Sie sind auf Seite 1von 93

Lathe Operations

Chapter 4

Lathe

Turning Operations
Machine

Tool LATHE Job (workpiece) rotary motion Tool linear motions Mother of Machine Tools Cylindrical and flat surfaces

Some Typical Lathe Jobs


Turning/Drilling/Grooving/ Threading/Knurling/Facing...

Lathe
Head stock Spindle speed selector Feed change gearbox Spindle Guide ways Tool post Cross slide Dead center Tailstock quill Tailstock Handle Compound rest and slide(swivels) Bed Carriage Apron Feed rod Lead screw

Lathe
Head Stock

Tail Stock
Bed

Feed/Lead Screw

Carriage

Lathe

Lathe Bed
Heavy, Made

rugged casting

to support working parts of lathe top section are machined ways

On

Guide and align major parts of lathe

Lathe Bed

Headstock
Clamped on left-hand end of bed Headstock spindle Hollow cylindrical shaft supported by bearings Provides drive through gears to work-holding devices Live center, faceplate, or chuck fitted to spindle nose to hold and drive work Driven by stepped pulley or transmission gears Feed reverse lever :Reverses rotation of feed rod and lead screw 9

Headstock

10

Quick-Change Gearbox
Contains number of different-size gears Provides feed rod and lead-screw with various speeds for turning and threadcutting operations Feed rod advances carriage when automatic feed lever engaged Lead screw advances the carriage for thread-cutting operations when split-nut lever engaged

11

Quick-Change Gearbox

Top View

12

Carriage
Used

to move cutting tool along lathe bed Consists of three main parts Saddle H-shaped casting mounted on top of lathe ways, provides means of mounting cross-slide and
13

Carriage

14

Cross-slide Mounted on top of saddle Provides manual or automatic cross movement for cutting tool Compound rest (fitted on top of crossslide) Used to support cutting tool Swiveled to any angle for taperturning Has graduated collar that ensure accurate cutting-tool settings (.001 in.) (also cross-slide)

15

Cross-slide

16

Apron
Fastened to saddle Houses gears and mechanism required to move carriage or crossslide automatically Locking-off lever inside apron prevents engaging split-nut lever and automatic feed lever at same time Apron hand wheel turned manually to move carriage along lathe bed

17

Apron

18

Automatic Feed Lever


Engages clutch that provides automatic feed to carriage Feed-change lever can be set for longitudinal feed or for crossfeed In neutral position, permits split-nut lever to be engaged for thread cutting Carriage moved automatically when split-nut lever engaged

19

Tailstock
Upper and lower tailstock castings Adjusted for taper or parallel turning by two screws set in base Tailstock clamp locks tailstock in any position along bed of lathe Tailstock spindle has internal taper to receive dead center Provides support for right-hand end of work

20

Tailstock

21

Setting Speeds on a Lathe


Speeds measured in revolutions per minute Belt-driven lathe Various speeds obtained by changing flat belt and back gear drive Geared-head lathe Speeds changed by moving speed levers into proper positions according to r/min chart fastened to headstock

22

Types of Lathes
Engine Lathe Tool Room Lathe Gap Bed Lathe Capstun lathe Turret lathe Speed Lathe Bench Lathe Special Purpose Lathe

Specifications of Lathe
Workpiece Length

Swing

Specifications of Lathe
Example: 300 - 1500 Lathe Maximum Diameter of Workpiece that can be machined = SWING (= 300 mm) Maximum Length of Workpiece that can be held between Centers (=1500 mm)

Workholding Devices
Equipment

used to hold Workpiece fixtures Tool - jigs

Securely HOLD or Support while machining

Three jaw chuck

- For holding cylindrical stock centered. - For facing/center drilling the end of your aluminum stock Four-Jaw Chuck - This is independent chuck generally has four jaws , which are adjusted individually on the chuck face by means of adjusting screws

Workholding Devices ..

Chucks
Three jaw Four Jaw

Collet Chuck Collet chuck is used to hold small workpieces

Thin jobs can be held by means of magnetic chucks.

Magnetic Chuck

Thin jobs can be held by means of magnetic chucks.

