Machine Tools & Metrology

III Year I Sem

Subject Code:

Google Classroom Code:

Dr. M Sandeep Kumar

8/5/2020 B. V. Raju Institute of Technology, Narsapur 1
 Manufacturing Processes

Casting Processes Powder Metallurgy

Welding Processes (or) Bulk Deformation Processes

Joining processes (Rolling, forging, Extrusion, Drawing)

Machining Processes
Metrology
(Lathe, Shaper, Planner, Slotter, Drilling etc)

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 MACHINE TOOLS AND METROLOGY

Prerequisite: Manufacturing Processes

L T P C
UNIT I 3 0 0 3
Course Objective:
To impart the fundamental aspects of the metal cutting principles and
their application in studying the types of Lathe machine operations.

Metal cutting: Introduction, elements of cutting

process – Geometry of single point tools. Chip formation and
types of chips, Merchant circle diagram, Role of cutting
fluids. Engine lathe – Principle of working,
specifications. Taper turning, – Lathe attachments. Capstan
and Turret lathe

Course Outcome:
Acquire knowledge of various basic metal cutting principle and lathe machines.
 MACHINE TOOLS AND METROLOGY

Prerequisite: Manufacturing Processes

UNIT II L T P C
3 0 0 3
Course Objective:
To train in knowing the fundamental parts of various Drilling and boring
machine tools and their applications

Drilling Machines – Principles of working,

types (Radial, gang, multi spindle), operations
performed; twist drill.
Boring Machine - Types of Boring machines
and applications. Introduction to Slotting Machine.

Course Outcome:
Get familiarize with various drilling boring machines.
 MACHINE TOOLS AND METROLOGY

Prerequisite: Manufacturing Processes

UNIT III L T P C
3 0 0 3
Course Objective:
To understand various milling machine operations

Milling machines – Principles of working – Types of

milling machines (Horizontal and vertical machine) –
Types of milling cutters, methods of indexing.
Grinding – classification of grinding machines. Types of
abrasives, bonds. Selection of a grinding wheel.
Introduction to Lapping, honing and broaching machines.

Course Outcome:
Understand the principal and basic operations of milling machines.
 MACHINE TOOLS AND METROLOGY

Prerequisite: Manufacturing Processes

UNIT IV L T P C
3 0 0 3
Course Objective:
To acquire the knowledge of limits, fits and tolerances and its
importance in industry.

Limits, fits and tolerances- Unilateral and

bilateral tolerance system, hole and shaft basis system. Limit
Gauges: Taylor‘s principle, Design of GO and NO GO gauges
Measurement of angles, Bevel protractor, and
Sine bar. Measurement of flat surfaces, straight edges,
surface plates, optical flat and auto collimator.

Course Outcome:
Acquire knowledge of limits, fits and tolerances for measurements.
 MACHINE TOOLS AND METROLOGY

Prerequisite: Manufacturing Processes

L T P C
UNIT V
3 0 0 3

Course Objective:
To discuss various applications aspect in the measurements such as
surface roughness, screw thread measurement, and CMM.

Measurements: Roughness, Waviness, RMS, Rz

Values. Method of measurement of surface finish, Talysurf,
Screw thread measurement, Gear measurement; Machine
Tool Alignment Tests on lathe, milling and drilling
machines. Coordinate Measuring Machines: Types and
Applications of CMM.

Course Outcome:
Recognize various measuring techniques for surface roughness, screw
thread, gear profile, machine tool alignment and CMM.

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MACHINE TOOLS AND METROLOGY

8
MACHINE
MACHINETOOLS
TOOLSAND
ANDMETROLOGY
METROLOGY
 Marks Allotment

• End Semester examination : 60

• Internal marks : 40

20 marks Descriptive

10 marks Objective

10 marks Assignment

1 Assignment/
Unit
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 Prerequisite Test

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 Prerequisite Test

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Previous
Question Paper
-- Machine Tools

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Previous Question Paper- Engineering Metrology

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16

Manufacturing Processes

Casting Processes Powder Metallurgy

Welding Processes (or) Bulk Deformation Processes

Joining processes (Rolling, forging, Extrusion, Drawing)

Machining Processes
(Lathe, Shaper, Planner, Slotter, Drilling etc)
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 Production or manufacturing can be simply defined as value addition
processes by which raw materials of low utility and value due to its inadequate
material properties and poor or irregular size, shape and finish are converted
into high utility and valued products with definite dimensions, forms and finish
imparting some functional ability.

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Machine Tools:
Any portable power driven devices designed to perform machining operations are
called machine tools.

The basic function of machine tools are:

- to hold the workpiece
- to position the cutting tool relative to the workpiece
- to provide relative motion between tool and workpiece.

Machining:
A material removal process in which a sharp cutting tool is used to mechanically
cut away material so that the desired part geometry remains.
Machining is the most versatile and accurate of all manufacturing processes in its
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capability to produce a diversity of part geometries and geometric features.
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Machining is an essential process of finishing by which jobs are produced to the

desired dimensions and surface finish by gradually removing the excess material
from the preformed blank in the form of chips with the help of cutting tool(s)
moved past the work surface(s).

