Machining

• Machining is the process of removing the excess

material from the work piece in the form of
chips, by forcing a cutting tool with one or more
cutting edges.
• Machine tool is a power driven machine to
perform machining. A machine tool performs
three major functions;
(i)It rigidly supports the work piece and
the cutting tool.
(ii)It provides relative motion between the work
piece and the cutting tool
(iii) It provides a range of speeds & feeds.
 Machining
• Generally, machine tools produce
either cylindrical or flat surfaces.

• The most commonly used machine tools are;

(i) Lathe
(ii) Drilling Machine
(iii) Shaping Machine
(iv) Planing Machine
(v) Milling Machine
(vi) Grinding machine
 Lathe
• It is a machine tool which holds the work in a
holding device and rotating it against a suitable
cutting tool to remove the excess metal from the
work.
• If the tool is moved parallel to the axis of
rotation of the work, a cylindrical surface is
produced.
• If the tool is moved perpendicular to the axis of
rotation of the work, a flat surface is produced.
• Lathes are classified as;
(i) Bench Lathe (ii) Speed lathe (iii) Engine Lathe
(iv) Tool room lathe (v) Capstan & Turret lathe
(vi) Automatic lathe (vii) Special purpose lathe
Bench Lathe
Speed Lathe
Engine Lathe (or) Center Lathe
Tool Room Lathe
Capstan & Turret Lathe
Automatic Lathe
Special Purpose Lathe
 Lathe Specifications
Overall length of bed

Distance between centers

Swing diameter
over gap in the bed
Swing diameter
Lathe Bed
over lathe bed

Specifications of a Lathe
 Lathe Specifications
The size of a lathe is specified by the following:
1. Maximum diameter of the work piece that can
be revolved over the lathe bed.
It is also called as height of centers above the
lathe bed Or Swing diameter over lathe bed.
2. Maximum diameter and width of the work
piece that can swing when the lathe has a gap
bed.
3. Maximum length of work piece that can be
mounted between centers
4. Overall length of bed: It is the total length of
the lathe itself.
5. Maximum number of speeds & feeds
available.
 Gear box controls
Chuck Tailstock
Cross slide
HeadStock Tool post

Rack

Feed box Lead screw

Carriage Feed Feed rod

engage Bed
Tray
Screw cutting
engage lever

Parts of a Lathe
 Major parts of a Lathe & their functions
The major parts of a lathe are:
1. Bed
2. Headstock
3. Tailstock
4. Carriage
5. Feed rod
6. Lead screw
 Major parts of a Lathe & their functions
1. Bed:
• The lathe bed forms the support for all other
parts.
• At the top of the bed, precision machined
guide ways (inner & outer) are present.
• The headstock & tailstock are mounted on the
inner ways which keep them perfectly aligned
with each other.
• The outer ways guide the movement of
carriage assembly.
• Bed is usually made of grey cast iron because
of its good damping property and low
frictional resistance.
Lathe Bed
 Major parts of a Lathe & their functions
2. Headstock
• Headstock is a box like casting mounted at
the left end of the machine.
• It consists of a spindle and gear box to
rotates the spindle at different speeds.
• The spindle has external threads to
receive a work holding device such as a
chuck or face plate.
• The gear box distributes power to the feed
rod and lead screw for turning or thread
cutting Operation
Headstock
 Major parts of a Lathe & their functions
3. Tailstock
• Tailstock is mounted at the right end of the
machine.
• It may be slided on the guide ways to support
different lengths of work pieces between
centers and clamped to bed at any desired
location.
• It carries a dead center or revolving center.
• Tailstock can be offset for taper turning. It can
also carry tools like drill bit, reamer, tap, etc.
Tailstoc
k
 Major parts of a Lathe & their functions
4. Carriage Assembly
• It supports and feeds the cutting tool against
the work during operation of the lathe.
• The carriage slides along the outer guide ways
and consists of the following parts;
(i) Saddle
(ii) Cross slide
(iii) Compound slide
(iv) Tool post
(v) Apron
Carriage Assembly
 Major parts of a Lathe & their functions
(i) Saddle :
It is a H-shaped casting that slides over the
outer guide ways and serves as a base for
the cross slide.

