Republic of the Philippines

ZAMBOANGA PENINSULA POLYTECHNIC STATE UNIVERSITY

Region IX, Western Mindanao
R.T. Lim Boulevard Baliwasan, Zamboanga City
Telephone No:995-4024 / 991 -4012

MT-221 MACHINE PRACTICE-I (LATHE & GRINDING)

TOPIC:

Lathe machine operations:

 Lathe types and specifications
 Lathe parts and functions
 Setting cutting speed, rpm, feed rate
 Workholding and tool holding devices
Turning tools and tool geometry
OBJECTIVES:

By the end of this topic, you should be able to:

1. Understand different types of lathe machines and their specifications.
2. Identify the main parts of a lathe machine and their functions.
3. Calculate cutting speed, RPM, and feed rate for different materials.
4. Learn about various workholding and tool holding devices.
5. Understand different turning tools and tool geometry.

INSTRUCTOR: TIMOTHY TRON T. TRIVELES

1. Lathe Types and Specifications
Types of Lathes
Lathe machines are classified based on their construction and use:
1. Engine Lathe
o Most commonly used, manually operated.
o Used in workshops for general-purpose turning, facing, threading, and drilling.
2. Turret Lathe
o Used for mass production.
o Has a turret (rotating tool holder) for multiple tool operations.
3. CNC Lathe (Computer Numerical Control)
o Operated using programmed commands.
o Ensures high precision and repeatability.
4. Bench Lathe
o Small-sized lathe, used for precision work and model making.
5. Capstan Lathe
o Similar to turret lathe but used for small and medium production.
6. Special Purpose Lathe
o Includes wheel lathes, gap-bed lathes, vertical lathes.
Specifications of a Lathe Machine
Common specifications include:
  Swing Over Bed: Maximum diameter of workpiece that can be rotated.
 Distance Between Centers: Maximum length of workpiece that can be mounted.
 Spindle Bore Diameter: The hole through which long workpieces pass.
 Maximum RPM: Speed of the spindle in revolutions per minute.
 Power Rating: Motor power in horsepower (HP) or kilowatts (kW).
Example of a Lathe Specification
A typical lathe specification might look like:
 Swing Over Bed: 300 mm
 Distance Between Centers: 1000 mm
 Spindle Speed: 50-2000 RPM
 Motor Power: 5 HP

2. Lathe Parts and Functions

A lathe machine consists of various components with specific functions:
Main Parts of a Lathe
1. Headstock – Contains the main spindle, speed-changing mechanism, and drive system.
2. Tailstock – Supports long workpieces and holds drill tools.
3. Carriage – Moves the cutting tool along the workpiece.
o Saddle: Holds the tool post and cross-slide.
o Cross-slide: Moves the tool perpendicular to the spindle axis.
o Compound Rest: Adjusts the cutting tool at an angle.
o Tool Post: Holds the cutting tool.
4. Bed – The base structure supporting the entire machine.
5. Lead Screw & Feed Rod – Used for threading and feed movement.
Example of Functionality
If you want to drill a hole in the center of a workpiece, you can mount a drill bit in the tailstock and
push it against the rotating workpiece.

3. Cutting Speed, RPM, and Feed Rate in Lathe Operations

1. Cutting Speed (CS)
Cutting speed refers to the speed at which the cutting tool moves relative to the workpiece surface. It
is expressed in meters per minute (m/min) or feet per minute (ft/min).
Formula for Cutting Speed:
CS=πDN1000CS = \frac{\pi D N}{1000}CS=1000πDN
where:
 CS = Cutting Speed (m/min)
 D = Workpiece diameter (mm)
 N = Spindle speed (RPM)
 π = 3.1416
Example Calculation:
Let's say we need to determine the cutting speed when:
 Workpiece diameter = 100 mm
 Spindle speed = 400 RPM
CS=3.1416×100×4001000CS = \frac{3.1416 \times 100 \times 400}{1000}CS=10003.1416×100×400
CS=1256641000=125.66 m/minCS = \frac{125664}{1000} = 125.66 \text{ m/min}CS=1000125664
=125.66 m/min
So, the cutting speed is 125.66 m/min.

