MACHINE SHOP

Course outline

 Brief History about Lathe Machine

 Introduction to Lathe Machine
 Types of Lathe Machine
 Parts of Engine Lathe Machine
 Operations perform on Lathe Machine
 Tools used on Lathe Machine For Different Operations
 Taper Turning Formula
 Single Point Cutting Tool Terminologies
 Chip formation
 Introduction to Shaper Machine
 Introduction to Milling Machine
 Introduction to Surface Grinding Machine
 Difference between Lathe Machine, CNC Lathe Machine and Turning Center
 Difference between Milling Machine, CNC Milling Machine and Machining Center
 Brief History About Lathe Machine
The origin of lathe started around 13th century when the Egyptians first developed a two- person lathe. It is the most simplest method in which one
person would turn the wood (work piece) with a rope and meanwhile the other person would use the sharp tool to cut the shapes in the wood.

Then after Romans improved the Egyptians design with the addition of a turning bow and so on. Now it’s a well-known fact that improvement with the
time in a technology is sustainability. Hence there have been many proposed lathe design from 13th century to current 21st century. But, in medieval
period, during industrial revolution it was on hike in Europe and considered as the mother of all machines.
INTRODUCTION
TO LATHE
MACHINE
A lathe machine is a type of machine
which is used for shaping and
machining of various types of
workpiece. There are different types of
lathe machine in use according to the
material and size of workpiece.
Traditionally it was only used for metal
machining but with the advancement
of technology it is also used for
machining of various types of material.
The main function of the lathe is to
remove the unwanted material from
the workpiece to make it a value
added product. The lathes are
capable of producing a lot of shapes
and forms with great accuracy in very
less time. More importantly, these
shapes come in various sizes and
specifications.
  SPEED LATHE/ WOOD LATHE
 ENGINE LATHE
TYPES OF LATHE  TOOL–ROOM LATHE
MACHINE  CAPSTAN AND TURRET LATHE
 SPECIAL PURPOSE LATHE
Here we will discuss
1. Wheel Lathes
the types of lathe
Machines that we 2. Bench Type Jewelers Lathes
are using now. 3. Automatic lathes
4. Crankshaft Lathe
5. Vertical Lathes
6. CNC LATHES
SPEED LATHE/
WOOD LATHE
These are some of the products which can
be easily made on wooden lathes or speed
lathes. As name suggest, there is a high
speed spindle which can be operate in 3 to
4 varying speeds ,near 1000 to 2100 rpm, by
shifting the position of the drive belts on the
pulley system.
Yes it is very simple in design because the
components like gearbox ,feed rod,
leadscrew, carriage, are not the part of
these lathes which make it more simple and
easy to operate in any condition. the major
components of these lathes are headstock,
tailstock, tool rest, and bed.
unlike other lathes, there is less precision in
these lathes since the cutting tool is
operated by hand. So these lathes require
good skill and steady hands to provide spick
and span contours and smooth curves
accurately on the workpiece.
Operations that can be done on these
lathes are wood turning, metal spinning,
polishing, centering.
ENGINE LATHE
Do you want to do operations like turning, drilling, boring, reaming,
knurling etc. on a metal? (in short metal machining)

Then have a glance on this.

It is all started during the 19th and 20th century when the Engine
lathes were considers as the ‘KING’ of all machines. It was one of
the most common machine set up in every blacksmith shop. The
usage of word “engine” is little confusing here. During its early days
it was operated on the steam engines, as steam engines were the
major invention and power source during the industrial revolution,
and with the advancement of time it shifted its power source to
the motors (concerning eco-friendly environment).

Due to availability for low and high power operation these are
widely used in industries and available in many sizes which can
vary up to 60 feet.

Now come to its major mounting parts like headstock, tailstock,

carriage, compound rest, cross slide, lead screw, feed rod etc. All
are mounted on the machine in which headstock and tailstock are
mounted in the longitudinal direction of machine with gear
selector, rpm selector, feed selector in the former and barrel in the
later one. More importantly, similar to speed lathe, headstock
contain spindle which has a wide range of speed ratios in the
presence of gearbox.

Carriage travels in the longitudinal direction of the bed for the

turning operation.

Compound rest and cross slide are mounted on the top of the
carriage to provide angular movement and cross or transverse
movement.