P R Venkatesh, Mech Dept, RVCE, B'lore

 Major parts of a Lathe & their functions
(ii) Cross slide:
It is mounted on the saddle and enables the
movement of the cutting tool laterally across
the lathe bed by means of a cross feed hand
wheel.
 Major parts of a Lathe & their functions
(iii) Compound rest:
It is mounted on the top of the cross slide
and supports the tool post. It can be
swiveled to any angle to facilitate taper
turning & threading operations.
 Major parts of a Lathe & their functions
(iv) Tool Post
It is mounted on the top of the
compound rest and carries the cutting
tool.
 Major parts of a Lathe & their functions
(v) Apron:
The portion of the carriage that extends in front
of the lathe is called an apron. It houses feed
mechanisms. It contains pinion which engages
with the rack for longitudinal feed.
 Major parts of a Lathe & their functions
6. Feed Rod:
The feed rod is a long shaft used to drive the
apron mechanism for cross & longitudinal
power feed during turning, boring & facing
operations. The feed rod is powered by a set of
gears from the headstock.
 Major parts of a Lathe & their functions
5. Lead Screw:
It is a long threaded shaft geared to the
headstock. Closing a split nut around the
lead screw engages it with the carriage. It
used only for thread cutting operations.
 Lathe Operations
The most common operations performed on
a lathe are:
1. Turning
2. Facing
3. Parting
4. Grooving
5. Knurling
6. Drilling
7. Boring
8. Taper turning
9. Thread cutting
 Turning or Plain Turning:
Chuck
Work
Spindle piece Depth of cut

Dead center

Feed Cutting Tool

Plain Turning
 Turning or Plain Turning:
• Plain turning is a lathe operation to remove
excess material from the workpiece & to
produce cylindrical surface.
• Using the cross slide the cutting tool is first
adjusted for desired depth of cut.
• As the workpiece revolves, the tool is fed against
the workpiece in a direction parallel to the axis
of the spindle.
Plain turning animation
 Facing Operation
Chuck
Work piece
Spindle

Machined
flat surface

Feed

Facing Tool
 Facing:
• Facing is a lathe operation to produce a flat
surface normal to the axis of rotation of the
spindle.
• During facing, the carriage is locked to the lathe
bed to prevent its movement.
• Using cross slide the cutting tool is fed at right
angles to the axis of the work piece.
Parting off & Grooving
Chuck
Work piece
Spindle
Groove

Feed

Parting tool

Parting & Grooving

 Parting & Grooving:
• Parting or cutting off is the operation of
separating a piece of finished work from the bar
stock. It is done with a narrow cutting tool called
Parting tool.
• Grooving or necking is the operation of reducing
the diameter of the workpiece over a narrow
surface. It is done by feeding a form tool or
parting tool into the work using cross slide.
Parting off & Grooving

P R Venkatesh, Mech Dept, RVCE, B'lore

 Knurling
Chuck
Knurled
Spindle surface

Knurlin
g tool

Feed Movement
for depth

Tool

Post
 Knurling
• Knurling is the process of embossing a diamond
shaped pattern on the surface of the workpiece
by the use of revolving hardened steel wheels
pressed against the work.
• Knurling is done to provide grip on handles,
screw heads and other cylindrical parts to be
gripped by hand.
Knurling Tool
Knurled surface
 Drilling
Chuck

Work piece Tailstock

Spindle Drill bit

Sleeve
Feed
 Drilling
• Drilling is an operation of producing cylindrical
hole by means of a cutting tool called drill.
• A drill it is placed in the tapered hole of a
tailstock sleeve and is fed into the work by
rotating the hand wheel of the tailstock.

Twist Drill
 Boring
Chuck
Work piece
previously drilled
Spindle Depth of cut

Feed

Boring Tool
Feed
Boring in Lathe
 Boring
• Boring is an operation of enlarging a hole
previously drilled with the help of a boring tool.
• As in turning, the depth of cut is adjusted by the
cross slide and the feed is obtained by carriage
movement.