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 Requirements of Machining
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 Classification of Machined Parts
22

1. Rotational - cylindrical or disk-like shape

2. Non-rotational (also called prismatic) - block-like or plate-like

(a) rotational, or (b) non-rotational, shown here by block

and flat parts
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 Machining Operations and Part Geometry
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Each machining operation produces a characteristic part geometry due to two

factors:

1. Relative motions between the tool and the work part

• Generating –part geometry is determined by the feed trajectory of the
cutting tool
2. Shape of the cutting tool
• Forming –part geometry is created by the shape of the cutting tool

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Generating to create shape: (a) straight turning, (b) taper turning,

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(c) contour turning, (d) plain milling, (e) profile milling
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Forming to create shape: (a) form turning, (b) drilling,

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and (c) broaching
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Combination of forming and generating to create shape:

(a) thread cutting on a lathe, and (b) slot milling 8/5/2020
 Wedge
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 Basic Cutting Parameters
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 Basic Cutting Parameters
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-Cutting Speed, Feed and Depth of Cut

- Cutting Speed: The cutting speed is the peripheral or surface speed of the
work with respect to the tool. It is expressed in m/min.

D = Diameter of bar stock or tool, in mm

N = Spindle or tool speed, in rpm

- Feed: The motion of cutting tool into the work per revolution is called feed.
It represents the rate at which cutting tool advances into the work surface and
is expressed in mm/rev. 8/5/2020
 Basic Cutting Parameters
30

-In turning, the feed is measured by the distance moved by the tool per
revolution of the work in the direction parallel to the axis of rotation.
- In case of drilling, feed is the distance that drill enters into the work per
revolution of the drill spindle
- In milling, feed is the distance moved by the work into the cutter per 8/5/2020
revolution of the arbor on which the cutter is mounted.
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- Depth of cut: The depth of cut is the distance between bottom of the cut and
uncut surface of the work, measured in a direction at right angles to the
machined surface of the work.

the depth of cut (t) t = d/2 mm.

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 Production of Geometrical Shapes
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-The line generated by primary (cutting) motion is called ‘Generatrix’

-The line indicating secondary (feed) motion is called ‘Directrix’

Generation of flat surfaces by Generatrix and Directrix.

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Generation of cylindrical surfaces (of revolution)
 Production of Geometrical Shapes
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 Types of Cutting Tools
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 Single point cutting Tools
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 Single point cutting Tools
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Shank
Rake
Face

Flank Face Rake Angles

 Single point cutting Tools
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Relief Angles
 Single point cutting Tools
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Cutting Edge Angles

Nose
 Single point cutting Tools
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Feed

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Shank : Shank is main body of a tool. It is held in a holder.

Flank : Flank is the surface or surfaces below and adjacent to cutting edge.
Heel : Heel is intersection of the flank and base of the tool.
Base : Base is the bottom part of the shank. It takes the tangential force of cutting.
Face : Face is surface of tool on which chip impinges when separated from workpiece.
Cutting Edge :
Cutting edge is the edge of that face which separates chip from the workpiece. The
total cutting edge consists of side cutting edge, the nose and end cutting edge.
Side Cutting Edge Angle:
The angle between side cutting edge and side of the tool shank is called side cutting edge
angle. It is also called as lead angle or principle cutting angle.
End Cutting Edge Angle:
The angle between the end cutting edge and a line perpendicular to the shank of tool is
called end cutting edge angle.
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Rake angle: is provided for ease of chip flow and overall machining.

• Positive rake – helps reduce cutting force and thus cutting power
requirement.
• Negative rake – to increase edge-strength and life of the tool
• Zero rake – to simplify design and manufacture of the form tools. 8/5/2020
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Clearance angle: is essentially provided to avoid rubbing of the tool (flank) with the
machined surface which causes loss of energy and damages of both the tool and the job
surface. Hence, clearance angle is a must and must be positive (3° ~ 15° depending upon
tool-work materials and type of the machining operations like turning, drilling, boring etc.)

Relief Angle
The main significance of relief angle is that it prevents rubbing action below cutting edge.
Small relief angle gives maximum support below the cutting edge and is necessary while
machining hard and strong workpiece. Too much relief angle weakens the cutting edge and
failure of tool may takes place. Relief angles generally lie between 5° to 15°.

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Side Relief Angle

The angle between the portion of the side flank immediately below the side cutting edge and
line perpendicular to the base of tool measured at right angles to the side flank is known as
side relief angle. It is the angle that prevents interference, as the tool enters the work
material.
End Relief Angle
End relief angle is the angle between the portion of the end flank immediately below the end
cutting edge and the line perpendicular to the base of tool, measured at right angles to end
flank. It is the angle that allows the tool to cut without rubbing on the workpiece.
Back rake angle (αb)
It is the angle between the face of the tool and a line parallel with base of the tool measured
in a perpendicular plane through the side cutting edge. This angle helps in removing the
chips away from the work piece.

