Beruflich Dokumente
Kultur Dokumente
The Lathe
Section 11
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
History
Lathe forerunner of all machine tools
First application was potter's wheel
Rotated clay and enabled it to be formed into
cylindrical shape
Turret lathe
Used when many duplicate parts required
Equipped with multisided toolpost (turret) to
which several different cutting tools mounted
Employed in given sequence
PowerPoint to accompany
Engine Lathe
Accurate and versatile machine
Operations
Turning, tapering, form turning, threading,
facing, drilling, boring, grinding, and polishing
Three common
Toolroom
Heavy-duty
Gap-bed
Lathe Size
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
Tailstock
Bed
Quick
Change
Gearbox
Carriage
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
Safety
Belt-driven
lathe
Note!!
NEVER change speeds
Various speeds obtained by changing flat belt
when
lathe
is
running.
and back gear drive
Geared-head lathe
Speeds changed by moving speed levers into
proper positions according to r/min chart
fastened to headstock
PowerPoint to accompany
Lathe Accessories
Unit 46
46-15
Lathe Accessories
Divided into two categories
Work-holding, -supporting, and driving devices
Lathe centers, chucks, faceplates
Mandrels, steady and follower rests
Lathe dogs, drive plates
Cutting-tool-holding devices
Straight and offset toolholders
Threading toolholders, boring bars
Turret-type toolposts
46-16
Lathe Centers
Work to be turned between centers must
have center hole drilled in each end
Provides bearing surface
46-17
Chucks
Used extensively for holding work for
machining operations
Work large or unusual shape
46-18
46-19
46-20
Headstock Spindles
Universal and independent chuck fitted to
three types of headstock spindles
1. Threaded spindle nose
Screws on in a
clockwise direction
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
46-21
Headstock Spindles
3. Cam-lock spindle nose
46-22
Collet Chuck
Most accurate chuck
Used for high-precision work
Spring collets available to hold round,
square, or hexagon-shaped workpieces
Each collet has range of only few
thousandths of an inch over or under size
stamped on collet
46-23
Collet Chuck
46-24
46-25
46-26
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
46-27
Designated by letter R
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
46-28
Straight Toolholder
General-purpose type
Used for taking cuts in either direction and
for general machining operations
Designated by letter S
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
46-29
46-30
46-31
Threading Toolholder
Designed to hold special form-relieved
thread-cutting tool
Has accurately ground 60 angle
Maintained throughout life of tool
Only top of cutting surface sharpened when
becomes dull
46-32
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
PowerPoint to accompany
Cutting Speed,
Feed, and Depth
of Cut
Unit 47
47-34
Cutting Speed
Rate at which point on work circumference
travels past cutting tool
Always expressed in feet per minute (ft/min)
or meters per minute (m/min)
Important to use correct speed for material
Too high: cutting-tool breaks down rapidly
Too low: time lost, low production rates
47-35
ft/min
m/min
ft/min
m/min
11
Machine steel
90
27
100
30
35
Tool steel
70
21
90
27
30
Cast iron
60
18
80
24
25
Bronze
90
27
100
30
25
Aluminum 200
61
300
93
60
18
47-36
CS x 12 CS x 4
r/min
D
D
47-37
Example:
Calculate r/min required to rough-turn 2 in. diameter
piece of machine steel (CS 90):
CS x 4
r/min
D
90 x 4
r/min
180
2
CS x 320
r/min
Metric Formula
D
47-38
Lathe Feed
Distance cutting tool advances along length
of work for every revolution of the spindle
Feed of engine lathe dependent on speed of
lead screw for feed rod
Speed controlled by change gears in
quick-change gearbox
47-39
Finishing cut
Used to bring diameter to size
Fine feed: Produce good finish
.003- to .005-in (0.07- to 0.012-mm)
47-40
in.
Machine steel
Finish Cuts
mm
in.
