Part 2 Mounting and Attachments

MCE 4627 Machine Tools
Part 2
Mounting of Jobs and Tools
Machine Tools Attachments
Methods of mounting of jobs and

cutting tools in machine tools
Dr. Mohammad Ahsan Habib

Assistant Professor
E-mail: mahabib@iut-dhaka.edu
Department of Mechanical and Chemical Engineering (MCE)
Room: 405, Level 4, First Academic Building
Islamic University of Technology (IUT)

Universit Islamique de Technologie
Thu, 13 Jun, 2013

2:29:55 PM
(a) while mounting the job or blank in the machine tool

appropriate selection of work holding device or system from the available
resources depending upon;
configuration of the machine tool
shape, size and weight of the blank
kind of machining work to be done
order of dimensional accuracy desired
volume (number of same job) of production
correct location, strong support and rigid clamping of the blank against the
cutting and other forces
easy and quick loading and unloading to and from the machine tool or the
holding device
proper alignment like coaxiality, concentricity etc. of rotating jobs
free flow of chips and cutting fluid
3
Principles and Conditional Requirements
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2:29:54 PM
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2:29:57 PM
(b) while mounting the cutting tools

appropriate selection of tool holder and the method of mounting
proper positioning and orientation of the tool depending upon its
type
size and shape
geometry
proper alignment in respect of coaxiality, concentricity and machine tool
configuration
accurate and quick locating, strong support and rigid clamping
minimization of run out and deflection during cutting operation
easy and quick mounting and change
unobstructed chip flow and cutting fluid action.
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2:29:58 PM
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2:29:59 PM
Methods of Mounting Job in Center Lathe
Without additional support from tailstock:

Chucks : 3-jaw self centering chuck & 4- independent jaw chuck, which are
mounted at the spindle nose and firmly hold job in center lathes. Pre-machined round
bars are quickly and coaxially mounted by simultaneously moving the three jaws
radially by rotating the scroll (disc with radial threads) by a key as can be seen in the
diagram 1 (a)
The four jaw chucks, available in varying sizes, are generally used for essentially more
strongly holding non-circular bars like square, rectangular, hexagonal and even more odd
sectional jobs in addition to cylindrical bars, both with and without pre-machining at the
gripping portion. The jaws are moved radially independently by rotating the corresponding
screws which push the rack provided on the back side of each jaw.
Face plate: For turning, facing, boring, threading and similar operations, jobs of odd
shape and size are usually mounted on large face plate (instead of chuck) being fitted on the
spindle nose as shown in figure 2 (a).
Jigs and fixture: The job may be 2 (b) directly clamped on the face plate or 2 (c) in case
of batch or small lot production, in a fixture which is clamped on the face plate.
(b) 4-Jaw chuck

(a) 3-Jaw chuck
Figure 1: Chucks
Figure 2: Face plate, Jigs and Fixtures
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2:30:00 PM
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2:30:02 PM
Job mounting in center lathe using support from the tailstock (center):
In-between chuck and center: Heavy and reasonably long jobs of large diameter and
requiring heavy cuts (cutting forces) are essentially held strongly and rigidly in the chuck
at headstock with support from the tailstock through a revolving center as can be seen in
Figure 5.
In-between headstock and tailstock with additional support of rest: To prevent
deflection of the long slender jobs like feed rod, lead screw etc. due to sagging and cutting
forces during machining, some additional supports are provided are shown in the figure 6.
Such additional support may be a steady rest which remains fixed at a suitable location or a
follower rest which moves along with the cutting tool during long straight turning without
any steps in the job-diameter.
In-between center: Figure 3 schematically shows how long slender rods are held in
between the live center fitted into the spindle and the dead center fitted in the quill of
the tailstock. The torque and rotation are transmitted from the spindle to the job with
the help of a lathe dog or catcher which is again driven by a driving plate fitted at the
spindle nose.
Depending upon the situation or requirement, different types of centers are used at the
tailstock end as indicated in Figure 4. A revolving center is preferably used when
desired to avoid sliding friction between the job and the center which also rotates along
with the job.
Figure 3: Mounting bar type job in between centers in

center lathe.
Figure 4: Type of dead centers and revolving

center being fitted in the quill of the tailstock.
Figure 5: Job mounted in between chuck and center in

center lathe
Figure 6: Slender job held with extra support by steady rest
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Methods of Mounting Cutting Tool in Center Lathe
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2:30:04 PM
Different types of tools, used in center lathes, are usually mounted in the
following ways
HSS tools (shank type) in tool post: Figure. 7 is typically showing mounting of shank
type HSS single point tools in rotatable (only one tool) and index-able (up to four tools)
tool posts. Small tool bits are preferably fitted in a rectangular sectioned bar type tool
holder.
HSS form tools and threading tools in tool post: Figure. 8 typically shows how a
circular form or thread chasing HSS tool is fitted in the tool holder which is mounted in
the tool post.
Carbide and ceramic inserts in tool holders: Carbide, ceramic and cermet inserts of
various size and shape are mechanically clamped in the seat of rectangular sectioned steel
bars which are mounted in the tool post. Figure. 9 shows the common methods of
clamping of such inserts. After wearing out of the cutting point, the insert is indexed and
after using all the corner-tips the insert is thrown away.
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2:30:05 PM
Figure 7: Mounting of shank type lathe tools in tool posts
Figure. 9 Mounting of tool inserts in tool holders by mechanical clamping