Workholding Devices ..

Centers
Headstock center (Live Centre) Tailstock center (Dead Centre)

Workpiece

Workholding Devices ..

Faceplates
Workpiece

Workholding Devices ..

Dogs
Tail

Tail

Workholding Devices ..

Mandrels
Workpiece (job) with a hole
Workpiece Mandrel

Workholding Devices ..

Rests
Steady Rest
Jaws Work Hinge

Follower Rest
Work

Jaws

Carriage Lathe bed guideways

Operating/Cutting Conditions
1. 2.

3.

Cutting Speed v Feed f Depth of Cut d


Tool post Workpiece Chip Tool
D

N (rev/min) S peripheral speed (m/min)

Operating Conditions
Tool post Workpiece Chip

N (rev/min)

S Tool peripheral D speed (m/min) relative tool travel in 1 rotation D peripheral speed S D N

Operating Conditions..

Cutting Speed
D Diameter (mm) N Revolutions per Minute (rpm)

DN
1000

m/min

The Peripheral Speed of Workpiece past the Cutting Tool

=Cutting Speed

Operating Conditions..

Feed
f the distance the tool
advances for every rotation of workpiece (mm/rev)
D1 D2

f Feed

Operating Conditions..

Depth of Cut
perpendicular distance between machined surface and uncut surface of the Workpiece d = (D1 D2)/2 (mm)
D1 D2 d Depth of Cut

3 Operating Conditions
Cutting speed Workpiece
N

Depth of cut (d) Machined surface Chip Depth of cut Tool

Chuck Feed (f )

Operating Conditions..

Selection of ..
Workpiece

Material Tool Material Tool signature Surface Finish Accuracy Capability of Machine Tool

Operations on Lathe ..

Material Removal Rate


MRR
Volume of material removed in one revolution MRR = D d f mm3 Job makes N revolutions/min

MRR = D d f N (mm3/min) In terms of v MRR is given by


MRR = 1000 v d f (mm3/min)

Operations on Lathe ..

Operations on Lathe
Turning
Facing Chamfering Taper

knurling
Grooving Parting

turning Drilling Threading

Lathe Operations

Operations on Lathe ..

Turning
Cylindrical job

Operations on Lathe ..

Turning ..
Cylindrical job
Cutting speed Workpiece
N

Depth of cut (d) Machined surface Feed Tool Chip Depth of cut

Chuck

Operations on Lathe ..

Turning ..
Excess Material is removed to reduce Diameter Cutting Tool: Turning Tool

reduce diameter by 2 mm

depth of cut of 1 mm will

Operations on Lathe ..

Facing
Flat Surface/Reduce length
Chuck Workpiece d Machined Face Cutting speed Tool Feed Depth of cut

Operations on Lathe ..

Facing ..
machine

end of job Flat surface or to Reduce Length of Job Turning Tool Feed: in direction perpendicular to workpiece axis Length of Tool Travel = radius of workpiece Depth of Cut: in direction parallel to workpiece axis

Operations on Lathe ..

Facing ..

Operations on Lathe ..

Eccentric Turning
4-jaw chuck Axis of job

Axis Cutting speed Eccentric peg (to be turned)

Operations on Lathe ..

Knurling
Produce

Knurling

rough textured surface For Decorative and/or Functional Purpose

Tool

A Forming Process MRR~0

Operations on Lathe ..

Knurling
Knurled surface Cutting speed Feed Knurling tool Tool post Movement for depth

Operations on Lathe ..

Knurling ..

Operations on Lathe ..

Grooving
Produces

a Groove on workpiece Shape of tool shape of groove Carried out using Grooving Tool A form tool Also called Form Turning

Operations on Lathe ..

Grooving ..
Shape produced by form tool Groove

Form tool

Feed or depth of cut

Grooving tool

Operations on Lathe ..

Parting
Cutting

workpiece into Two Similar to grooving


Parting Hogging

Tool

tool rides over at slow feed Coolant use

Operations on Lathe ..

Parting ..

Parting tool

Feed

Operations on Lathe ..

Chamfering Chamfer

Feed Chamfering tool

Operations on Lathe ..