.010.020 0.250.5
.003.010 0
Tool steel
.010.020 0.250.5
.003.010 0.070
Cast iron
.015.025 0.40.65
.005.012 0.130
Bronze
.015.025 0.40.65
.003.010 0
.005.010 0.130
47-41
Depth of Cut
Depth of chip taken by cutting tool and onehalf total amount removed from workpiece
in one cut
Onlyoneroughingandonefinishingcut
Roughingcutshouldbedeepaspossibleto
reducediametertowithin.030to.040in.(0.76
to1mm)ofsizerequired
Finishingcutshouldnotbelessthan.005in.
47-42
47-43
47-44
Inch System
Circumference of crossfeed and compound
rest screw collars divided into 100-125
equal divisions
Each has value of .001 in.
Turn crossfeed screw clockwise 10 graduations,
cutting tool moved .010 in. toward work
Lathe revolves, so .010 depth of cut taken from
entire work circumference reducing diameter .020 in.
47-45
47-46
47-47
47-48
Shoulder turning
Facing
47-49
PowerPoint to accompany
Lathe Safety
Unit 48
48-51
Safety
Be aware of safety requirements in any area
of shop
Always attempt to observe safety rules
Failure results in:
Serious injury
Resultant loss of time and pay
Loss of production to company
48-52
Safety Precautions
Lathe hazardous if not operated properly
Important to keep machine and surrounding
area clean and tidy
Accidents usually caused by carelessness
48-53
Safety Precautions
Always wear approved safety glasses
Rollup sleeves, remove tie and tuck in loose
clothing
Never wear ring or watch
48-54
Safety Precautions
Do not operate lathe until understand controls
Never operate machine if safety guards
removed
Stop lathe before measure work or clean, oil
or adjust machine
Do not use rag to clean work or machine
when in operation
Rag can get caught and drag in hand
48-55
Safety Precautions
Never attempt to stop a lathe chuck or
driveplate by hand
Be sure chuck or faceplate mounted securely
before starting
If loose, becomes dangerous missile
48-56
Safety Precautions
Move carriage to farthest position of cut and
revolve lathe spindle one turn by hand
Ensure all parts clear without jamming
Prevent accident and damage to lathe
48-57
Safety Precautions
Avoid horseplay at all times
Always remove chips with brush
Chips can cause cuts if use hands
Chips become embedded if use cloths
PowerPoint to accompany
Mounting,
Removing, and
Aligning Lathe
Centers
Unit 49
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
49-59
Objectives
Mount and/or remove lathe
centers properly
Align lathe centers by visual, trialcut, and dial-indicator methods
49-60
Lathe Centers
Work machined between centers turned for
some portion of length, then reversed, and
other end finished
Critical when machining work between
centers that live center be absolutely true
Concentric work
49-61
49-62
Dead center
Turn tailstock handwheel to draw spindle back
into tailstock
End of screw contacts end of dead center, forcing it out
of spindle
49-63
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
49-64
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
49-65
49-66
To Align Centers by
Trial-Cut Method
1. Take a light cut (~.005 in.) to true
diameter from section A at tailstock end
for .250 in. long
2. Stop feed and note reading on graduated
collar of crossfeed handle
3. Move cutting tool away from work with
crossfeed handle
4. Bring cutting tool close to headstock end
49-67
To Align Centers by
Trial-Cut Method
5. Return cutting tool to same graduated
collar setting as at section A
6. Cut a .500-in (13 mm) length at section B
and stop lathe
7. Measure both diameters with micrometer
49-68
To Align Centers by
Trial-Cut Method
8. If both diameters not same size, adjust
tailstock either toward or away from
cutting tool difference of two readings
9. Take another light cut at A and B at same
crossfeed graduated collar setting.
Measure diameters and adjust tailstock.