Lead screw is used to make threads on the work piece and feed
rod is used to give the linear moment to the carriage in the
longitudinal direction of the machine.
TOOL–ROOM LATHE
What if I want make precision tools and
products?
Some products like metal die, precision
tools, jigs and fixture require more
precision and accuracy to work; in that
case tool room lathe machines are
used. Unlike engine lathes, these are
much more precise and accurate.
These are also well-known as the
standard manufacturing lathes and are
used for various operations such as
boring, drilling, turning, reaming,
producing screw threads, knurling, taper
turning, and sometimes adapted for the
special milling operations with the
appropriate fixture.
These have gearbox attached in the
head-stock which provide wide range
of speeds ratios, can vary from a very
low speed to a very high speed, and
extended range of thread pitches.
CAPSTAN AND
TURRET LATHE
What if someone wants to go for a mass production?
Because mass production produce work piece in large
quantities with duplicate products, which by nature
known as interchangeability, reduces error, saves time.
All this can be done by using capstan and turret types
of lathe machine.
It is essentially a tool for production of work piece in
large quantities with duplicate products, which by
nature are usually interchangeable. It is used where
sequence of operations are required on the work
piece.
Unlike engine lathe, these machines have hexagonal
turret mounted on saddle instead of tailstock on which
multiple tools may be fitted and feed into the work
with proper sequence which also reduces the time to
remove work piece from one machine and to hold it
on another for various operations such as turning,
drilling, boring, reaming, knurling etc. by manually or
automatically alter the tool position which also
reduces the chances of error in alignment and
machining process.
For operating these machines not so skilled labors are
required. Whatsoever skill is needed of the operator is
the setting of the tools in the turret or capstan head,
and after the completion of this task further operations
of these machines are automatic.
The difference between turret and capstan lathe is
only that the capstan lathe is somewhat enhanced
version of turret lathe. Unlike turret lathe, hexagonal
turret is mounted on the ram and which can move in
the longitudinal direction of the machine. These ram is
provided to absorb the vibrations.
 SPECIAL PURPOSE LATHE MACHINE
Wheel Lathes
These are very large in size and made
for turning solid wheels and tired wheel,
worn out treads of locomotive wheels,
roadways wheels etc. into a proper
required profile by removing spots,
shelling, unwanted shapes.
Bench Type Jewelers
Lathes
These are the miniature of standard
lathes which are designed for the
machining of the small parts with
greater precision. It contain collet
type chuck, feed screw, precise
manual cross feed etc.. Since the
controls and feeds are calibrated
in smaller increment which result in
better precision of the work piece.
Automatic lathes
These are the miniature of standard lathes
which are designed for the machining of
the small parts with greater precision. It
contain collet type chuck, feed screw,
precise manual cross feed etc.. Since the
controls and feeds are calibrated in
smaller increment which result in better
precision of the work piece.
 SPECIAL PURPOSE LATHE MACHINE
Crankshaft Lathe
It carries all the attachments like taper
turning, threading etc. It is mainly used for
turning very long parts like Turbine, Crank
shafts and Engine shafts etc.
Vertical Lathes
These machines are employed for jobs like
heavy and dense flywheel, large gear blanks
etc.
Vertical lathe machine is similar to the horizontal
lathe in which the machine stands up on its
ends. Some industries use this instead of
horizontal lathe because sometimes space
comes up as a constraint. While others prefer it
for doing turning and boring on large and
heavy rotating parts which cannot be otherwise
supported on other lathes. It has a heavy and
dense base to the lowermost part which carries
a face plate to grasp the work piece.
CNC LATHES
One of the most prevailing technology through which and
shape and size can be machined into a desired product.
Computer numeric control (CNC) has been incorporated
into variety of new technology and machinery, in this case
known as CNC lathes. It has been quickly replacing some
traditional and old lathes since the advancement in this
technology, which results in top notch accuracy and
precision. It can be easily setup and no skill set is required to
operate, though skill is required to programmed the tool
path which often done by CAD or CAM process, then
coded files are updated to CNC machine which produce
desired path for which it was programmed to design the
product. Operator can actually see a visual simulation of
how the machine will works during the production phase.
 Engine Lathe Machine
A lathe is a machine tool that rotates a workpiece about an axis of rotation to perform various
operations such as cutting, sanding, knurling, drilling, deformation, facing, and turning, with tools that
are applied to the workpiece to create an object with symmetry about that axis.
 Parts Of Engine Lathe Machine

