Unit IV: LATHE & DRILLING MACHINE INTRODUCTION The word manufacturing is derived from the Latin Manu

u factus meaning made by hand. The word manufacture first appeared in 1567 AD and the word manufacturing in 1683. The word production and manufacturing is used interchangeably. The conversion of resources into raw materials is normally taken care of by two sub disciplines of engineering mining and metallurgy. The real conversion starts from the stage where the material is obtained in the raw form. There are many processes involved in converting an available raw material into final product. These processes of conversation are known as manufacturing process. Manufacturing Processes This refers to science and technology of manufacturing products effectively, efficiently, economically and environment-friendly through: Application of any existing manufacturing process and system Proper selection of input materials, tools, machines and environments. Improvement of the existing materials and processes Development of new materials, systems, processes and techniques Purpose of Machining Most of the engineering components such as gears, bearings, clutch, tools, screws and nuts etc. need dimensional and form accuracy and good surface finish for serving their purposes. Pre forming like casting, forging etc. generally cannot provide the desired accuracy and finish. For such preformed parts, called blanks, need semi-finishing and finishing and it is done by machining. Machining is one such process, which involves removing excess material from the metallic object so as to obtain the required shape and size. The metal cutting operations may be carried out either, manually by using hand tools (cutting tool) or using metal cutting machines. A cutting tool is any tool that is used to remove material from the workpiece by means of shear deformation Eg: Chisel, files, saws, etc. A machine tool is a powered mechanical device to perform the metal cutting operations by the cutting tools mounted on them e.g.: lathe, drilling machine, grinding machine, milling machine etc. A machine tool performs 3 major functions: 1. It rigidly supports the workpiece and the cutting tool 2. It provides relative motion between the workpiece and the cutting tool 3. It provides a range of speed and feed Properties of cutting tool materials: The materials used for the manufacture of cutting tools should possess the following characteristics: 1. It should be harder than the material being cut. 2. It should be strong enough to withstand the cutting forces. ' 3. It should be tough. 4. It should be able to resist high temperature. 5. It should have low frictional coefficient.

6. It should have resistance to wear. Classification of cutting tools Depending upon the number of cutting edges, the cutting tools used in metal cutting are classified as follows. l. Single point cutting tools, i.e., those having only one cutting edge; such as lathe tools, shaper tools, boring tools, etc. 2. Multi-point cutting tools, i.e., those having more than one cutting edge; such as drills, milling cutters, grinding wheels, etc. Fig: lathe tools LATHE Henry Maudslay designed the first basic lathe, in the year 1797. A lathe is defined as a machine tool used to remove excess material by forcing a cutting tool against a rotating workpiece. Lathes are also called 'turning machines' because the workpiece is turned or rotated between two centers. It is the first machine tool which led to the inventions of other machine tools. Hence it is called mother of machine tools. It is mainly designed to produce cylindrical surfaces. It is so versatile, that almost all the machining operations which are performed on other machine tools like, drilling, grinding, shaping, milling, etc, can be performed on it. Hence it is also popular as 'king of machine tools. Classification Lathes are classified on the basis of drive mechanism, process, purpose etc. The main types are i) Centre lathes (Engine Lathes): This type of lathe were used to machine the parts of watt's steam engine and later driven by steam engines, hence they are known as Engine Lathe. As these support the work piece between a live centre and a dead centre, these are named as centre lathes. ii) Speed lathes: It is so called, because of its high spindle speeds. It is used in wood working, metal spinning, polishing, buffing etc. iii) Bench lathes: It is so called, because it is mounted on a bench. It is used for machining smooth and light jobs. iv) Tool room lathes: It is a modern engine lathe equipped with extra attachments suitable for more accurate and precision type of work carried out in a tool room. It is used for production of small tools and dies, gauges, etc. iv) Production lathes (Capstan Lathes and turret Lathes): It is a modern engine lathe with special tooling facilities used to perform many operations simultaneously. Hence, it is used in mass production. v) Special purpose lathes: these are fabricated according to customer specification vi) Automatic lathes: these are fabricated with acute precision and technologically advanced machinery. Working principle of Centre Lathes