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Side rake angle (αs)

⮚It is the angle by which the face of tool is inclined side ways.
⮚This angle of tool determines the thickness of the tool behind the cutting edge.
⮚It is provided on tool to provide clearance between work piece and tool so as to prevent
the rubbing of work- piece with end flank of tool.

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 Multi point cutting Tools
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 Mechanism of Chip Formation
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 Mechanism of Chip Formation
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A cutting tool exerts compressive force on the workpiece which stresses the work
material beyond the yield point and therefore metal deform plastically and shears off.

- Plastic flow takes place in a localized region called

the shear plane.
- Sheared material begins to flow along the cutting
tool face in the form of chips.
- Flowing chips cause tool wear.
-Applied compressive force which leads to
formation of chips is called cutting force.

⮚Heat produced during shearing action raises the temperature of the workpeice, cutting
tool and chips.
⮚Temperature rise in cutting tool softens and causes loss of keenness in cutting edge.
⮚Cutting force, heat and abrasive wear are important features in metal cutting.
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 Types of Chips
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Depends on the following factors: Types of Chips:

1. Continuous chip
1. Properties of material being machined 2. Continuous chip with BUE
3. Discontinuous chip or
2. Cutting conditions used segmental chip
- Tool geometry
- Cutting speed
- Feed and Depth of cut
- Cutting fluids

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 Types of Chips
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- Discontinuous or segmental chips consist of elements fractured into fairly small pieces
ahead of the cutting tool.
- As these chips are produced, the cutting edge smoothes over the irregularities and
fairly good surface finish is obtained. Tool life is also reasonably good and power
consumption is low.
- Conditions tending to promote its formation include: brittle metal, greater depth of cut,
low cutting speed and small rake angle.
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- Continuous chips consist of element bonded firmly together without being fractured.
- The continuous form is considered most desirable for low friction at the tool chip
interface, lower power consumption, long tool life and good surface finish.
- Factor favorable to its formation are: ductile metal, such as mild steel, copper, etc., fine
feed, high cutting speed, large rake angle, keen cutting edge, smooth tool face and an
efficient lubrication system.

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- The term built up edge implies the building up of a ridge of metal on the top surface of
the tool and above the cutting edge
- It appears that, when the cut is started in ductile metals, a pile of compressed and highly
stressed metal forms at the extreme edge of the tool.
- Owing to the high heat and pressure generated there, this piled up metal is welded to the
cutting tip and forms a ‘false’ cutting edge to the tool.This is usually referred to as the
‘built up edge’.
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55

Factors Work Material Cutting Speed Feed Rake

Angle
Type of Chip
1. Continuous Chip Ductile High Small Large

2. Continuous chip Ductile Medium High Small

with BUE
3. Discontinuous Brittle Low High Small
Chip

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 Orthagonal & Oblique Cutting
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 Orthogonal
57 Cutting

Velocity
V

Characteristics:
-Cutting edge perpendicular to cutting
velocity vector
- No spread of material across

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 Oblique Cutting
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Characteristics
Tool • Cutting edge at an angle(λ) to
normal to velocity vector
in the cutting plane
λ • Inclination angle λ
Chip - modifies Tool angles
- governs Direction of chip
flow
V
Stabler’s Law for Chip flow
nc = k.
ncλ= chip flow angle K = 0.8 –
1.0 8/5/2020
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 Forces in Machining
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 Forces in Machining
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 Forces in Machining
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 Lathe Machine
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 Lathe Machine
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 Lathe Machine
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▪ Introduction & history of lathe.

▪ Working principle of lathe.
▪ Classification of lathe.
▪ Construction and parts of lathe.
▪ Accessories of lathe.
▪ Specifications of lathe.
▪ Lathe operations.
▪ Work holding devices.
▪ Conclusion 8/5/2020
 Lathe Machine
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▪Lathe is one of the most important machine tools in the metal working
industry. A lathe operates on the principle of a rotating work piece and a
fixed cutting tool.
▪ The cutting tool is feed into the work piece, which rotates about its own
axis, causing the work piece to be formed to the desired shape.
▪ Lathe machine is also known as “the mother/father of the entire tool
family”.
HISTORY
▪ The lathe machine is one of the oldest and most important machine tools.
As early as 1569, wood lathes were in use in France. The lathe machine
was adapted to metal cutting in England during the Industrial
Revolution.

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▪ Lathe machine also called “Engine Lathe” because the first type of lathe
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Working Principle

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 Lathe Machine
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Function of lathe

•The main function of lathe is to remove material from the workpiece to give it
the required shape and size.
•This is accomplished by holding the workpiece securely on the machine and
then turning it against the tool which will remove the material from the
workpiece.
•To cut the material properly the tool should be harder than the workpiece
material, should be rigidly held on the machine and should be fed in a definite
way relative to the workpiece.

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 Lathe Machine
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Specification of
Lathe Machine :

•The height of the centers measured from the lathe bed.