 Bed:
Bed in the lathe machine is the main body of the machine. All main components are mounted on it.
The bed is usually made up of cast iron due to its high compressive strength and high lubrication quality.
It is made by a casting process and molted on floor area.
 Chuck:
Chuck in the lathe machine is used to hold the workspace. This is fastened on the spindle, which rotates the chuck
and the workpiece.
There are four jaws and three jaw chuck but according to the requirement of the machine they used.
 Head Stock:
Head Stock is the holding device in a lathe machine.
The headstock is the main body parts which are placed at the left side of the bed.
The Headstock is also made up of cast iron.
 Tool Post:
Tool Post on a lathe machine is fastened on the carriage.
The main work of tool post is to hold the tools at an accurate position and tool holder mounted on it.
 Lead Screw:
It also knew as a power screw.
This locates at the bottom side of the bed, which is used to move the carriage automatically during the thread
cutting operations.
 Carriage:
This locates between the headstock and tailstock.
It is used to hold and move the tool post on the bed vertically and horizontally.
It slides on the guideways. The carriage is also made up of cast iron.
 Legs:
Legs are used to carry all the loads of the lathe machine.
It locates the floor which prevents vibration.
 Apron:
An apron is attached to the carriage and hangs over the front side of the lathe bed.
It is useful in providing power and hand feed to both carriage and cross-slide.
It is also used to provide power feed to the carriage during thread cutting through two half nuts.
 Guideways:
The main function of guideways in a lathe machine is to guides the movement of carriage and
tailstock.
 Spindles:
This is the main part of the lathe machine which holds and rotates the chuck.
 Tailstock:
It is placed on the right-hand side of the bed.
The main function of the tailstock to support the job when required.
The main function of the tailstock is to lock the workpiece while performing a drilling operation.
 Compound rest:
The compound rest in a lathe machine which is used to fix the single point cutting tools while
performing different lathe operation.
 Hand Wheel:
Hand Wheel is used for moving tailstock forward or backward.
 Feed Rod:
Feed rod is a power transmission mechanism used for precise linear movement of the carriage
along the longitudinal axis of the lathe.
Operations
Perform on Lathe
Machine
 Operations perform on Lathe Machine

 Facing:
The process of making a flat surface on a lathe machine is called facing.
The job is held on a faceplate or chuck and the tool is fed at right angles to the bed to obtain flat surfaces.
To safely perform a facing operation the end of the workpiece must be as close as possible to the jaws of the chuck.
 Turning:
Tuning is the operation when metal removal takes place from the surface of the cylindrical workpiece. In this process, a tool
is fed along the axis of the spindle.
Turning is the removal of metal from the outer diameter of a rotating cylindrical workpiece.
Turning is used to reduce the diameter of the workpiece and the Step turning is an operation performed on a lathe
machine where the excess material is removed from the workpiece to obtain various steps of different diameters.
 Chamfering:
It removes the burrs and sharp edges, and thus makes the handling safe.
This can be done by a form tool having an angle equal to chamfer which is generally kept at 45°.
 Grooving:
The term grooving usually applies to a process of forming a narrow cavity of a certain depth,
on a cylinder, cone, or a face of the part.
 Forming:
The forming process is the operation or process where the workpiece is reshaped without
adding or removing material, and its mass remains unchanged.
 Knurling:
In the knurling process, some serration(meaning: a tooth or point of a serrated edge or
surface) is formed on the workpiece by deforming the top layer on the lathe.
The rough surface produced by knurling is useful for providing proper gripping.
 Taper Turning:
The taper turning is a lathe operation for producing a conical surface by a gradual reduction
in the diameter of a cylindrical workpiece.
 Thread Cutting:
A thread is a helically shaped groove formed on the cylindrical surface of a workpiece.
Thread cutting is an operation performed on a lathe to produce threads by using a tool whose shape will be the
same as that of the thread.
Types of screw threads, Screw thread nomenclature, Lathe setting for thread cutting, Types of gear trains Simple gear
train Compound gear train.
 Drilling:
Drilling is the process of making holes in the workpiece with the help of drill tools.
The drill is held on the tailstock and the drilling operation is carried out by advancing the drill in the
workpiece by rotating the handle of the tailstock.
on a lathe, Drilling is generally done in the center of the workpiece.
 Reaming:
The process of enlarging the hole in the workpiece is called reaming.
 Boring:
The process of removal of stock from a hole in the workpiece is called boring.
Holes are bored by the single point tool. The cutting tool shaves off a thin layer of material to
accurate size.
 Tapping:
Tapping is the process of cutting a thread inside a hole so that a cap screw or bolt can be threaded into the hole.
Also, it is used to make threads on nuts.
Tapping is done with a tool called a “Tap”.
 Parting:
This Parting process is used for cutting off the parts from the parent material.
The feed is given in the direction perpendicular to the axis of revolution.
Tools used
on LATHE
Machine
for Different
Operations
Taper Turning
Formula

𝐷−𝑑
tanϴ=
2𝐿
 Single Point Cutting Tool Terminology
The single point cutting tool is mainly used to metal remove from work piece become with require shape and size of
product. It remove large amount of metal in quickly again rotating the work piece. Boring, turning are performed by
using single point cutting tool in lathe machine.
 Geometry of Single Point Cutting Tool

