turning and related operations
TRANSCRIPT
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Turning is widely used for machining external cylindrical
and conical surfaces.
The workpiece rotates and a longitudinally fed single point
cutting tool does the cutting.
Machine tools used for this process are called lathes.
Turning and Related Operations
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Turning and Related Operations
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Besides turning, lathes
are capable of
performing a variety
of processes.
Turning and Related Operations
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Turning and Related Operations
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1. Turning
(Cylindrical (straight), taper,
form and contour turning)
Machining of an external surface
by rotating the workpiece and
feeding the tool along the
workpiece.
Turning
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2. Boring
(Cylindrical, taper, form and contour boring)
Enlargement of an existing hole, which may have been
made by drilling or be the result of a core in a casting.
Boring
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3. Facing
Producing a flat surface as
the result of the tool being
fed across the end of the
rotating workpiece.
4. Cut off or Parting
Operation by which one
section of a workpiece is
separated from the
remainder by feeding the
tool across the rotating
workpiece.
Facing, Cut off (Parting)
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5. Drilling, Reaming
Drilling, Reaming
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7. Thread cutting
There are two basic requirements for cutting a thread on a lathe.
The first is an accurately shaped and mounted tool, because the thread cutting is a form-cutting operation; the resulting thread profile is determined by the shape of the tool and its position relative to the workpiece.
The second requirement is that the tool must move longitudinally in a specific relationship to the rotation of the workpiece, because this determines the lead of the thread.
Both external and internal threads can be cut by using a lathe.
Thread Cutting ISO Metric thread
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Cutting speeds specified for turning are the speeds at
the surface which is being machined.
These surface speeds are used to calculate the rotational
speed of the workpiece.
N Rotational speed (rpm)
CS Cutting speed (m/min)
D Workpiece diameter (mm)
Speeds and Feeds in Turning
D
CSN
1000
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Feed is the axial advance of the tool along the workpiece
during each revolution of the workpiece.
It is expressed in mm/rev.
Cutting time
T Cutting time (min)
N Rotational speed (rpm)
f Feed (mm/rev)
L Workpiece length (mm)
A Allowance for tool overrun (mm)
Speeds and Feeds in Turning
Nf
ALT
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The essential components of a lathe are:
• Bed
• Headstock assembly
• Tailstock assembly
• Carriage assembly
• Quick-change gear box
• Lead screw
• Feed rod
Lathes
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Cross Slide
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Lathe Construction
Apron, which is attached to the front of the carriage,
contains mechanisms and controls for providing
manual and powered motion for the carriage and
powered motion for the cross slide.
For powered motions, apron takes the motion from the
quick-change gearbox via either the feed rod or the
lead screw.
Lathes
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Apron
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Through the quick-change gear box, the associated
gearing, and the lead screw and feed rod, the carriage
is connected to the spindle, and the cutting tool can be
made to move a specific distance for each revolution
of the spindle.
Lathes
Lathe Construction
Quick-change gear box
transmits motion from
the main spindle to the
feed rod and lead screw.
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Lathe Construction
Feed rod provides powered motion of the cross slide and
the carriage for operations other than thread cutting.
Lead screw is used to transmit the motion to the carriage
for thread cutting.
Lathes
Lead screw Feed rod
Spindle direction selector lever and rod
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Size Designation of Lathes
The size of a lathe is designated by two dimensions.
● The first one is the maximum diameter of work that
can be rotated on a lathe, which is known as swing.
● The second one is the maximum distance between
centers.
Lathes
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2. Engine Lathes
The most frequently used one in manufacturing.
They are heavy-duty machine tools with all the
components described previously and have power
drives for all tool movements except on the compound
rest.
Most have chip pans and a built-in coolant circulating
system.
Smaller engine lathes are also available in bench type,
designed for the bed to be mounted on a bench or
cabinet.
Types of Lathes
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Engine Lathe
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Bench Type Lathe
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5. Turret Lathes
Although engine lathes are versatile and very useful, they
are not suitable for quantity production, since,
● Large amount of time is required for changing and
setting tools, and for making measurements,
● Skilled operator is required.
Turret lathes, screw machines, and other types of
semiautomatic and automatic lathes have been
developed to get rid of these difficulties.