•Swing diameter over the bed. This the largest diameter of the workpiece which will
revolve without touching the bed. It is equal twice the height of centers from the bed.
•Swing diameter over the 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
headstock spindle. 8/5/2020
•Length of the bed.
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Types of lathe
Lathes are manufactured in a variety of types and sizes, from very small
bench lathes used for precision work to huge lathes used for turning large
steel shafts. But the principle of operation and function of all types of lathes
is same.
The different types of lathes are:
1. Speed Lathe 3. Bench lathe
Wood working 4. Tool room lathe
Centering 5. Capstan & Turret lathe
Polishing 6. Special purpose lathe
spinning A. Wheel lathe
2. Engine Lathe B. Gap bed lathe
Belt drive C. T – lathe
Individual motor drive D. Duplicating lathe 8/5/2020
Gear drive 7. Automatic lathe
 Lathe Machine
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1. Bench Lathe

•It is usually mounted on a bench.

•It has practically all the parts of an engine lathe and it performs all the operations,
its only difference being in the size. This is used for small and precise work. 8/5/2020
 Lathe Machine
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Speed Lathe Machine

* Speed lathe is the simplest type of lathe. It consists of bed, headstock, tailstock and tool
post. There is no feed box, lead screw or carriage
* Tool is mounted on the tool post and is fed into work purely by hand control. Due to this
characteristic of lathe enables the designer to give high speeds range from 1200 to 3600
r.p.m.
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* The headstock construction is very simple and only two or three speeds are available
 Lathe Machine
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Engine Lathe

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 Lathe Machine
76

•It is the most common types of lathe and is widely used in workshop.
•Similar to the speed lathe, the engine lathe has got all the basic parts, e.g. bed,
headstock and tailstock. But the headstock of an engine lathe is much more
robust in construction and it contains mechanism for multiple speeds.
•The cutting tool may be fed both in cross and longitudinal direction with
reference to the lathe axis with the help of carriage.
•Engine lathes are classified according to the method of power transmission to
the machine

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 Lathe Machine
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Tool Room Lathe

* A tool room lathe having features similar to an engine lathe and is much more accurate
and has wide range of speed from vary low to 2500 r.p.m.
* It is used for manufacturing precision components, dies, tools, jigs etc. and hence it is
called as tool rom lathe 8/5/2020
 Lathe Machine
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Capstan and Turret Lathe

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* These lathes have provision to hold a number of tools and can be used for performing
wider range of operations.
* These are particularly suitable for mass production of identical parts in minimum time.

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 Lathe Machine
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Special Purpose Lathe machine

Wheel lathe is used for machining of journals and rail rods. It is also used for turning the
threads on locomotive wheels.
Gap bed lathe is used to machine large diameter work piece i.e. up to 1.5 to 2 meters and
6-8 meters in length.
T-shape lathe are used to machine rotors used in jet engines and gas turbines. The shape
of its bed in T that’s why it is called as T-shaped lathes.
Duplicate or tracer lathe is used for duplicating or making replica of the shape. This
lathe can machine different type of contours. It traces the shape of one component and
makes a replica of same contour. Numerically controlled lathes are the modified version
of Duplicate lathes.

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 Lathe Machine
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Special Purpose Lathe

Wheel Lathe

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Gap Bed Lathe

Vertical Lathe

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Automatic Lathe

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Construction of Lathe

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 Lathe Machine
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Lathe Machine Operations:

1. Facing
2. Turning
3. Step turning
4. Chamfering
5. Grooving
6. Forming
7. Knurling
8. Taper turning
9. Thread cutting
10. Drilling
11. Reaming
12. Boring
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13. Tapping
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With the help of special attachment, operations like following can also be performed

◻ Key-way Cutting
◻ Cam and Gear Cutting
◻ Shaping
◻ Milling
◻ Fluting
◻ Grinding

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 Lathe Machine
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Facing:
•The process of making a flat surface on a lathe machine is called facing.
•The job is held on a faceplate or chuck and the tool is fed at right angles to the bed to
obtain flat surfaces.
•To safely perform a facing operation at the end of the workpiece must be as close as
possible to the jaws of the chuck.

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 Lathe Machine
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Turning:
•Tuning is the operation when metal removal takes place from the surface of the
cylindrical workpiece. In this process, a tool is fed along the axis of the spindle.
•Turning is the removal of metal from the outer diameter of a rotating cylindrical
workpiece.
•Turning is used to reduce the diameter of the workpiece.
and the Step turning is an operation performed on a lathe machine where the excess
material is removed from the workpiece to obtain various steps of different diameters.

Taper Turning:
The taper turning is a lathe operation for producing a conical surface by a gradual
reduction in the diameter of a cylindrical workpiece. 8/5/2020
 Lathe Machine
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Chamfering:
This operation can be done by a form tool having an angle equal to chamfer which is
generally kept at 45°.

Grooving:
The term grooving usually applies to a process of forming a narrow cavity of a certain
depth, on a cylinder, cone, or a face of the part.
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 Lathe Machine
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Forming:
The forming process is the operation or process where the workpiece is reshaped
without adding or removing material, and its mass remains unchanged.