 Lathe works on the principle, that a cutting tool can remove material in the form of chips from the rotating workpiece to produce circular objects. Chuck holds the workpiece rigidly and rotates it at high speed, while the cutting tool is fed against it. The operation is as shown in figure A single point cutting tool held against the workpiece opposite to its direction of rotation when moved parallel to the axis of the workpiece produces circular surfaces. When the tool moves perpendicular to the axis of the rotation of workpiece, a flat surface is produced. When the tool moves at an angle to the axis of rotation of the workpiece, a tapered surface is produced. The tool material should be harder and stronger than the workpiece material. Lathe Specifications The size of a lathe is specified by the following as shown in Fig. 1. Maximum diameter of the workpiece that can be revolved over the lathe bed. This is nothing but the height of the centers above the lathe bed. This is called Swing of the lathe. 2. The Maximum diameter and the width of the workpiece that can swing when the lathe has a gap bed. 3. The maximum length of the workpiece that can be mounted between the centers. 4. Overall length of the bed. Major Parts of a Lathe 1. Bed: It is the foundation of a lathe upon which all parts are mounted It is made up of grey cast iron because of its good damping property & low frictional resistance for the accurate movement of the carriage & tailstock It is casted into a single piece. Top of the bed consists of 2 sets of precision machined guide ways. Head stock & tailstock are mounted on inner guide ways so that they are perfectly aligned. Carriage moves on the outer guide ways. 2. Main drive: An electric motor mounted in the left leg of the lathe. Belt drive or gear drive connects the motor to the spindle.

3. Cone pulley & back gear: Spindle speeds can be varied by shifting the belt on the different steps of the cone pulley and by using a back gear arrangement. Cone pulley drives the spindle through belt which is driven by the motor 4. Head stock: It is casting rigidly mounted at the left end of the lathe bed. It consists of the spindle, feed gear box and the cone pulley.

Gear box enables the spindle to rotate at different speeds & distributes the power to the lead screw for threading & to the feed rod for turning.

5. Tailstock It is mounted loosely on the lathe bed ways and can be moved, locked at any desired position. It can slide to support different length of workpieces between centers. It is also used to clamp the tools like twist drills and reamers for making holes, and taps. 6. Carriage Assembly It supports & feed the tool against the workpiece during the operation on lathe. It slides along the bed ways longitudinally between head stock & tailstock. It consists of five main parts Saddle is an H shaped casting that slides over the outer set of the guide ways & serves as the base for the cross slide. Cross Slide is mounted on the saddle and enables the movement of the cutting tool laterally across the lathe bed by means of cross-feed hand wheel. Compound rest. It is mounted on the top of the cross slide and supports the tool post. It can be moved independent of the lathe cross feed It can be turned to any angle in the horizontal plane for taper turning and threading operations. Apron It is mounted at the front of the saddle beneath it & houses the carriage and the cross slide. Apron hand wheel moves the carriage assembly manually by rack and pinion gears. Tool Post It is mounted in the T slot of the compound rest. It clamps the tool holder in proper position for machining operations. 7. Lead Screw It is a long threaded shaft geared to the headstock which moves the carriage to and fro longitudinally in front of the lathe bed during thread cutting operations. 8. Feed rod It is a stationary rod which facilitates longitudinal movement of the carriage during turning operation It is powered by a set of gears from the head stock 9. Feed gear box It is mounted on the left side of the lathe bed to transmit various feed gear ratios from the head stock spindle to the lead screw or feed rod LATHE OPERATIONS 1. Plain/Cylindrical turning It is an operation of removing excess material from the workpiece to produce straight cylindrical surface. This operation reduces the diameter of the work piece to the required diameter as shown in figure. The centers are marked, punched and slightly drilled. The work piece is held firmly in between live and dead centers. A proper turning tool is selected and mounted in