Figure 8: Mounting of form tool in tool post
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Methods of Mounting Job in Milling Machine

Job or blank is mounted in general purpose milling machines as follows :
Figure. 10. Holding drill chuck and drill in tailstock
Figure. 11. Boring tool mounted in the tool post

in center lathe.
Drills and reamers, if required, in tailstock: For originating axial hole in center lathe,
the drill bit is fitted into the tailstock which is slowly moved forward against the rotating
job as indicated in Figure. 10. Small straight shank drills are fitted in a drill chuck whereas
taper shank drill is fitted directly into the tailstock quill without or with a socket.
Boring tools in tool post: Often boring operation is done in center lathes for enlarging
and finishing holes by simple shank type HSS boring tool. The tool is mounted on the tool
post and moved axially forward, along with the saddle, through the hole in the rotating job
as shown in Figure. 11.
11
Relatively large and irregular shaped jobs for piece or job order production are directly
mounted and clamped on the table with the help of clamps, supports, Vee-blocks, T-bolts etc.
Small components of geometrical shape are gripped in the vice which is rigidly clamped on
the table.
Jobs requiring indexing motion, e.g., prisms, bolt-heads, gears, splines etc. are mounted
directly or indirectly (using a mandrill) in a dividing or indexing head as shown in Figure. 12.
Small jobs, for its repetitive or batch production, are preferably mounted (located, supported
and clamped) in the fixture (designed for the purpose) which is firmly clamped on the table.
Figure 12: Mounting of job on the dividing head in milling machine.

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2:30:08 PM
Methods of Mounting Cutting Tool in Milling Machine
Methods of Mounting Cutting Tool in Milling Machine
Milling cutters are rotary tools of various sizes, configurations and materials.
The general methods of mounting cutting tools in general purpose milling
machines are :
Plain or slab milling cutters and disc type profile sharpened or form relieved
cutters (having central bore) are mounted on horizontal milling arbour as shown
in Figure 13.
End milling cutters with straight shank are mounted coaxially in the spindle bore with the help of collet - chuck as shown in Figure 14.
Shell milling cutters and heavy face milling cutters are mounted in the hollow
spindle with the help of a short but rugged arbour, a fastening screw and a draw
bar as shown in Figure 15.
In case of carbide tipped milling cutters, the uncoated or coated carbide inserts
of desired size, shape and number are mechanically clamped at the periphery of
the plain and disc type milling cutters, large end milling cutters and face milling
cutters as typically shown in Figure 16. End mills of very small diameter are
provided with one or two carbide inserts clamped at the tool - end.
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Sat, 14 Jul, 2012

5:57:56 AM
Figure 13: Mounting of cutting tools on milling arbours.
Figure 14:Mounting of straight shank end

milling cutters in spindle by collet.
Figure 16: Carbide tips clamped in milling

cutters
Figure 15: Mounting

shell and face milling
cutters in milling
machine spindle
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2:30:13 PM
Accessories :
A general purpose machine tool is basically comprised of power drive and
kinematic system for the essential formative and auxiliary tool work motions
and a rigid body or structure to accommodate all of the above. But several
additional elements or devices called accessories are also essentially required
for that machines general functioning, mainly for properly holding and
supporting the workpiece and the cutting tool depending upon the type and size
of the tool work and the machining requirements. These accessories generally
include for instance, in case of
Use of various Attachments in