Boring Bar
 Taper Turning
• Taper turning is an operation on a lathe to
produce conical surface on work pieces.
• Taper on a lathe is the difference between the
diameters over a length.
• If ‘D’ is the larger diameter & ‘d’ the smaller diameter, l is
the length between the two diameters, then
Taper (or) Conicity = (D-d)/ l


(D-d)/2
-1D - d 
Half angle of taper α = tan  
 D  2l 
d

l
 Taper Turning Methods
• A taper may be turned by any one of the following
methods.
1. By form tool
2. By swiveling the compound rest
3. By Tailstock off set method
4. By using Taper turning attachment
 Taper Turning using form tool
• Here a form tool which has a straight edge set at the
desired angle is used.
• The angle between the cutting edge and the axis of
the spindle equals half taper angle.
• This method is limited to short tapers & is
mainly used for chamfering.
Work piece
Taper

Feed
Form tool
 Taper Turning swiveling the compound rest
• The compound rest may be swiveled & clamped at any
desired half angle of taper on a circular base graduated in
degrees.
• The tool is fed by rotating the compound slide screw.
• This is also limited to short tapers as the movement of
the compound slide screw is limited.
Work piece
Tool




d
Fee
Compound
slide

Cross slide
 Taper Turning by tailstock set over (offset)
• In this method, the center line of the work piece
may be offset from the axis of the lathe and the tool
is fed parallel to the axis of the lathe.
• This is achieved by moving the tailstock either
towards or away from the operator by means of a
set over screw. Used for small tapers on long jobs.
L

l
center line of lathe
D Tailstock set over
Offset (s)

D-d 
d
s =  2l ×
Headstock
center Center line of work
Tailstock L
where L = length of
center

work
 Taper Turning by using attachment
Guide bar Slide Block
• A taper turning
Scale (deg) attachment is a fixed
 casting attached to the
back of the lathe bed.
• It consists of a guide
Link Bed bar which may be set
Cross slide
at any desired angle of
taper.
• A sliding block moves
over the guide bar
Compound Rest thus moving the cross
slide & hence the tool
parallel to the guide
bar.
• Used for long tapers
with small included
angles.
Taper Turning by using attachment
 Standard Tapers
Machine parts and tools having tapers are standardized to
ensure interchangeability of components.
The most commonly used standard tapers are
Morse Taper and Metric taper.
Morse Taper: Available in eight sizes. Taper is 5/8 inch per foot length.
Standard sizes 0,1,2,3,4,5 ,6 & 7
The number indicates the size of larger diameter in
inches as below:
• #0 is 0.356
• #1 is 0.475
• #2 is 0.700
• #3 is 0.938
• #4 is 1.231,
• #5 is 1.748
• #6 is 2.494
• #7 is 3.270
 Metric Taper :
Metric Taper :
Available in eight sizes. Taper is 1:20.
Standard sizes 4,6,80,100,120140,160 & 200.
The number indicates the size of larger diameter in mm.
 Thread Cutting
Chuck • The principle of thread
Spindle
Work piece cutting on a lathe is to
produce a helical groove
on a revolving
cylindrical surface by
tool
feedinglongitudinally
the as
Threading tool shown in fig.
Change gears
Lead Screw Split nut • The change
calculations
gear are made
for the desired pitch of
the screw and the split
nut is closed.
• This the
carriage
engages with the lead
screw and the threading
tool is fed into the work
using both cross feed &
longitudinal feed.
Threading Tool
Milling Attachment on a lathe
Grinding Attachment on a lathe
 Cutting Tool Materials
The following materials are commonly used
in making the cutting tools;
(i) Carbon Tool steel
(ii) High speed Steel (HSS 18-4-1)
( Means 18% Tungsten 4% Chromium &
1% Vanadium)
(iii) Cemented carbides
(iv) Ceramics
(v) Diamonds
 Desirable properties of Cutting Tool materials
1. Hardness, strength to withstand cutting
forces & toughness.
2. Ability to resist high temperature
3. Low frictional coefficient
4. Resistance to wear
5. Ability to be formed into desired shape
Single Point Cutting Tools:
They have only one cutting edge.
Ex: Lathe tools, Shaper Tools, Boring tools, etc.
Multi Point Cutting Tools:
They have more than one cutting edge.
Ex: Drills, Milling cutters, Grinding wheels, etc.
 Single Point Cutting Tool
Shank Axis

Side rake
Face angle

End cutting Back

edge angle rake
angle

cutting edge
Nose
Side releif angle

Flank
End releif angle
 Flank Side rake
Back rake angle
angle

Lip
angle

End releif
Front view Left side view
angle Base
Shank Side releif
angle
Shank

End cutting
edge angle

N
o
s
e
side cutting
edge angle r Top
a View
d