Knurling:
In the knurling process, some serration(meaning: a tooth or point of a serrated edge
or surface) is formed on the workpiece by deforming the top layer on the lathe.
The rough surface produced by knurling is useful for providing proper gripping.
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Thread Cutting:
•A thread is a helically shaped groove formed on the cylindrical surface of a
workpiece.
•Thread cutting is an operation performed on a lathe to produce threads by using a
tool whose shape will be the same as that of the thread.
•Types of screw threads, Screw thread nomenclature, Lathe setting for thread
cutting, Types of gear trains Simple gear train Compound gear train.

Drilling:
•Drilling is the process of making holes in the workpiece with the help of drill
tools. The drill is held on the tailstock and the drilling operation is carried out by
advancing the drill in the workpiece by rotating the handle of the tailstock. 8/5/2020
On a lathe, Drilling is generally done in the center of the workpiece.
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Taper Turning: Definition

• Gradual decrease in the diameter of the work piece resulting in a

cone shape is taper.
• According to units of measurement tapers are classified as Inch
Tapers and Metric Tapers
• Metric tapers are expressed as a ratio of 1mm per unit of length:
for example 1:20 taper would have a 1-mm change in diameter in
20mm of length.

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Types of Tapers-continued
• Standard Tapers include Morse Taper, Brown & Sharpe, Jarno Taper
and Standard Taper pins
• Morse Taper : They are available in 8 sizes ranging from #0 to # 7.
tpf= 5/8’’. They are used mostly on lathe center shanks, reamers,
drills.
• Brown & Sharpe: They are available in sizes from # 4 to # 12.
tpf=0.502’’. Brown and sharpe tapers are used on Brown and Sharpe
tapers.
• Jarno Taper: They are used on lathe and drill spindles and sizes vary
from # 2 to # 20. They have a tpf of 0.600’’.
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 Lathe Machine
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Taper Turning - Methods

• Form tool method
• Tail stock method
• Compound rest method
• Taper turning attachment method

Tan ⍺ = D-d
2l
D – Large diameter of taper
d – small diameter of taper
l – length of taper 8/5/2020
α - Half taper angle
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Form Tool Method

• Short taper
• Form tool ground to required angle
• Tool fed perpendicular to lathe axis
• Operation done @ slow speed

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Tail Stock Set Over Method

• Small tapers (> 8º)on long work pieces
• Work piece - b/w centers

• Line centre i.e. tail stock is off-set to a distance set over

• Axis of work piece turned to an angle from lathe axis

• Tool fed over rotating work piece parallel to lathe axis

• Then taper is made on work piece
• Contd..
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 Tail Stock Set Over Method
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• The principle of turning taper by this method is to shift the axis of rotation of
the work piece at an angle to the lathe axis and feeding the tool parallel to the
lathe axis.
• This is done when the body of the tailstock is made to slide on its base
towards or away from the operator by a set over screw.

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 Lathe Machine
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Dog
Mandrel Tail stock quill

Tail stock

Face plate Direction of feed

Tool post & Compound rest
Slide
Tool holder Compound rest
Cross slide α 98 8/5/2020
Hand crank
 Lathe Machine

Advantages and Disadvantages of Tail Stock Off set

• The main disadvantage of this method is that live and dead center are not
equally stressed out and the wear is not uniform.
• This method is suitable for turning small taper on long jobs
• The advantage is that it is suitable for turning small tapers

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Compound Rest Method

• Work piece held in chuck –

rotated
• Compound rest – swiveled to
• Angle tan α = D - d
2l

• Tool fed by compound rest hand

wheel
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 Lathe Machine
Taper Turning Attachment
101

• Arrangement
– Taper turning operation
– Attached - rear end of bed using bottom plate or bracket
– Swinging guide bar set to required angle - swiveled to a max of
100
– Guide block moves on guide bar & connects rear end of the
cross slide
• Operation
–– Work
Crosspiece
slide held
made to centers
b/w move along
or inthe guide block by removing
a chuck
the binder screw
– Guide bar turned to a required angle
– Longitudinal feed - tool
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– Tool moves in angular way
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Taper Turning Attachment

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Work Holding Devices

1. Chucks
2. Collets
3. Face Plates

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Chucks
• may have 2, 3, 4, or 6 jaws to hold work by external or internal
surfaces
• many chucks operate manually, but in CNC lathes they operate
automatically
• indexing chucks can index to different positions to present multiple
surfaces of a workpiece to the cutting tool
• for longer parts, a tailstock support is used with the chuck or other
lathe workholding
• chucks may also be magnetic, to grip irregularly-shaped ferrous
workpieces

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Combination chuck

•As the name implies a combination chuck may be used both as a self-centering and
independent chuck to take advantages of both the types.
•The jaws may be operated individually by separate screws or simultaneously by
scroll disc
•The screws mounted on frame have teeth cut on its underside which meshes8/5/2020
with
scroll and all the jaws move radially
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Air or hydraulic operated chuck

1 – Cylinder, 2 – Air Passage, 3 – Headstock spindle, 4 – Piston, 5 –

Valves, 6 – Piston rod, 7 – Link, 8 – Jaw, 9 – Guide, 10 – sliding unit
•This type of chuck is used in mass production work for its fast and effective
gripping capacity
•In mechanism, a hydraulic cylinder is mounted at the back end of headstock
spindle and rotates with it.
•The movement of piston is transmitted to the jaws by a connecting rod and
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links and the jaws grip the workpiece securely
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109