49-69
49-70
49-71
PowerPoint to accompany
Grinding Lathe
Cutting Tools
Unit 50
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
50-73
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-74
To Grind a
General-Purpose Toolbit
1. Dress face of grinding wheel
2. Grip toolbit firmly, supporting hands on grinder
toolrest
3. Hold toolbit at proper
angel to grind cutting
edge angle
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-75
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-76
50-77
70 to 80 Point Angle
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-78
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-79
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
50-80
PowerPoint to accompany
Machining
Between Centers
Unit 52
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
52-82
Common operations
Facing, rough and finish-turning, shoulder
turning, filing and polishing
52-83
52-84
52-85
52-86
52-87
52-88
52-89
52-90
52-91
Rough Turning
Removes as much metal as possible in
shortest length of time
Accuracy and surface finish are not
important in this operation
.020- to .030-in. feed recommended
Work rough-turned to
Within .030 in. of finished size when removing
up to .500 in. diameter
Within .060 in. when removing > .500 in.
52-92
52-93
52-94
Finish Turning
Follows rough turning
Produces smooth surface finish and cuts
work to an accurate size
Factors affecting type of surface finish
Condition of cutting tool
Rigidity of machine and work
Lathe speeds and feeds
52-95
52-96
4. Take light trial cut .250 in. long at righthand end of work
52-97
Filing in a Lathe
Only to remove small amount of stock,
remove burrs, or round off sharp corners
Work should be turned to within .002 to .003
in. of size
For safety, file with left hand so arms and
hands kept clear of revolving chuck
Remove toolbit from toolholder before filing
Cover lathe bed with paper before filing
52-98
52-99
6. Start lathe
7. Grasp file handle in left hand and support
file point with fingers of right hand
52-100
52-101
Procedure for
Polishing in a Lathe
1. Select correct type and grade of abrasive
cloth for finish desired
52-102
52-103
Shoulder
Shoulder: the change in diameters, or step,
when turning more than one diameter on a
piece of work
Three common types of shoulders
Square
Filleted
Angular or Tapered
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
52-104
PowerPoint to accompany
Knurling,
Grooving,
andFormTurning
Unit 53
53-106
Knurling
Process if impressing a diamond-shaped or
straight-line patter into the surface of the
workpiece
Improve its appearance
Provide better gripping surface
Increase workpiece diameter when press fit
required
53-107
Knurling
Diamond- and
straight-pattern
rolls available in
three styles
Fine
Medium
Course
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
53-108
Knurling Tool
Toolpost-type toolholder on which pair of
hardened-steel rolls mounted
Knurling tool with
one set of rolls in
self-centering head
Knurling tool with
three sets of rolls
in revolving head
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
53-109
Versatility
Rigidity
Ease of handling
Simplicity
53-110
53-111
53-112
53-113
53-114
Grooving
Done at end of thread to
permit full travel of nut up
to a shoulder or at edge of
Square
shoulder for proper fit
Also called recessing,
undercutting, or necking
Rounded grooves used
Round
where there is strain on
part
V-shaped
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
53-115
53-116
53-117
PowerPoint to accompany
Threads and
Thread Cutting
Unit 55
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
55-119
Threads
Used for hundreds of years for holding parts
together, making adjustments, and
transmitting power and motion
Art of producing threads continually
improved
Massed-produced by taps, dies, thread
rolling, thread milling, and grinding
55-120
Threads
Thread
Helical ridge of uniform section formed on
inside or outside of cylinder or cone
55-121
Thread
Terminology
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
55-122
Thread Terminology
Screw thread
Helical ridge of uniform section formed on
inside or outside of cylinder or cone
External thread
Cut on external surface or cone
Internal thread
Produced on inside of cylinder or cone
55-123
Major diameter
Largest diameter of external or internal thread
Minor diameter
Smallest diameter of external or internal thread
Pitch diameter
Diameter of imaginary cylinder that passes
through thread at point where groove and thread
widths are equal
Equal to major diameter minus single depth of
thread
Tolerance and allowances given at pitch
diameter line
55-124
Pitch
Distance from point on one thread to
corresponding point on next thread, measured
parallel to axis
Expressed in millimeters for metric threads
Lead
Distance screw thread advances axially in one
revolution (single-start thread, lead = pitch)
55-125
Root
Bottom surface joining sides of two adjacent
threads
External thread on minor diameter
Internal thread on major diameter
Crest
Top surface joining two sides of thread
External thread on major diameter
Internal thread on minor diameter
Flank
Thread surface that connects crest with root
55-126
Depth of thread
Distance between crest and root measured
perpendicular to axis
Angle of thread
Included angle between sides of thread
measured in axial plane
Helix angle
Angle that thread makes with plane
perpendicular to thread axis
55-127
Right-hand thread
Helical ridge of uniform cross section onto
which nut is threaded in clockwise direction
When cut on lathe, toolbit
advanced from right to left
Left-hand thread
Helical ridge of uniform cross section onto
which nut is threaded in counterclockwise
direction
When cut on lathe, toolbit
advanced from left to right
Copyright The McGraw-Hill Companies, Inc.