2. RPM (Spindle Speed)

RPM (Revolutions Per Minute) is the number of times the spindle rotates in one minute.
Formula to Calculate RPM:
N=CS×1000πDN = \frac{CS \times 1000}{\pi D}N=πDCS×1000
where:
 N = RPM (Revolutions per Minute)
 CS = Cutting Speed (m/min)
 D = Workpiece Diameter (mm)
Example Calculation:
If we need to determine the spindle speed when:
 Cutting Speed = 100 m/min
 Workpiece Diameter = 50 mm
N=100×10003.1416×50N = \frac{100 \times 1000}{3.1416 \times 50}N=3.1416×50100×1000
N=100000157.08=636.6≈637 RPMN = \frac{100000}{157.08} = 636.6 \approx 637 \
text{ RPM}N=157.08100000=636.6≈637 RPM
Thus, the required spindle speed is 637 RPM.
Typical Cutting Speeds for Different Materials:
Material Cutting Speed (m/min)
Mild Steel 25 - 50
Cast Iron 20 - 40
Aluminum 100 - 300
Brass 60 - 150
Stainless Steel 15 - 40

3. Feed Rate (f)

The feed rate refers to the distance the tool moves along the workpiece per revolution of the spindle.
It is expressed in mm/rev.
Types of Feed in Lathe:
1. Longitudinal Feed – Movement of the tool parallel to the workpiece axis.
2. Cross Feed – Movement of the tool perpendicular to the axis.
Feed Rate Formula:
f=Cutting speed×1000Nf = \frac{\text{Cutting speed} \times 1000}{N}f=NCutting speed×1000
Typical Feed Rates:
Type of Operation Feed Rate (mm/rev)
Rough Turning 0.2 - 0.5
Finishing 0.05 - 0.2
Thread Cutting 0.1 - 0.4
Boring 0.1 - 0.3
Example Calculation:
For a mild steel workpiece:
 Cutting Speed = 40 m/min
 Spindle Speed = 300 RPM
f=40×1000300=40000300=133.3 mm/minf = \frac{40 \times 1000}{300} = \frac{40000}{300} = 133.3 \
text{ mm/min}f=30040×1000=30040000=133.3 mm/min

4. Depth of Cut
Depth of cut refers to how deep the tool cuts into the workpiece in one pass. It is measured in
millimeters (mm).
Formula:
d=D1−D22d = \frac{D_1 - D_2}{2}d=2D1−D2
where:
 d = Depth of cut (mm)
 D1 = Initial diameter of workpiece
 D2 = Final diameter after machining
Typical Depth of Cut Values:
Operation Depth of Cut (mm)
Rough Turning 1 - 3 mm
Finish Turning 0.2 - 1 mm

Summary of Important Formulas

Calculation Type Formula
Cutting Speed
CS=πDN1000\text{CS} = \frac{\pi D N}{1000}CS=1000πDN
(m/min)
RPM (Spindle Speed) N=CS×1000πDN = \frac{\text{CS} \times 1000}{\pi D}N=πDCS×1000
f=Cutting Speed×1000Nf = \frac{\text{Cutting Speed} \times 1000}
Feed Rate (mm/min)
{N}f=NCutting Speed×1000
d=D1−D22d = \frac{D_1 - D_2}{2}d=2D1−D2
Depth of Cut (mm)

4. Turning Tools and Tool Geometry in Lathe Operations

1. What are Turning Tools?
Turning tools are cutting tools used in a lathe to remove material from a rotating workpiece by means
of a cutting action. These tools are categorized based on their function, tool material, and geometry.

2. Types of Turning Tools

(A) Based on Purpose
1. Roughing Tool
o Used for removing a large amount of material quickly.
o Has a large nose radius for strength.
o Requires high feed rates and depth of cut.
2. Finishing Tool
o Used for achieving smooth surface finishes.
o Small nose radius for finer cuts.
o Requires lower feed rate and depth of cut.
3. Parting Tool (Cut-off Tool)
o Used to cut off a workpiece after machining.
o Thin, narrow blade for deep cuts.
4. Thread Cutting Tool
 o Used for cutting screw threads.
o Includes external and internal thread-cutting tools.
5. Boring Tool
o Used to enlarge an existing hole.
o Held in a boring bar for stability.
6. Grooving Tool
o Cuts a groove into the workpiece.
o Similar to parting tools but used to create internal or external grooves.
7. Knurling Tool
o Used to create textured patterns for better grip.
o Consists of hardened rollers with serrations.

(B) Based on Tool Shape and Hand

1. Right-Hand Tool
o Removes material when fed from right to left.
o Cutting edge is on the left side.
2. Left-Hand Tool
o Removes material when fed from left to right.
o Cutting edge is on the right side.
3. Straight Tool (Neutral Tool)
o Cutting edge is perpendicular to the workpiece axis.
o Used for simple turning operations.

