Turning

Engine Lathe
Turning is another of the basic machining processes. Information in this
section is organized according to the subcategory links in the menu bar
to the left.
Turning produces solids of revolution which can be tightly toleranced
because of the specialized nature of the operation. Turning is performed
on a machine called a lathe in which the tool is stationary and the part is
rotated. The figure below illustrates an engine lathe. Lathes are designed
solely for turning operations, so that precise control of the cutting results
in tight tolerances. The work piece is mounted on the chuck, which
rotates relative to the stationary tool.

Turning refers to cutting as shown below.

The term "facing" is used to describe removal of material from the flat
end of a cylindrical part, as shown below. Facing is often used to improve
the finish of surfaces that have been parted.

Engine Lathe Detail

Engine Lathe Carriage

The figure below illustrates the carriage of an engine lathe. The carriage
allows cross-feed and diagonal movements in addition to axial
movement.

Chucks
The chuck is integral to a lathe's functioning because it fixtures the part
to the spindle axis of the machine. Below is shown a three-jaw chuck
with jaws that are all driven by the same chuck key. This arrangement
provides convenience in that parts can be mounted and dismounted
quickly.

Three-Jaw Chuck
The inner construction of the three-jaw chuck is shown below. A spiral
gear meshes with cog teeth on the jaws to move all three jaws in or out
simultaneously. Parts can be fixtured on outer or inner surfaces since
there are gripping surfaces on the inner and outer surfaces of the chuck
jaws.

Four-Jaw Chuck
If the part needs to be off center or is not a solid of revolution (axially
symmetric), a four-jaw chuck with independently-actuated jaws needs to
be used. Such a chuck is depicted below.

Engine Lathe Tool Post

Since the tool is stationary on a lathe, there is great flexibility for
mounting the tool to best advantage. The tool post and carriage of a
lathe provide several ways of positioning and feeding the tool. Below is
shown the work area of an engine lathe.

The cutting tool is fixtured on the tool post, which sits atop the carriage
assembly. The carriage can move the tool post along the axis of part
rotation, perpendicular to the axial direction, and on a diagonal.

The tool post is shown below. The tool post can pivot the tool about a
vertical axis and the cutting tool can be moved in and out along its long
axis. The cutting tool is held in by the vertical screws, the heads of which
can be seen above the cutting tool groove.

Engine Lathe Tail Stock

The tail stock of an engine lathe is used to provide a fixture at the end of
the part opposite from the chuck. The tail stock can be used to support a
long, thin part so that more radial cutting force can be applied and higher
rotational speeds can be attained without a "whipping" instability effect.
Below is illustrated another use for the tail stock. Drill bits can be
fixtured in the tail stock to cut axial holes in a turned part. These central
holes are more accurate than a drill press or mill could provide since the
lathe is dedicated to operations in which an axially-symmetric part is
rotated about its central axis. The fixturing is more accurate since all
fixturing is based upon surfaces of revolution about the central axis, and
the machining is more rigidly supported for the same reason.

Boring
Boring can be accomplished on a mill or even a drill press, but is most
accurate on a lathe. The boring tool is fixtured in the tail stock. Again,
since all fixturing is relative to the central spindle axis, boring on a lathe
is more accurate than most other boring methods, an exception being jig
boring on a dedicated jig boring machine. The length of the boring bar is
of critical importance because of its tendency to bend. The figure below
illustrates a boring tool which is double-ended so that it is less prone to
the cantilever "diving board" effect.

For design guidelines for bored holes in parts, please check the design
for boring section.

Below are illustrated some of the many types of machining that can be
accomplished on a lathe.

Standard Tool Post Tool
The tool inserted in the tool holder is shown below:

Single-Point Cutting Tool Variety

There are many types of cutting tools for different operations. Below is
shown a few of the variety, here shown with a tool holder adapter that
fits into a larger tool post fixture.

Below is shown how single-point lathe tools can be used.

Parting Tool
The illustration below shows how a parting tool is fixtured and used.
Parting is important at the end of a turning process in order to separate
the part from the raw material. Parting must be carried out slowly and

carefully since the tool is quite long and is prone to chattering. Parting is
not very accurate, and a finishing cut must often be undertaken after
parting if the parted surface is to be accurate.

Knurling
Knurling is an operation used to produce a texture on a turned machine
part. Handles are often knurled in order to provide a gripping surface.
The two wheel inserts shown on the tool below contact the work piece,
and with pressure, cold-form a pattern into the surface of the part.

Screw Machines
Screw machines are automated lathes which can quickly mass-produce
turned parts. A screw machine uses cutting methods similar to that of a
lathe but is highly automated. Screw machines are typically used for
high-volume, low-cost turned parts. Feed stock for a screw machine is a
long cylindrical rod of material. The screw machine automatically
turns/faces the part, parts it off, and advances the rod for the next part.
A screw machine is illustrated below.

Cross Slide Simultaneous Operation
Below is illustrated an on-axis view of how cross slides in a screw
machine sequentially cut the work piece. Simultaneous action increases
throughput. The view is down the axis of the spindle and shows how
tools on cross slides can cut the work piece, some simultaneously with
others.

Design of Parts for Turning

The following are general guidelines for design of turned parts:

Where possible, turned parts should be designed so that a tail

stock is not required. This is done by designing the part to be

 stubby rather than long with a high aspect ratio. The figure below
shows the difference.

Chuck-clamped cylindrical surfaces should not contain parting

lines so that flash does not introduce errors.

For cast parts with surfaces to be faced, cast-in relief allows for
tool clearance, as shown below.

On cast parts that are subsequently turned down, burrs can be

avoided by avoiding surfaces perpendicular to the turned-down
surface, as shown below.

Be as specific as possible when referring to removal of burrs.

Blanket specifications such as "break all corners" are not
recommended since removing all burrs is expensive. Only certain
burrs are gross enough and compromise safety and functionality
enough to warrant removal.

Keyways should be able to be milled with the endmill traversing

the part axially. Radii at the ends of the keyway are those of the
endmill.

Avoid turning in the areas of weldments, parting lines, and flash.

This will tend to extend cutter life.

 Minimize the number of set ups required. Milling should be
grouped into sets of parallel planes.

Design for the largest diameter cutters possible. Larger cutters are
less prone to breakage and require lower speeds when compared
to smaller cutters. Larger cutters also can accomodate carbide
cutting inserts.

Carbide cutting surfaces require fewer tool changes and have

higher cutting performance.

Blending of radii into existing surfaces should be avoided, even

with a ball end mill. Cosmetic-quality blending is expensive to
achieve.

If a surface is to be faced, it preferably should be angled in order

to provide tool clearance.

Sharp inside corners need to conform to the cutter radius that is

used in that vicinity. If possible, inside corner radii should be left
to the discretion of the fabricator.

For the cutter perpendicular to the turning axis, rules of thumb for
angles on the part are shown below:

For the cutter at fifty-five degrees to the turning axis, rules of

thumb for angles on the part are shown below:

Boring

1. Boring is more expensive than drilling, so drilling should be used if

possible.

2. Deep holes with aspect ratios greater than 3:1 should be avoided
since accuracy and cutting time will suffer.

3. Use through holes instead of blind holes where possible.

4. As with all machining operations, the part must be as rigid as

possible while being machined. With boring, this applies to the
boring bar itself as well as to the part.

5. As shown below, relief for the bottoms of blind holes should be

provided.

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