Permission required for reproduction or display.
55-128
Thread Forms
April, 1975 ISO came to an agreement
covering standard metric thread profile
Specifies sizes and pitches for various threads
in new ISO Metric Thread Standard
Has 25 thread sizes, range in diameter from 1.6
to 100 mm
Identified by letter M, nominal diameter, and
pitch M 5 X 0.8
55-129
55-130
.6134
D .6134 x P or
N
.125
F .125 x P or
N
55-131
Unified Thread
Developed by U.S., Britain, and Canada for
standardized thread system
Combination of British Standard Whitworth and
American National Standard Thread
55-132
.6134
D (external thread) .6134 x P or
N
.5413
D (internal thread) .5413 x P or
N
.125
F (external thread) .125 x P or
N
.250
F (internal thread) .250 x P or
N
55-133
=maximum.500P+0.010
F=.3707P
C=.3707P-.0052
(formaximumdepth)
55-134
55-135
Square Thread
Being replaced by Acme thread because of
difficulty in cutting it
D = .500P
Often found on vises
F = .500P
and jack screws
C = .500P + .002
55-136
F = 0.125P
R = 0.0633P (maximum)
= 0.054P (minimum)
55-137
Nominal size
Designation used to identify size of part
Actual size
Measured size of thread or part
Basic size: size from which tolerances are set
55-138
Allowance
Permissible difference between largest
external thread and smallest internal thread
Difference produces tightest fit acceptable
for any given classification
The allowance for a 1 in.8 UNC Class 2A and 2B fit is:
Minimum pitch diameter of the
internal thread (2B)
= .9188 in.
Maximum pitch diameter of the
external thread (2A)
= .9168 in.
Allowance = .002 in.
55-139
Tolerance
55-140
Limits
Maximum and minimum dimensions of part
The limits for a 1 in.8 UNC Class 2A thread are:
Maximum pitch diameter of the
external thread (2A)
= .9168 in..
Minimum pitch diameter of the
external thread (2A)
= .9100 in.
55-141
Classes 2A and 2B
Used for most commercial fasteners
Medium or free fit
Classes 3A and 3B
Used where more accurate fit and lead required
No allowance provided
55-142
1
1
.628 in.
P
.100 in.
tpi 10
P 1 1
Width of flat x
D .61343 x P
8 8 10
.61343 x .100 .061 in.
.0125 in.
55-143
55-144
55-145
55-146
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
55-147
Thread Cutting
Produces a helical ridge of uniform section
on workpiece
Performed by taking successive cuts with
threading toolbit of same shape as thread
form required
Work may be held between centers or in
chuck
55-148
55-149
55-150
Thread-Cutting Operation
Procedure to cut a 60 thread
1. Check major diameter of work for size
2. Start lathe and chamfer end of workpiece
with side of threading tool to just below
minor diameter of thread
3. Mark length to be threaded by cutting
light groove at this point with threading
tool while lathe revolving
55-151
55-152
55-153
55-154
55-155
tpi
30
29
24
20
18
16
14
table taken
13 Portion
.050of.0577
.057
from textbook
11
.059
.068 .0674
55-156
55-157