Machine Tools
Centre lathes: chucks, collets, face plate, steady and follower rests, centres, tool holders
etc.
Drilling machines: vices, clamps, drill chuck and sockets etc.
Shaping and planning machines: vices, clamps, tool holders etc.
Milling machines: vices, clamps, parallel blocks, collets, job support like tailstock etc.
Such accessories, inevitable for general functioning of the machine tools, are
usually enlisted in the supply list and covered within the total price of the
machine tools.
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Attachments:
Attachments:
Each general purpose conventional machine tool is designed and used for a set
of specific machining work on jobs of limited range of shape and size. But
often some unusual work also need to be done in a specific machine tools, e.g.
milling in a lathe, tapping in a drilling machine, gear teeth cutting in shaping
machine and so on. Under such conditions, some special devices or systems
are additionally used being mounted in the ordinary machine tools. Such
additional special devices, which augment the processing capability of any
ordinary machine tool, are known as Attachments, Unlike accessories,
Attachments are not that inevitable and procured separately as and when
required and obviously on extra payment. Some attachments being used in the
general purpose conventional machine tools are :
Some attachments being used in the general purpose conventional machine
tools are :
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2:30:16 PM
In centre lathes :
Taper turning attachment
Copy turning attachments
Milling and cylindrical grinding
attachments
Spherical turning attachments
Relieving attachment
In drilling machines :
Tapping attachment
In shaping machines :
In planing machines :
Contour forming attachment
Helical grooving attachment
Oil grooving attachments
Milling and grinding attachments
In Milling machines :
universal milling attachment
indexing / dividing head
rotary table
slotting attachment
Double cut tool head

Thread rolling attachment
Mattersons attachment (gear teeth
cutting)
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2:30:17 PM
Attachments used in center lathes
Copy turning attachment: There are two common types of copy turning:
Taper turning attachment

Taper cylindrical surface, which is a very
common feature of several engineering
components, is generally produced in lathes in
a number of methods, depending upon length
and angle of the tapered position of the job,
such as offsetting tailstock, swiveling the
compound slide using form tool and combined
feed motions. But jobs with wide ranges of
length and angle of taper, are easily machined
by using a simple attachment, called taper
turning attachment.
Figure schematically shows a taper turning attachment where the cross slide is delinked
from the saddle and is moved crosswise by the guide block which moves along the guide
bar preset at the desired taper angle. Thus, the cutting tool, which is fitted on the cross
slide through the tool post and the compound slide, also moves along with the guide
black in the same direction resulting the desired taper turning.
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2:30:15 PM
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Mechanical type: A simple mechanical type copy turning attachment has been
schematically shown in Figure. The entire attachment is mounted on the saddle after
removing the cross slide from that. The template replicating the job-profile desired is
clamped at a suitable position on the bed. The stylus is fitted in the spring loaded tool
slide and while travelling longitudinally along with saddle moves in transverse direction
according to the template profile enabling the cutting tool produce the same profile on
the job as indicated in the Figure.
Hydraulic type: The mounting and working principle of hydraulic copying attachment
for profile turning in center lathe are schematically shown in Figure. Here also, the stylus
moves along the template profile to replicate it on the job. In mechanical system (Figure)
the heavy cutting force is transmitted at the tip of the stylus, which causes vibration,
large friction and faster wear and tear. Such problems are almost absent in hydraulic
copying, where the stylus works simply as a valve spool against a light spring and is
not affected by the cutting force. Hydraulic copying attachment is costlier than the
mechanical type but works much smoothly and accurately. The cutting tool is rigidly
fixed on the cross slide which also acts as a valve cum cylinder as shown.
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2:30:18 PM
So long the stylus remains on a straight edge parallel to the lathe bed, the cylinder does
not move transversely and the tool causes straight turning. As soon as the stylus starts
moving along a slope or profile, i.e., in cross feed direction the ports open and the
cylinder starts moving accordingly against the piston fixed on the saddle. Again the
movement of the cylinder i.e., the slide holding the tool, by same amount travelled by
the stylus, and closes the ports.
Hydraulic copying attachment.
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2:30:20 PM
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2:30:21 PM
Relieving attachment:
The teeth of form relieved milling cutters like gear milling cutters, taps, hobs etc. are
provided with flank having arch median spiral curvature. Machining and grinding of
such curved flanks of the teeth need relieving motion to the tool (or wheel) as indicated
in Figure (a). The attachment schematically shown in Figure (b) is comprised of a
spring loaded bracket which holds the cutting tool and is radially reciprocated on the
saddle by a plate cam driven by the feed rod as indicated.
(a)
(b) Spherical turning without template.
Spherical turning attachments

These simple attachments are used in center lathes for machining spherical; both convex
and concave surfaces and similar surfaces. Figure schematically visualizes the usual
setting and working principle of such attachments. In Figure (b), the distance Ri can be
set according to the radius of curvature desired. In the type shown in Figure (a) the
desired path of the tool tip is controlled by the profile of the template which is pre-made
as per the radius of curvature required. The saddle is disconnected from the feed rod and
the lead screw. So when the cross slide is moved manually in transverse direction, the
tool moves axially freely being guided by the template only.
(a) Spherical turning using template.
Mechanical type copying attachment.

