Beruflich Dokumente
Kultur Dokumente
Chapter 4
Lathe
Turning Operations
Machine
Tool LATHE Job (workpiece) rotary motion Tool linear motions Mother of Machine Tools Cylindrical and flat surfaces
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
On
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
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
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
- 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
Magnetic Chuck
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
Operating/Cutting Conditions
1. 2.
3.
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
=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
Chuck Feed (f )
Operating Conditions..
Selection of ..
Workpiece
Material Tool Material Tool signature Surface Finish Accuracy Capability of Machine Tool
Operations on Lathe ..
Operations on Lathe ..
Operations on Lathe
Turning
Facing Chamfering Taper
knurling
Grooving Parting
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
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
Operations on Lathe ..
Knurling
Produce
Knurling
Tool
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
Grooving tool
Operations on Lathe ..
Parting
Cutting
Tool
Operations on Lathe ..
Parting ..
Parting tool
Feed
Operations on Lathe ..
Chamfering Chamfer
Operations on Lathe ..
Chamfering
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
tailstock
Operations on Lathe ..
.. By Form Tool
Taper Turning
Workpiece Taper
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 ,,
65
Note: Make sure both setscrews snugged up to prevent any lateral movement of tailstock
66
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
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69
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
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.
:(
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
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.
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
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Operations on Lathe ..
Process Sequence
How
Steps:
40
Operations on Lathe ..
Possible Sequences
Process 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
Machining time:
t
t
Lj f N
min
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
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
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
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