the tool holder at a height equal to the height of the axis of the job or slightly above it. Suitable spindle speed is selected. The required feed is set. The automatic feed is engaged to move the carriage parallel to the axis of the job to the desired length. Cutting tool is fed against a revolving workpiece perpendicular to the axis of the workpiece. This operation will cut the material and waste material comes out which is termed as chip. 2. Taper turning A rod is said to be tapered when it increases or decreases in diameter at a uniform rate. E.g. cone It is an operation to produce a conical surface called taper on the cylindrical work piece using a suitable cutting tool. The most common methods to produce taper are, (i) Compound slide swiveling method and (ii) Tail stock off set method. (i) Compound slide swiveling method Here the workpiece is mounted co-axial with the axis of the lathe & the cutting tool is moved linearly inclined to it. The half taper angle, i.e., the angle at which the compound rest to swiveled is calculated using the formula Tan = D-d 2l Where D = larger diameter of taper in mm d = smaller diameter of taper in mm. l = Length of taper in mm and = half of taper angle. A suitable cutting tool is mounted on the tool post. The compound rest, whose circular base is graduated in degrees, is swiveled to one half of the taper angle i.e. to the horizontal (either towards right side or left side of the operator depending on the direction of taper to be produced) and clamped as shown in the Figure. The carriage is locked for any axial movement. Suitable depth of cut is given and the tool is brought near the job and made it to just touch the work piece using cross side. The lathe is started and by rotating the, compound tool rest wheel by hand, the tool is made to travel linearly at, an angle to lathe axis. As soon as the tool reaches the other end of the taper, it is withdrawn using cross slide and setback for the next cut. This method is suitable for producing steep taper with short lengths Limitation (i) Only short tapers can be produced due to the limited movement of the cross slide. (ii) Poor surface finish due to manual operation

(ii) Tail stock off set method The workpiece itself is mounted inclined to the axis of the lathe centers & cutting tool is moved linearly parallel to the axis of lathe bed. The amount of tail stock off-set is calculated by Offset x = L (D-d) 2l Where D = Larger diameter of workpiece d = smaller diameter of workpiece l =length of taper L = length of workpiece The workpiece is held in between the centers. The adjustable screw of tail stock is loosened and slowly the tail stock slides on its base (either towards or away from the operator depending on the direction of taper to be produced) by an amount x mm from the lathe axis as shown in the Figure. The screw is tightened. Now the axis of the workpiece is at an angle with the longitudinal movement of the tool which is parallel to the lathe bed. A suitable cutting tool is selected and mounted on the tool holder. The tool is brought near one end of the taper and made it to just touch the job. The lathe is started with suitable depth of cut is given; the tool is slowly moved parallel to the lathe axis. As soon as the tool reaches the other end of the taper, it is withdrawn and setback for the next cut. Limitation (i) Only small tapers on long work pieces are possible. (ii) Only external tapers can be produced 3. Thread cutting A thread is a helical ridge formed on a cylindrical or conical rod. It is an operation for cutting V-threads or square threads of desired pitch on a workpiece using a suitable thread cutting tool. Here the work piece is held in between the centers. The screw thread of required pitch can be cut by maintaining appropriate gear ratio between the spindle and lead screw The carriage is connected to the lead screw with the help of a split nut. The rotation of the lead screw gives the required motion to the carriage relative to the rotation of the workpiece (or spindle). A suitable thread cutting tool is selected and mounted in the tool post.

 The lathe is then started and suitable depth of cut is given The tool is allowed to move parallel to the axis of the job using automatic arrangement. At the end of the travel, it is quickly withdrawn using cross slide and the split nut is disengaged. The tool is brought back to the starting position for the next cut. NOTE: To cut right hand threads the tool has to travel from right to left and vice versa. 4. Facing It is an operation performed to generate flat surface at the ends of the workpiece and hence reduces the length. The workpiece is held in the chuck. A facing tool is fixed in the tool post at a height equal to the centre of the work piece. Axial movement of the tool is avoided by locking carriage. A suitable spindle speed is selected and the lathe is started. The tool is fed perpendicular to the axis of rotation of the workpiece either from outer edge of the workpiece towards the centre or vice versa. NOTE: 1.the length of the workpiece should not be more than 1.5 times the diameter of the work. 2. Rough cut is given from outer surface of the workpiece to the center 3. Finishing cut is given from center to the outer surface of the workpiece.