Chamfering

Beveling sharp machined edges Similar to form turning Chamfering tool 45 To


Avoid Sharp Edges Make Assembly Easier Improve Aesthetics

Operations on Lathe ..

Taper Turning
Taper:

D1 D2 tan 2L
90

D1

D2

B A

Operations on Lathe ..

Taper Turning..
Conicity
D1 D2 K L

Methods

Offsetting

Form Tool Swiveling Compound Rest Taper Turning Attachment

Simultaneous Longitudinal and Cross Feeds

tailstock

Operations on Lathe ..

.. By Form Tool
Taper Turning
Workpiece Taper

Form Straight tool cutting edge

Direction of feed

Operations on Lathe ..

By Compound Rest
Dog Mandrel Tail stock quill Tail stock Face plate Tool post & Tool holder Cross slide Direction of feed Compound rest Slide Compound rest Hand crank

Taper Turning ,,

Tailstock Offset Method


Generally used to cut taper when no taper attachment available Involves moving tailstock center out of line with headstock center Amount tailstock may be offset limited Will not permit steep tapers to be turned or standard tapers turned on end of long piece of work

65

Procedure to Offset Tailstock by the Visual Method


Loosen the tailstock clamp nut Offset upper part of tailstock by loosening one setscrew and tightening the other until required amount is indicated on graduated scale at end of tailstock

Note: Make sure both setscrews snugged up to prevent any lateral movement of tailstock

66

Procedure to Offset the Tailstock Accurately


1.

2.

3.

Adjust tailstock spindle to distance it will be used in machining setup and lock tailstock spindle clamp Mount a dial indicator in toolpost with plunger in horizontal position and on center Using crossfeed handle, move indicator so registers ~.020 in on work, and set indicator and crossfeed graduated collars to zero 67

4.
5.

6.

7.

Loosen tailstock clamp nut With tailstock adjusting setscrews, move tailstock until required offset shown on dial indicator Tighten tailstock setscrew that was loosened, making sure indicator reading does not change Tighten tailstock clamp nut

Note: Tailstock may also be offset by using feeler gage between toolpost and tailstock spindle in conjunction with crossfeed graduated collar
68

Plain Taper Attachment

69

Procedure to Taper Using a Taper Attachment


1. 2.

3. 4.

Clean and oil guide bar Loosen lock screws and offset end of guide bar the required amount or, for inch attachments, set bar to required taper in degrees . Tighten lock screws With compound rest set at 90, set up cutting tool on center

70

Operations on Lathe ..

Drilling
Drill cutting tool held in TS feed from TS
Quill clamp moving Drill quill Tail stock Feed Tail stock clamp

Cutting Screw Threads

Screw-Thread Nomenclature Standardization of screw threads began in the middle 1880s a) Standard nomenclature for screw threads, (b) Unified National thread and identification of threads, (c) ISO metric thread and identification of threads.
:(

Cutting Screw Threads

Design Considerations for Screw-Thread Cutting

Should allow for the termination of threads before they reach a shoulder Eliminate shallow, blind tapped hole Chamfers should be specified at the ends Threaded sections should not be interrupted with slots, holes, or other discontinuities Use standard tooling for threads Operations should be completed in one step

Cutting Screw Threads

Fig :

(a) Cutting screw threads on a lathe with a single-point cutting tool. (b) Cutting screw threads with a single-point tool in several passes, normally utilized for large threads. The small arrows in the figures show the direction of feed, and the broken lines show the position of the cutting tool as time progresses. (c) A typical carbide insert and tool holder for cutting screw threads. (d) Cutting internal screw threads with a carbide insert.

Types of Screw threads

Fig : Various types of screw threads

Thread-Chasing dial

Lathe spindle and lead screw must be in same relative position for each cut

Thread-chasing dial attached to carriage for this purpose Even threads use any division Odd threads either numbered or unnumbered: not both

Dial has eight divisions

76

Operations on Lathe ..

Process Sequence
How

to make job from raw material 45 long x 30 dia.?


15
Operations Sequence 20 dia Tools Process

Steps:

40

Operations on Lathe ..

Possible Sequences

Process Sequence ..