Types of Lathes
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A turret lathe has,
● Two turrets, one on the tailstock, and the other on the
cross slide,
● Automatic indexing at the end of the motion of the
tailstock turret which is moved by turning a capstan
wheel, thus bringing the next tool into cutting position,
Turret Lathe
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A giant horizonal lathe (Bilim Makina A. Ş.-BURSA)
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Brown and Sharpe type is essentially a small automatic
turret lathe designed for bar stock with the main turret
mounted in a vertical plane on a ram.
All motions of the machine are controlled by disk cams.
These machines usually are equipped with an automatic
rod-feeding magazine that feeds bar stock.
Single Spindle Screw Machines
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Brown and Sharpe Type Screw Machine
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On the Swiss type screw machine the cutting tools are
held and moved in radial slides.
Disk cams move the tools into cutting position and provide
feed into the work in a radial direction only; they
provide any required longitudinal feed by reciprocating
the headstock.
These machines are particularly well suited for machining
very small parts and are used primarily for such work.
Single Spindle Screw Machines
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Swiss Type Screw Machine
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2. Multiple-Spindle Screw
Machines
Have multiple (usually six)
spindles used to hold and
rotate workpieces.
Since different operations are
performed on a number of
workpieces
simultaneously, they are
more productive when
compared to single spindle
machines.
Screw Machines
Tools are on a tool head.
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1. Holding between Centers
Workpieces that are relatively
long with respect to their
diameters usually are
machined between centers.
There are two types of lathe
centers.
● Plain (solid) center
● Live center
Supporting Work in Lathes
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Plain (Solid) Center
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Live centers are often used in tailstock quill.
They are free to rotate, thus no lubrication is necessary.
They may not be as accurate as the plain type, so they
often are not used for precision work.
Live Center
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Workpieces that must be machined on both ends and
those that are disk like in shape are mounted on
mandrels for turning between centers.
Mandrel
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2. Holding in a Chuck
Lathe chucks are used to support a wider variety of
workpiece shapes and to permit more operations to be
performed than can be accomplished when the work is
held between centers.
The jaws on most chucks can be reversed to facilitate
gripping either the inside or the outside of workpieces.
● Three-jaw, self centering chucks
● Four-jaw independent chucks
● Combination four-jaw chucks
● Two-jaw chucks
● Special chucks
Supporting Work in Lathes
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Three-jaw, self centering chucks are used for work that
has round or hexagonal cross-section.
The three jaws are moved inward or outward
simultaneously by rotation of a spiral cam, which is
operated by means of a special wrench through a
bevel gear.
Three-jaw, Self Centering Chucks
Due to this
simultaneous
motion, these
chucks provide
automatic
centering.
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Each jaw in a four-jaw independent chuck can be moved inward and outward independent of the others by means of a chuck wrench.
Thus they can be used to support a wide variety of work shapes.
Combination four-jaw chucks are available in which each jaw can be moved independently or all can be moved simultaneously by means of a spiral cam.
Four-jaw Chucks
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● Two-jaw chucks are also available.
● For mass-production work, often special chucks are used in which the jaws are actuated by air or hydraulic pressure, permitting very rapid clamping of the work.
● Chucks can also be used with soft jaws (typically made from an aluminum alloy) that can be machined to conform to a particular workpiece.
They are self centering.
Two-jaw Chucks, Special Chucks
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3. Holding in a Collet
Smooth bar stock or workpieces that have been machined
to a given diameter can be held more accurately by
collets.
At the split end the smooth internal surface is shaped to fit
the piece of stock that is to be held and the external
surface is a taper which fits within an internal taper of
collet sleeve placed in the spindle hole.
Collets are made to fit a variety of symmetrical shapes.
Supporting Work in Lathes
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Collets
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4. Mounting on a Face Plate
Face plates are used to support irregularly shaped work that cannot be gripped easily in chucks or collets.
The work can be bolted or clamped directly on the face plate.
For machining in large quantities, workpieces can be held in fixtures.
Supporting Work in Lathes
Fixture
Workpiece
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5. Mounting on the Carriage
When no other means is available, boring occasionally is
done on a lathe by mounting the work on the carriage,
with the boring bar mounted between centers and
driven by means of a dog.
Supporting Work in Lathes
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Mounting on the Carriage
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***MACHINING/turning and lathes (SME/Wiley’s video)***
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