3. Tool Geometry and Angles

The efficiency of a cutting tool depends on its geometry, which includes rake angles, clearance angles,
and cutting edge properties.
Important Angles in Turning Tool Geometry
Angle Name Purpose
Rake Angle (γ) Affects chip formation and cutting force.
Relief Angle (α) Prevents tool rubbing against workpiece.
Cutting Edge Angle (β) Determines tool strength and surface finish.
Nose Radius (r) Influences surface finish and tool life.
(A) Rake Angle (γ)
 The rake angle is the angle between the rake face (chip-flow face) and the vertical reference
line.
 It controls chip flow and cutting forces.
 Positive rake angle:
o Reduces cutting force.
o Improves tool sharpness for soft materials like aluminum.
 Negative rake angle:
o Increases tool strength.
o Used for hard materials like stainless steel.
📌 Example:
 Aluminum: Uses +10° rake for smooth cutting.
 Cast Iron: Uses -5° rake for durability.
(B) Relief Angle (α)
 The relief angle prevents the tool from rubbing against the workpiece.
 Small relief angle → More tool contact → More friction.
 Large relief angle → Less friction but weak cutting edge.
📌 Example:
 Hard Materials (Steel, Cast Iron) → Use 5° relief for strength.
 Soft Materials (Aluminum, Brass) → Use 10° relief for smoother cutting.

(C) Cutting Edge Angle (β)

 The cutting edge angle controls the direction of chip flow and tool strength.
 It is also known as the side cutting edge angle.
 Larger angles reduce cutting force but may increase vibration.
📌 Example:
 For finishing operations, use 60° cutting edge angle for better surface finish.
 For roughing operations, use 30° cutting edge angle to withstand cutting force.

(D) Nose Radius (r)

 The nose radius is the rounded tip of the cutting tool.
 Larger nose radius improves surface finish but increases cutting force.
📌 Example:
 Roughing: 0.8 mm nose radius (stronger tool, rougher surface).
 Finishing: 0.2 mm nose radius (smoother finish, weaker tool).

4. Tool Material Selection

The material of a turning tool determines its performance, wear resistance, and suitability for different
workpiece materials.
Common Tool Materials
Material Properties Example Application
High-Speed Steel Used for manual and semi-automatic
High toughness, good for general use
(HSS) lathes
High hardness, good for high-speed
Carbide Used for CNC machining
cutting
Heat-resistant, best for high-speed
Ceramics Used for cutting hardened steel
machining
Used for aerospace and automotive
Diamond (PCD) Ultra-hard, best for precision machining
industries
📌 Example:
 Mild Steel Workpiece: Use HSS tool with positive rake angle.
 Hardened Steel: Use Carbide tool with negative rake angle.

5. Tool Holder and Insert Systems

Modern lathe tools use indexable inserts instead of traditional one-piece cutting tools. Inserts are
replaceable carbide or ceramic tips mounted in a tool holder.
Common Insert Types
1. TNMG (Triangular Insert)
o Used for general turning and roughing.
 2. CCMT (Diamond-Shaped Insert)
o Used for precision turning and finishing.
3. WNMG (Hexagonal Insert)
o Used for heavy-duty cutting.

6. Practical Example: Choosing the Right Tool

Scenario 1: Rough Turning of a Steel Rod
 Tool Type: Roughing Tool
 Material: Carbide Insert (WNMG 0804)
 Rake Angle: -5° (for strength)
 Cutting Speed: 80 m/min
 Feed Rate: 0.3 mm/rev
 Depth of Cut: 2 mm

Scenario 2: Finishing an Aluminum Shaft

 Tool Type: Finishing Tool
 Material: HSS with a polished edge
 Rake Angle: +10° (for smooth cutting)
 Cutting Speed: 200 m/min
 Feed Rate: 0.1 mm/rev
 Depth of Cut: 0.5 mm

Conclusion
 Turning tools vary based on function, shape, and material.
 Proper tool geometry improves efficiency and surface finish.
 Selecting the right tool material enhances cutting performance and tool life.

References
1. Bhattacharyya, A. (2004). "Theory of Metal Cutting." New Delhi: New Age International.
2. HMT. (2001). "Production Technology." New Delhi: Tata McGraw-Hill.
3. Krar, S. F., & Gill, A. (2003). "Technology of Machine Tools." McGraw-Hill Education.
4. Ghosh, A., & Mallik, A. K. (2010). "Manufacturing Science." East-West Press.