What is an Optimal Sequence?

TURNING - FACING - KNURLING TURNING - KNURLING - FACING X FACING - TURNING - KNURLING FACING - KNURLING - TURNING X KNURLING - FACING - TURNING X KNURLING - TURNING FACING X

Operations on Lathe ..

Machining Time
Turning Time Job length Lj mm Feed f mm/rev Job speed N rpm f N mm/min
t Lj f N min

Operations on Lathe ..

Manufacturing Time
Manufacturing Time
= + + + Machining Time Setup Time Moving Time Waiting Time

Examples
(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 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

DN
1000

m/min

calculate the required spindle speed as: N = 191 rpm

Machining time:

t
t

Lj f N

min

= 500 / (0.7191) = 3.74 minutes

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. Given data: D1 = 80 mm, D2 = 50 mm, Lj = 80 mm (with usual notations) tan = (80-50) / 280 or = 10.620 The compound rest should be swiveled at 10.62o

Example
(3)A 150 mm long 12 mm diameter stainless steel rod is to be reduced in diameter to 10 mm by turning on a lathe in one pass. The spindle rotates at 500 rpm, and the tool is traveling at an axial speed of 200 mm/min. Calculate the cutting speed, material removal rate and the time required for machining the steel rod. Given data: Lj = 150 mm, D1 = 12 mm, D2 = 10mm, N = 500 rpm DN m/min Using Equation . v 1000 v = 12500 / 1000 = 18.85 m/min. depth of cut = d = (12 10)/2 = 1 mm

feed rate = 200 mm/min, we get the feed f in mm/rev by dividing feed rate by spindle rpm. That is f = 200/500 = 0.4 mm/rev From Equation ,MRR = D d f N (mm3/min) MRR = 3.142120.41500 = 7538.4 mm3/min from Equation . Lj t min f N

= 150/(0.4500) = 0.75 min.

Calculation of the machining time when there is more than one operation?

Example
(4)Calculate the time required to machine a workpiece 170 mm long, 60 mm diameter to 165 mm long 50 mm diameter. The workpiece rotates at 440 rpm, feed is 0.3 mm/rev and maximum depth of cut is 2 mm. Assume total approach and overtravel distance as 5 mm for turning operation. Given data: Lj = 170 mm, D1 = 60 mm, D2 = 50mm, N = 440 rpm, f = 0.3 mm/rev, d= 2 mm

Time for Turning:


Total length of tool travel = job length + length of approach and over-travel L = 170 + 5 = 175 mm Depth to be cut d= (60 50)/2 = 5 mm Since maximum depth of cut is 2 mm, 5 mm cannot be cut in one pass. Therefore, we calculate number of cuts or passes required. Number of cuts = 5/2 = 2.5 = 3(since cuts cannot be a fraction) Machining time for one cut = L / (fN) Total turning time = [L / (fN)] Number of cuts = [175/(0.3440)] 3 = 3.97 min.

Time for facing:


Now, the diameter of the job is reduced to 50 mm. Recall that in case of facing operations, length of tool travel is equal to half the diameter of the job. That is, l = 25 mm. Lj Substituting in equation , t min f N we get t = 25/(0.3440) = 0.18 min.

Total time:
Total time for machining = Turning Time + Facing Time = 3.97 + 0.18 = 4.15 min.

Example
Write

the process sequence to be used for manufacturing the component from raw material of 175 mm length and 60 mm diameter

Example
20 Threading

50

40 Dia

50

40

50

20 Dia

Example
To write the process sequence, first list the operations to be performed. The raw material is having size of 175 mm length and 60 mm diameter. The component shown in Figure 5.23 is having major

diameter of 50 mm, step diameter of 40 mm, groove


of 20 mm and threading for a length of 50 mm. The total length of job is 160 mm. Hence, the list of

operations to be carried out on the job are turning,


facing, thread cutting, grooving and step turning

Example
A

possible sequence for producing the component would be: Turning (reducing completely to 50 mm) Facing (to reduce the length to 160 mm) Step turning (reducing from 50 mm to 40 mm) Thread cutting. Grooving

Das könnte Ihnen auch gefallen