Lecture outline

Chapter two
Conventional Machine Tools and Machining Process
Introduction,
Lathe machine and related operations,
Drilling and grinding processes,
Milling and related operations,
Kinematics of machine tools,
Geometry of tools and tool materials, and
Mechanics of machining and related parameters
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Introduction
In the field of manufacturing, the term of Machining
means removal of extra size from a raw material, by
cutting small chips, in order to obtain the desired shape
and dimensions for final part.
Machining operation produces a predefined geometry
due to two factors:
(1) The relative motions between the tool and the work part
(2) The shape of the cutting tool

Introduction
Tool is a device use to carry out various machining
operation. It can be classified as;
Hand tools; which are used manually by human
effort. E.g. hack saw
Machine tools; power driven machine which
accomplishes the cutting or machining operation.

Tools
Hand
tools

Machine
tools
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Introduction
Machined parts can be rotational or non rotational.
A rotational work part has a cylindrical or disk-like shape
and achieved when cutting tool removes material
from a rotating work part. E.g. turning and boring.
A non rotational (prismatic) work part is block-like and its
geometry is achieved by linear motions of the work part,
combined with either rotating or linear tool motions. E.g.
milling, planing, and sawing

Rotational work part

Prismatic/non rotational part

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Introduction
Machining process is carried out by using conventional
and non conventional machining technology.
Conventional machining (CM) uses mechanical (motion)
energy. It involves single point or multiple point cutting
tools. For instance, operations performed on lathe,
milling, and drilling machine.
Non-conventional machining (NCM) utilizes other forms
of energy, Such as: thermal energy, chemical energy, and
electrical energy.
NCM evolved to machine hard metals and alloys and to
reduce cost of tool wear in conventional machining.
Conventional machining usually involves an implement
made of a harder material (cutting tool) to get machined
part or products.
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Conventional machining tools

Lathe machine
Milling machine
Drilling Machine
Planing machine
Grinding machine

Lathe machine
A lathe is machine tool employed generally to
produce or machine circular objects.
Its specific function is to produce cylindrical profiles
It is commonly known as the mother of all other
machine tool.

Lathe machine

Working principle of lathe

A lathe works on the principle that a cutting tool can
remove chips from the rotating work pieces to
produce circular objects.
- The figure shows a work holding
device known as chuck and which
rotates at a very high speed.
- A V-shaped cutting tool is held
against the work piece.
- When the tool is moved parallel to
axis of work piece extra size is
removed/machined.
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Working principle of lathe

Feed mechanism: the movement of the tool relative to the
work piece is termed as feed. The lathe tool can have
three types of feed.
Longitudinal, Cross slide and Angular feeds
1. When the tool moves parallel to the axis of the lathe, the
movement is called longitudinal feed. this is achieved by
moving the carriage.
2. When the tool moves perpendicular t the axis of the lathe, the
movement is called cross feed. this is achieved by moving the
cross slide.
3. When the tool moves at an angle to the axis of the lathe, the
movement is called angular feed. this is achieved by moving
the compound slide, after swivelling it at an angle to the axis.
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Feed mechanism

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Video 1: machining or metal turning in a lathe

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Major components of lathe machine

Machine Bed, usually made of cast iron.

It is the foundation part of lathe and supports all its

parts. Such as; headstock, tailstock, carriage etc.
The top of the machine bed is flat and is machined
to form guide ways on which the carriage slides
along the length of the lathe.
The bed should have sufficient weight and be of
proper material so that the vibrations generated
during operations are damped out.

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Major components of lathe machine

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Major components of lathe machine

Head stock; It is fixed at the extreme left hand of the bed.
The driving shaft inside is driven by an electric motor which
in turn drives hollow spindle.
The spindle can be driven at various R.P.M. by changing
gears inside head stock using control levers.
These control levers can be either spindle control lever or
feed control levers
The work piece can be held in the jaws of the chuck.
When the spindle rotates, the chuck as well as the work piece
held also rotates about the longitudinal axis of the spindle.

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Major components of lathe machine

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Major components of lathe machine

Tail stock

Movable part of the lathe that carries dead center.

Main function is to support the free end of the work piece.
Also used to clamp tools like twist drill and reamers for
making holes.
Tailstock is mounted loosely on guide ways can be moved
and locked in position.

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Major components of lathe machine

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Major components of lathe machine

Carriage assembly
Saddle is H shaped casting that slides over the outer set
of guide ways and serves as base for cross slide.
Cross slide is mounted on the saddle, it enables lateral
or side movement of cutting tool laterally by means of
cross slide hand wheel.
Compound rest is mounted on top of cross slide and
supports the tool post. It can be swiveled at an angle to
perform taper turning operation.
Tool post is used to clamp the tool holder in position
Apron is the part which is fitted saddle, facing
operator. It houses levers, hand wheels mechanism for
manual and automatic movement of carriage assembly.19

Major components of lathe machine

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Compound rest and tool post

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Other components of lathe machine

Feed rod: is a long shaft, used to move the carriage
or cross-slide for turning, facing, boring and all other
operations except thread cutting.
Lead screw is a rod which runs longitudinally in front
of lathe bed.
Lead screw is brought into operation only when
threads have to be cut. In other times it is
disengaged from the gear box and remain stationary.
The rotation of the lead screw is used to traverse the
tool along the work to produce screw threads.
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Other components of lathe machine

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Basic components of a lathe

Bed
Headstock
Tailstock
Carriage

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Major components of lathe machine

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Video 2: Parts of engine lathe

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Lathe specifications

Maximum diameter of the work piece that can be revolved over the lathe bed.
Maximum diameter &width of the work piece that can revolve over gap in bed.
Maximum length of work piece that can be mounted between centers.
Overall length of the bed.

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Specifications to Lathe machine

A lathe is machine tool employed generally to
produce or machine circular objects.
Its specific function is to produce cylindrical profiles
It is commonly known as the mother of all other
machine tool.

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Lathe accessories and Attachments

The devices employed for holding and supporting the
work piece and the tool on the lathe referred as
accessories. To suit different types of jobs,
different holding and supporting devices are;

Lathe center or live center: are made of very hard

materials to resist deflection and wear and they

are used to hold and support the cylindrical jobs.

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Lathe accessories and Attachments

Driving/lathe dogs are attached to the end of the job by
a set screw. It used for holding and supporting the job

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Lathe accessories and Attachments

Chucks: is one of the most important devices for
holding and rotating a job in a lathe.
There are a number of types of lathe chucks, e.g.
Three jaws or universal
Four jaw independent chuck

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Lathe accessories and Attachments

Three-jaw chuck: is a rotating clamp which uses
three dogs or 'jaws', usually interconnected via a scroll
gear (scroll plate), to hold onto a tool or work piece.
Three-jaw chucks are usually self - centering (as a
result of the jaws' meshing with the scroll plate) and
are best suited to grip circular or hexagonal cross
sections when very fast, reasonably accurate

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Lathe accessories and Attachments

Four-jaw chuck: is similar to a three-jaw chuck, but
with four jaws, each of which can be moved
independently. This makes them ideal for
Gripping non-circular cross sections and
Gripping circular cross sections with extreme
precision.

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Lathe accessories and Attachments

Steady Rests: is a lathe device, which supports a long
cylindrical work, when it is turned between centers or
by a chuck, at some intermediate point to prevent
bending of the job due to its own weight and vibration
set up due to the cutting force that acts on it.

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Face Plate
A face plate is mounted onto the spindle and is used to
hold work pieces with non-cylindrical shapes.

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Video 3: lathe work holding/accessories

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