LATHE

HL. EXAM Q7
1. THE CENTRE LATHE
 THE CENTRE LATHE
 The Centre Lathe or more commonly known as the Lathe
 Used predominantly for producing cylindrical and conical
shaped work
 Can produce a flat end on a Workpiece
 Can also be used on workpieces other than cylindrical shape,
for example square bar.
 Uses a single point cutting tool
 Machining parts on the lathe is also called Turning
THE TURNING PROCESS
THE TURNING PROCESS
2 Basic Operations on
a Lathe

 Parallel Turning:
Generating a smaller cylindrical
shape than the original size
of workpiece

 Facing/ Facing off:

Generating a flat surface on the
end of a workpiece
MAIN PARTS OF THE
LATHE
 PARTS OF THE LATHE
Feed Gearbox

Situated at base of headstock.

Feedshaft and leadescrew protrude from gearbox across front of bed.

Feedshaft provides power to the apron for automatic carriage feed.

Leadscrew is used when cutting screw threads on lathe.

Leadscrew and feedshaft rotate simultaneously. Because leadscrew is not

used that often, it can be disengaged with a dog clutch preventing any
unnecessary wear of it’s bearings
FEEDSHAFT & LEADSCREW
Chuck Headstock

Leadscrew

Feedshaft
 PARTS OF THE LATHE
 The Tailstock:
Stands on the bed opposite the headstock.

Can be clamped at any spot.

Body made from cast iron.

The barrel is an accurately machined cylindrical

part which slides in the body when
handwheel is turned. Barrel can also be
locked in position.

Tailstock used for drilling and reaming.

Live centre can be fitted to support long

workpieces.

Centre of barrel is on axis of lathe.

Tailstock can be moved side to side for long

taper turning.
TAILSTOCK
 TAILSTOCK

Tailstock with chuck, Tailstock with live centre, for

For Drilling and maching between centres.
Reaming
 PARTS OF THE LATHE
Toolpost:
Used to hold the cutting tool when machining

4 Way Toolpost Quick Change Toolpost

 PARALLEL TURNING

Rotation of workpiece
towards the cutting tool

Cutting Tool
moves Parallel to
the axis

Cutting Tool
 FACING/ FACING OFF

Direction of rotation of
workpiece

Chip produced

Single point cutting

tool
Movement of the
cutting tool
FACING OFF USING CROSS SLIDE
 PARTING OFF

Direction of rotation of
workpiece

Movement of
parting tool

Chip
 PARTING OFF Workpiece

Chip Parting Tool moves

Parting Tool perpendicular to the
axis
DRILLING/ REAMING
Direction of
rotation

Drill bit or reamer

is held in the chuck
of the Tailstock

Movement of Drill
bit or Reamer
DRILLING & REAMING ON
THE LATHE
Work

Drill bit

Chip Barrel

Chuck

Morse Taper
CENTRE DRILLING ON THE
LATHE
 CENTRE DRILLING

Centre Drill
Finds exact centre of
work
TAPER TURNING
Direction of Rotation

Workpiece

Lathe Axis

Cutting Tool is moved at an

angle to the axis of lathe.

Achieved by offsetting the

topslide to required angle
SHORT TAPERS
PRODUCING A SHORT TAPER
 PRODUCING A LONG TAPER
Lathe Axis no
longer going
through centre
of work

End View Of Tailstock,

shows it being offset
TAPER TURNING ATTACHMENT
FOR LONG TAPERS
 KNURLING
Rotation of Work.
Work rotates very
slowly for Knurling

Knurl,
Pattern produced

Direction of
Wheels are pushed
Knurling Tool
against surface to
produce a pattern
Knurling
Tool
KNURLING
BORING
FORM TURNING
 GENERATING AND FORMING
Forming is when the surface produced is a copy of the tool producing it. Contour work
and screw-cutting are examples of forming. Tool is fed directly into the work piece.

Generating uses a single pointed cutting tool that moves in various directions until the
required surface is machined.
Facing and taper turning on the lathe are examples of machining by generation.
EFFECT OF TOOL HEIGHT
SURFACE FINISH ON THE LATHE
 WORKHOLDING IN THE
LATHE
The most important means of holding workpieces
are:

The three-jaw self-centring chuck. (Also a six-jaw

self-centring chuck)
The four-jaw independent chuck
The Collet chuck
The faceplate
Mandrels
Between centres
THREE-JAW SELF-
CENTRING CHUCK

3 jaws move
simultaneously when
chuck key is rotated

Chuck key inserted

in this slot

Jaws are
labelled because
they must be
inserted in
correct order
SIX-JAW SELF-CENTRING
CHUCK

6 jaws move at the

same time when
chuck key rotates
FOUR-JAW INDEPENDENT
CHUCK

Each jaw is tightened

separately
TRAVELLING STEADY
Used to prevent
long bars from
deflecting

Attached to the
top of the carriage
and positioned in
front of the cutting
tool
 TRAVELLING STEADY

Positioned at all
Work Fixed to times ahead of
Fixed Steady Cutting Tool cutting tool
carriage
supporting work
FIXED STEADY
 FIXED STEADY
Closed Open

Travelling steady
Supporting work fixed to lathe
slideways
METAL CUTTING

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 METAL CUTTING
Metal cutting is the process of removing or cutting unwanted metal
from a work piece.
The metal is cut away in the form of chips or swarf using a cutting
tool or tools.
All cutting tools are based on the wedge shape whether, the tool is a
single point one or a multi point one.

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 TYPE OF SWARF
There are three different types of swarf produced during
metal cutting. The type of swarf produced depends on
the type of materials been cut.