Magnetic Chucks
• Used to hold iron or steel parts that are too thin or may be damaged if held in
conventional chuck
• Fitted to an adapter mounted on headstock spindle
• Used only for light cuts and for special grinding applications

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110

Collets:
• accurately and tightly hold the smooth surfaces of round bar and
cylindrical slug workpieces
• special collets can grip square and hex shapes
• collets may be multi-sized, with a stepless gripping size range
• collets are available for workpieces that are decimal, metric, and non-
standard sizes
• collets are often used in conjunction with automatic bar stock feeders

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111

Spring-collet chuck
• One form: Handwheel draws collet into tapered adapter
• Another form: Uses chuck wrench to tighten collet on workpiece
• Can hold larger work than draw-in type

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112

Jacobs collet chuck

• Utilizes impact-tightening handwheel to close collets
• Wider range than spring-collet chuck

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113
Faceplates
• Used to hold work too large or shaped so it cannot be held in chuck or
between centers
• Usually equipped with several slots to permit use of bolts to secure work
– Angle plate used so axis of workpiece may be aligned with lathe
centers
• Counterbalance fastened to faceplate when work mounted off center
– Prevent imbalance and resultant vibrations

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114

Work supporting Devices

1. Steady Rest
2. Follower Rest
3. Mandrels
4. Lathe Dogs

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115

Steady rest
• Used to support long work held in
chuck or between lathe centers
– Prevent springing
• Located on and aligned by ways of
the lathe
• Positioned at any point along lathe
bed
• Three jaws tipped with plastic, bronze
or rollers may be adjusted to support
any work diameter with steadyrest
capacity
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116

Follower Rest

• Mounted on saddle
• Travels with carriage to
prevent work from springing
up and away from cutting tool
– Cutting tool generally
positioned just ahead of
follower rest
– Provide smooth bearing
surface for two jaws of
follower rest
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 Lathe Machine
Rests
Steady Rest Follower Rest

Work Jaws
Work Jaws
Hinge

Carriage

Lathe bed guideways

117
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Mandrel
• Holds internally machined workpiece between centers so further
machining operations are concentric with bore
• Several types, but most common
– Plain mandrel
– Expanding mandrel
– Gang mandrel
– Stub mandrel

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121
Plain Mandrel

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122

•This type of mandrel is most commonly used in shops and finds wide application
where a large number of identical pieces having standard size holes are required to
be mounted on it.
•The body of mandrel is slightly tapered, the difference in diameter being 1 to 2
mm per 100 mm length.
•Length varies from 55 to 430 mm
•The taper is provided for proper gripping of the workpiece. This type of mandrel
is suitable for only one size of bore.
•For different sizes of holes in workpiece different mandrels are used. 8/5/2020
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123

Step Mandrel

•A step mandrel having steps of different diameter may be employed to drive

different diameter sizes of hole without replacing the mandrel every time
•This type of mandrel is suitable for turning collars, washers and odd sized jobs.

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124

Collar Mandrel

•A collar mandrel having solid collars used for turning workpiece having holes of
larger diameter usually above 100 mm.
•This construction reduces weight and fits better than solid mandrel of equal size

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125

Screwed mandrel

•A screwed mandrel is threaded at one end with a collar

•A workpiece having internal threads are screwed on to it against collar for
machining.
•The size and type of thread used on the mandrel depends on the internal thread
of workpiece.
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126

Cone Mandrel

1 – Solid cone, 2 – Sliding cone, 3 – Nut

•Cone mandrel consists of a solid attached to the one end of body and a sliding one
which can be adjust by turning a nut at a threaded end.
•This type of mandrel is suitable for holding workpiece having different hole
diameter. 8/5/2020
•Forcing the cone to much tightly open the workpiece may spoil its outer edge
 Lathe Machine
127

Gang Mandrel

1 – Fixed collar, 2 – Hollow workpieces, 3 – Moveable collar, 4 – Nut

•This has a fixed collar at one end and a movable collar at the threaded end which
may be adjust to the position by a nut.
•This mandrel is used to set of hollow workpiece between to collars by tightly of
nut
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Expansion mandrel

1 – Sleeve, 2 – Tapered pin

•There are different types of expansion mandrels. The mandrel consists of tapered
pin which is driven into sleeve that parallel outside and tapered inside.
•The sleeve has three longitudinal slots, two of which are cut nearly through and
third splits completely
•This construction is used to grip various workpiece with different hole diameter
within a limit and cannot held by an ordinary mandrel 8/5/2020
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Expanding Mandrel

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Lathe Dogs
• Drives work machined between centers
• Has opening to receive work and setscrew to fasten the dog to work
• Tail of dog fits into slot on driveplate and provides drive to workpiece
• Made in variety of sizes and types to suit various workpieces

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Standard bent and straight tail lathe dog

• Most commonly used for round workpieces
• Available with square-head setscrews of headless
setscrews

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Bent tail engages in slot on drive plate • Driven by stud in drive plate
• Used in precision turning

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Safety clamp lathe dog

• Used to hold variety of work

• Wide range of adjustment

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• TURNING - FACING - KNURLING

• TURNING - KNURLING – FACING
• FACING - TURNING – KNURLING
• FACING - KNURLING – TURNING
• KNURLING - FACING – TURNING
• KNURLING - TURNING – FACING

What is an Optimal Sequence?