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2:30:19 PM
(b)
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Thread
pitch
correcting
attachment:
While cutting screw thread in
center lathes by single point
chasing tool, often the actual
deviates from the
pitch,
desired (or stipulated) pitch,
by an error (say ) due to
some kinematic error in the lathe.
Mathematically,
Therefore for correct pitch, the

error
need
to
be
compensated and this may be
done by a simple differential
mechanism, namely correcting
bar attachment as schematically
indicated in Figure.
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2:30:22 PM
Attachments used in Milling machines
Universal milling attachment

Amongst the knee type conventional milling machines,
horizontal arbour type is very widely used, where various
types and sizes of milling cutters viz. plain or slab milling
cutters and disc type cutters including single and double
side(s) cutter, slot cutter, form cutters, gear milling cutters,
slitting cutter etc. having axial bore are mounted on the
horizontal arbour. For milling by solid end mill type and
face milling cutters, separate vertical axis type milling
machines are available. But horizontal arbour type milling
machines can also be used for those operations to be done
by end milling and smaller size face milling cutters by
using proper attachments. The universal milling
attachment is shown in Figure. The rotation of the
horizontal spindle is transmitted into rotation about
vertical and also in any inclined direction by this Universal milling attachment.
attachment which thus extends the processing capabilities
and application range of the milling machine.
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2:30:24 PM
Indexing or Dividing head

This device is essentially so frequently and widely needed and used that it is also
considered as an accessory. But it is taken as an attachment possibly for being
procured separately. This attachment is basically used for equi-angular rotation by
simple compound or differential indexing of the job while machining. Figure
typically shows a universal type dividing head and its mounting and an application.
A Universal type dividing head and its application.

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2:30:26 PM
Rotary table
This device may also be considered both accessory or attachment and is generally used
in milling machines for both offline and online indexing / rotation of the job, clamped
on it, about vertical axis. Figure visualizes such a rotary table which is clamped or
mounted on the machine bed / table.
Slotting attachment
Such simple and low cost attachment is
mounted on the horizontal spindle for
producing keyways and contoured surface
requiring linear travel of single point tool
in milling machine where slotting machine
and broaching machine are not available.
The configuration of such a slotting
attachment and its mounting and operation
can be seen in Figure. The mechanism
inside converts rotation of the spindle into
reciprocation of the single point tool in
vertical direction. The direction of the tool
path can also be tilted by swiveling the
circular base of the attachment body.
Slotting attachment
A rotary table which can be clamped or mounted on the machine bed.

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Part 2 Mounting and Attachments

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MCE 4627 Machine Tools

MCE 4627 Machine Tools

Methods of mounting of jobs and

Dr. Mohammad Ahsan Habib

Islamic University of Technology (IUT)

MCE 4627 Machine Tools

Thu, 13 Jun, 2013

(a) while mounting the job or blank in the machine tool

Dr. Mohammad Ahsan Habib

MCE 4627 Machine Tools

Principles and Conditional Requirements

Dr. Mohammad Ahsan Habib

Thu, 13 Jun, 2013

Thu, 13 Jun, 2013

(b) while mounting the cutting tools

Dr. Mohammad Ahsan Habib

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Methods of Mounting Job in Center Lathe

Methods of Mounting Job in Center Lathe

Without additional support from tailstock:

(b) 4-Jaw chuck

Figure 2: Face plate, Jigs and Fixtures

Dr. Mohammad Ahsan Habib

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Dr. Mohammad Ahsan Habib

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Methods of Mounting Job in Center Lathe

Methods of Mounting Job in Center Lathe

Figure 3: Mounting bar type job in between centers in

Figure 4: Type of dead centers and revolving

Figure 5: Job mounted in between chuck and center in

Dr. Mohammad Ahsan Habib

Figure 6: Slender job held with extra support by steady rest

MCE 4627 Machine Tools

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Methods of Mounting Cutting Tool in Center Lathe

Thu, 13 Jun, 2013

Methods of Mounting Cutting Tool in Center Lathe

Dr. Mohammad Ahsan Habib

MCE 4627 Machine Tools

Thu, 13 Jun, 2013

Figure 7: Mounting of shank type lathe tools in tool posts

Figure. 9 Mounting of tool inserts in tool holders by mechanical clamping

MCE 4627 Machine Tools

Methods of Mounting Cutting Tool in Center Lathe

Figure 8: Mounting of form tool in tool post

Thu, 13 Jun, 2013

Methods of Mounting Job in Milling Machine

Figure. 10. Holding drill chuck and drill in tailstock

Figure. 11. Boring tool mounted in the tool post

Figure 12: Mounting of job on the dividing head in milling machine.

MCE 4627 Machine Tools

Thu, 13 Jun, 2013

MCE 4627 Machine Tools

Methods of Mounting Cutting Tool in Milling Machine

Methods of Mounting Cutting Tool in Milling Machine

Dr. Mohammad Ahsan Habib

MCE 4627 Machine Tools