knurling is a process of impressing a diamond shaped or straight

line pattern into the surface of a workpiece by using specially
shaped hardened metal wheels to improve its appearance and to
provide a better gripping surface.
Example 1.
A mild steel rod having 50 mm diameter and 500 mm
length is to be turned on a lathe. Determine the
machining time to reduce the rod to 45 mm in one
pass when cutting speed is 60 m/min and a feed of 0.7
mm/rev is used.
Example 2.
Determine the angle at which the compound rest would
be swiveled for cutting a taper on a workpiece having a
length of 150 mm and outside diameter 80 mm. The
smallest diameter on the tapered end of the rod should
be 50 mm and the required length of the tapered portion
is 80 mm.
 tan α = (80-50) / 2×80

or α = 10.620

The compound rest should be swiveled at 10.620 .