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Heavy Duty Lathe Dog

• Wider range than others

• Used on all shapes

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Tool post Workpiece

Chip N (rev/min)
S
Tool peripheral
D
speed
relative tool travel in 1 rotation = π
D peripheral speed = S = π D N 8/5/2020
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Cutting Speed
138

D – Diameter (mm)
N – Revolutions per Minute (rpm)
v=π D
1000N m/min
The Peripheral Speed of Workpiece past the
Cutting Tool
=Cutting Speed 8/5/2020
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feed – the distance the tool advances for

every rotation of workpiece (mm/rev)

D1 D2

f
Feed 8/5/2020
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140

• perpendicular distance between machined

surface and uncut surface of the Workpiece

d = (D 1 – D2)/2 (mm)

D1 D2
d Depth of Cut
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Operating Conditions
141

cutting Speed
Workpiece
Depth of cut
N
Machined
surface
Chuck Feed (f
) Tool Chip
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MRR
Volume of material removed in one
revolution MRR = π D d f mm3
• Job makes N revolutions/min
MRR = π D d f N (mm3/min)
■ In terms of v MRR is given by
MRR = 1000 v d f (mm3/min)
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143

dimensional consistency by substituting the units

MRR: D d f N
(mm)(mm)(mm/rev)(rev/min)
= mm3/min

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Machining Time
Turning Time
■ Job length Lj mm
■ Feed f mm/rev
■ Job speed N rpm
■fN mm/min
Lj
t min
f 8/5/2020
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Manufacturing Time
= Machining Time
+ Setup Time
+ Moving Time
+ Waiting Time
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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 30 m/min and a feed of 0.7 mm/rev is used.

Given data: D = 50 mm, Lj = 500 mm, v = 30 m/min, f = 0.7

mm/rev, Substituting the values of v and D in

v = π1000
DN m/min N = 191 rpm 8/5/2020
 Lathe Machine
Can a machine has speed of 191
147

rpm?
Machining time:

t Lj min
f
■=t = 500 / (0.7×191)
N 8/5/2020
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148

■ 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.

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■ Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm (with usual

notations)
tan α = (80-50) / 2×80
■ or α = 10.620

■ The compound rest should be swiveled at 10.62o

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 Cutting-Tool-Holding Devices
150

◻ Available in three styles

🞑 Left-hand offset
🞑 Right-hand offset
🞑 Straight
◻ Each has square hole to accommodate square tool
bit held in place by setscrew
🞑 Angle of approximately 15º to 30º to base of tool holder
 Left-Hand Offset Tool holder
151

◻ Offset to the right

◻ Designed for machining work close to chuck or faceplate and
cutting right to left
◻ Designated by letter L
 Right-Hand Offset Tool holder
152

◻ Offset to the left

◻ Designed for machining work close to the tailstock and
cutting left to right
🞑 Also for facing operations
◻ Designated by letter R
 Carbide Tool holder
153

◻ Has square hole parallel to base of tool holder to accommodate

carbide-tipped tool bits
◻ Holds tool bit with little or no back rake
◻ Designated by letter C
154
 Turning Equations
Rotational Speed: N (RPM’s)
v N = Rotational Speed (RPM’s)
N=
π DO v = Cutting Speed (m/min)
DO = Original Diameter
Feed Rate: fr (Dist/Min)

fr fr = Feed Rate (m/Min)

=Nf N = Rotational Speed (RPM’s)
f = Feed (mm/Rev)
 Turning Equations
Machining Time (Min.)
L Tm = Machining Time (Min.)
Tm
fr L = Length of Cut
= fr = Feed Rate (m/Min.)
Material Removal Rate (mcu./Min)
MRR = v f d MRR = Material
v = Cutting Speed Removal
(SFPM)Rate ( /Min)
mcu.

f = Feed (mm/Rev.)
d = Depth of Cut
Problem-:
A turning operation has to be performed on an aluminum rod of diameter50 mm and
length 300mm. The Spindle speed of lathe is given to be 500 RPM. The feed and depth
of cut are 0.15mm/rev and 0.3 mm respectively. Draw a neat sketch
of the turning operation described above. Find out the cutting speed in mm/s
and the volumetric material removal rate (MRR vN). = 500RPM
1
Solution
: f = 0.15mm / rev d
1 1
W/P
= 0.3mm
N1 D1
Depth of cut Turning operation
CuttingSpeed , Vc = ω.R
V c = ⎡ 500 × 2π ⎤ × 25
L ⎢⎣ 60 ⎥⎦
Tool Vc = 1308.9mm / sec
Feed