Continuous chip:

Discontinuous chip:

Chip with a build up edge:

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CONTINUOUS CHIP

Continuous chip: Ductile material, copper, aluminium and

nylon..

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 DISCONTINUOUS CHIP
Discontinuous chip: Brittle material, brass and cast iron.

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 CHIP WITH A BUILD UP EDGE
Chip with a build up edge: Forms when bits of the metal
been cut become welded on the rake face of the tool, caused
by high temperature, high pressure, happens when turning
some types of aluminium. Use coolant

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 TOOL GEOMETRY
The basic shape of all cutting tools are, as mentioned based on a
wedge shape. This wedge shape has two very important angles on it
that allow it to work efficiency when cutting.

Clearance angle: Front & Side

Rake Angle:

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RAKE & CLEARANCE
ANGLES

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TOOL ANGLES
 CLEARANCE ANGLE
Clearance Angles are needed to prevent the front and sides of the cutting tool
rubbing off the work piece.

If there was no Rake or Clearance angles on a cutting tool, it would be impossible

for the tool to cut.

51
 RAKE ANGLE
• The rake angle is on the top edge of the tool, its angle
depends on the type of material been cut, hard materials
require a small rake angle, ductile metals have a large
rake angles.
• There are two types of rake that can be found on tools;
negative rake and positive rake
• Another function of the rake angle is to allow the swarf
or cut metal to flow away from the work piece.
• The angle of the rake on a cutting tool affects how sharp
it is, which in turn affects the size of the Shear Plane
Angle.

52
TOOL ANGLES
The Rake Angle will directly affect the size of the shear
plane angle & area. The shear plane happens at almost 90°
to the rake angle.
 SHEAR PLANE ANGLE

A large rake angle gives a small shear angle, easy to

cut. A sharp tool needs less force to cut.

Shear Plane
Swarf
Work piece

Cutting Tool

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 SHEAR PLANE ANGLE
A small rake angle gives a large shear angle, tool not as sharp
so more difficult to cut a material.

Shear Plane

Swarf
Work piece

Cutting Tool

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 POSITIVE & NEGATIVE RAKE
Negative Rake Angle: The tangential cutting force is taken
on a more well supported part of the tool. The force is
transmitted down into the machine base. This increases the
strength of the tool and allows for higher cutting speeds

Tangential Force

Cutting Tool

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 POSITIVE RAKE
Positive Rake Angle: the tool is not well supported at the
cutting edge and so the tangential force could easily break it.

Tangential Force

Cutting Tool

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 TOOL WEAR

 Four types:
 Flank wear: tool become flat on clearance face.
 Crater wear: crater appears on rake face.
 Plastic deformation: cutting edge becomes plastic and
rounded.
 Spalling/chipping: edges chip or breaks away.

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 TOOL WEAR

Crater Wear Plastic Spalling/Chipping

Deformation

Flank
Wear

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 FORCES IN METAL CUTTING
• Two types:
1. Orthogonal Cutting:
2. Oblique Cutting:

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 ORTHOGONAL CUTTING
Orthogonal Cutting: two forces acting on the cutting
tool; axial force and tangential force.

Axial Force

Tangential Force

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 OBLIQUE CUTTING
Oblique Cutting: Three forces acting on the cutting tool;
Axial force, tangential force and radial force.

Axial Force

Tangential Force
Radial Force

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 Lathe

PREVIOUS EXAM QUESTIONS

2015-2004
 2015

 (iii) State two uses for a chuck guard on the lathe;

 (c)
 2014

 (ii) Describe the formation of a built-up edge on a

cutting tool.
 (iv) Differentiate between forming and generating
when machining.
 2013

 (i) Identify three safety features incorporated in the

design of a centre lathe.

 (iii) Distinguish between any two types of chip

formed when machining.

 (v) Identify one advantage and one disadvantage of

using carbide tipped cutting tools when machining.
 2012

 Identify two benefits of the use of cutting fluids in

machining

 (iv) Describe the main factors that influence metal

surface finish when parallel turning on the lathe
 2011

 Identify two safety precautions that reduce the

formation of a built-up edge while turning on a
centre lathe;

 (ii) Distinguish between oblique cutting and

orthogonal cutting
 (iv) Describe the main features of a Morse taper
sleeve;
 (v) State the function of a reamer.
2011
 2010

 (i) Identify two cutting tool materials used on a

centre lathe;

 (iii) Explain the differences between forming and

generating;
2010
 2009

 (ii) Describe the process of knurling;

 2008

 (i) Name three types of chip formed in metal cutting;

 (ii) Describe the function of a reamer;
 (iii) Outline two factors that influence the amount of
heat generated in a
 machining operation;
 (iv) Identify two safety issues associated with
machining mild steel;
 2007

 (I) Identify three safety features that should be

incorporated into a centre lathe;
 (ii) List three reasons for using a cutting fluid when
machining;
 (iv) Distinguish between orthogonal and oblique
cutting forces;
 (v) Describe how surfaces are machined by forming
and generating.
2006
 2006

 (b) (iii) Rake angle and clearance angle;

 (c) Identify two safety hazards associated with each

of the following:

 (i) Using cutting fluids;

 (ii) Machining mild steel.
 2005

 Distinguish between countersinking and

counterboring when drilling;
 (ii) Identify two safety hazards associated with the
use of cutting fluids;
 (iii) State two factors which influence the surface
finish during parallel
 turning;
 (v) Differentiate between orthogonal cutting and
oblique cutting.
 2004

 (b)
 (i) Outline the difference between drilling and
reaming;

 (iv) Name three types of chip formed in metal

cutting.