MRRv = (π × D1 × N1 ) f1 ⋅ d1

MRR = (Vc ) f1 ⋅ d1 3
MRRv v = 58.905 mm / sec
 MATERIAL REMOVAL PROCESSES
MRPs

Traditional Advanced

Cutting Finishing

Other/ Bonded Loose

Circular
Prismatic Abrasive Abrasive
Shape
Shape
• Lapping
• Turning • Milling • Grinding • Polishing
• Drilling • Planning • Honing
• Boring • Shaping • Coated
• Gear Cutting Abrasive
• Broaching
Metal Cutting: Relative Motion between workpiece & cutting edge of
tool Cutting Tools: 1. Single Point tool
2. Multiple Point tool
 Factors Influencing Cutting Process
PARAMETER INFLUENCE AND
INTERRELATIONSHIP
CUTTING SPEED, FORCES, POWER, TEMPERATURE RISE, TOOL
DEPTH OF CUT, LIFE, TYPE OF CHIP, SURFACE FINISH.
FEED, CUTTING
TOOL
FLUIDS ANGLES AS ABOVE, INFLUENCE ON CHIP FLOW
DIRECTION, RESISTANCE TO TOOL CHIPPING.
CONTINUOUS
GOOD SURFACE FINISH; STEADY CUTTING
CHIP
BUILT-UP FORCES; UNDESIRABLE IN AUTOMATED
EDGE CHIP MACHINERY.
DISCONTINUOU DESIRABLE FOR EASE OF CHIP
POOR SURFACE FINISH,
FLUCTUATING CUTTINGTHIN STABLE EDGE
FORCES;
S CHIP DISPOSAL;
CAN PROTECT TOOL SURFACES.
SURFACECAN AFFECT
FINISH AND CAUSE
TEMPERATURE VIBRATION
WEAR, AND AND CHATTER. ACCURACY
DIMENSIONAL
OF
RISE INFLUENCES
WORKPIECE; TOOL
MAY LIFE,
CAUSE PARTICULARLY
THERMAL
WORKPIECE SURFACE.
CRATER
DAMAGETO
TOOL WEAR INFLUENCES DIMENSIONA
SURFACE FINISH, L FORCES
ACCURACY, TEMPERATURE AND
TOOL WEAR RELATED TO TOOL LIFE, SURFACE FINISH,
MACHINABILIT RISE, POWER.
FORCES AND POWER
Y
Approximate Energy Requirements in Cutting
Operations
Approximate Energy Requirements in Cutting Operations
(at drive motor, corrected for 80% efficiency;
multiply
by 1.25 for dull tools).
Specific energy
Material
W-s/mm3 hp-min/in.3
Aluminum alloys 0.4–1.1 0.15–0.4
Cast irons 1.6–5.5 0.6–2.0
Copper alloys 1.4–3.3 0.5–1.2
High-temperature alloys 3.3–8.5 1.2–3.1
Nickel alloys 0.4–0.6 0.15–0.2
Refractory alloys 4.9–6.8 1.8–2.5
Stainless steels 3.8–9.6 1.1–3.5
 Temperature Distribution and Heat Generated

Typical temperature distribution in

the cutting zone. Note the steep

temperature gradients within the

tool and the chip. :

G. Vieregge. Source

Percentage of the heat generated in

cutting going into the workpiece,

tool, and chip, as a function of

cutting speed.
 Tool Wear
Allowable Average Wear Land (VB) for
Cutting Tools in
Allowable Various
wear land (mm)
Operation High-speed Steels
Operations Carbides
Turning 1.5 0.4
Face milling 1.5 0.4
End milling 0.3 0.3
Drilling
Note: 1 mm = 0.040 0.4 0.4
in.
Reaming 0.15 0.15
 Surfaces Produced by Cutting

(a) (b)

Figure 20.21 Surfaces produced on steel by cutting, as observed

with a scanning electron microscope: (a) turned surface and (b)

surface produced by shaping. Source: J. T. Black and S.

Ramalingam.
Tool Life

Tool-life curves
for cutting-
a
materials. tool The
variety of
inverse negative the
of
these curves is ofthe
slope
exponent n in the Taylor
tool-life equations and C
is the cutting speed at T
= 1 min.
 Threading Tool holder
165

◻ Designed to hold special form-relieved

thread-cutting tool
◻ Has accurately ground 60º angle
🞑Maintained throughout life of tool
🞑Only top of cutting surface sharpened when
becomes dull
 Styles of Boring Tool holders
166

◻ Held in standard toolpost

🞑 Light boring toolholder
■ Used for small holes and light cuts
🞑 Medium boring toolholder
■ Suitable for heavier cuts
■ May be held at 45º or 90º to axis of bar
◻ Mounted on compound rest of lathe
🞑 Heavy-duty boring bar holder
■ Three bars of different diameters
■ May be held at 45º or 90º to axis of bar
 Compound Rest Tooling Systems
167

◻ Standard, or round, tool post

🞑 Generally supplied with conventional engine lathe
🞑 Fits into T-slot of compound rest
🞑 Provides means of holding and adjusting type of tool
holder or cutting tool required
🞑 Concave ring and the wedge or rocker provide for
adjustment of cutting-tool height
 Conventional Tool Posts
168