 Shank: It is that part of single point cutting tool which goes into the tool holder. Or in
simple language shank is used to hold the tool.
 Flank: It is the surface below and adjacent of the cutting edges. There are two flank
surfaces, first one is major flank and second one is minor flank. The major flank lies
below and adjacent to the side cutting edge and the minor flank surface lies below
and adjacent to the end cutting edge.
 Base: The portion of the shank that lies opposite to the top face of the shank is called
base.
 Face: It is the top portion of the tool along which chips slides. It is designed in such a
way that the chips slides on it in upward direction.
 Cutting edge: The edge on the tool which removes materials from the work piece is
called cutting edges. It lies on the face of the tool. The single point cutting tool has
two edges and these are
(i) Side cutting edge: The top edge of the major flank is called side cutting edge.
(ii) End cutting edge: The top edge of the minor flank is called end cutting edge.
 Nose or cutting point: The intersection point of major cutting edge and minor cutting
edge is called nose.
 Nose radius: It is the radius of the nose. Nose radius increases the life of the tool and
provides better surface finish.
 Heel: It is a curved portion and intersection of the base and flank of the tool.
 Angle of single point cutting tool

 Side Cutting Edge Angle:

This angle is also known as the lead angle. This is the angle between the side cutting edge and side of the tool shank.
 End Cutting Edge Angle:
This is the angle between the end cutting edge and a line normal to the tool shank.
 Side Relief Angle:
It is the angle between the portion of the side flank immediately below the side cutting edge
and a line perpendicular to the base of the tool and measured at the right angle to the end flank.
 End Relief Angle:
It is the angle between the portion of the end flank immediately below the end cutting edge
and a line perpendicular to the base of the tool and measured at the right angle to the end flank.
 Back Rack Angle:
It is the angle between the tool face and a line parallel to the base of the tool and measured in a plane perpendicular through the side cutting edge.
The back rack angle is positive if the side cutting edge slopes downwards from the point towards the shank and The back rack angle is negative if the slope is side
cutting edge reversed.
 Side Rack Angle:
It is the angle between the tool face and a line parallel to the base of the tool and measured in a plane perpendicular to the base and the side cutting edge.
This angle gives the slope of the face of the tool from the cutting edge.
This side rack angle is negative if the slope is toward the cutting edge. And the side rack is positive if the slope is away from the cutting edge.
Advantages and Disadvantages of Single Point Cutting Tool

Advantages Disadvantages
 Design and fabrication are easy.  There is having little high tool wear
rate.
 This tool is a little cheaper in price.
 Shorter tool life.
 Low metal removal rate.
 Low productive.
Chip Formation

During the metal cutting

process, the tool removal of
small metal formation from
work piece is called chip. The  Continuous chip
types of chips in metal cutting
depends upon the work
 discontinuous chip
material and method of
 Continuous chip with built up edge
machining process obtained.
The types of chip in metal
cutting are as follows:
 Continuous Chip

 During the metal cutting of ductile material, a continue ribbon (Chip) is

provided due to pressure applied on the tool cutting edge in
compression and shearing. This type of chip having long coil formation
and same thickness throughout the length. The requirement of this type
of chip, give more advantages in the work metal, tool and
machine. The most advantages such as good surface finish of work
material, the tool life will be improved and require less power
consumption. The Chip disposal is not easily and surface finish on work
metal affected.
 How to get continuous chip formation during the metal cutting
process? Follow the below condition,
 Depth of cut in smaller
 Long rake angle
 Sharp cutting edge
 High cutting speed
 Using proper cutting fluid
 Low friction to be maintained in between tool face and chips.
 Discontinuous chip (or) segmental chips

 The discontinuous chip provided by using brittle material such a high

Carbon Steel, bronze ,Grey cast iron at low speed on cutting without
any fluid. when the friction existed between tools and chip. During the
machining of cutting, the brittle material lacks its ductility. So it is
necessary for plastic chip formation. Also it will be lesser. In this formation
named as Discontinuous chip. If continuous chip, the shearing of metal
will occur at cutting tool head for continuously without any fracture. In
discontinuous chip, Ruptures will occur intermittently. This type of chip
having small length. so easily handled and easily disposed off. It also not
affect on the surface finish of work material.
 The formation of discontinuous chip require follow below condition:
 Depth of cutting is higher
 Cutting speed will be low
 Excess amount of cutting fluid
 Machining the brittle material
 The rake angle will be small
 The cutting of ductile material at low feeding with small of rake angle
 Continuous chip with build up edge

 During the metal cutting process the interface pressure and temperature will
be high in quickly. Also the high friction presented in between chip and tools.
In this reason the material go to welding process itself to the tool face in near
of nose. It is known as “build up edge”.
The built up edge formation in continuous chip is a transient and not
stable of phenomenon. The accumulate build of chip metal will break away,
the part adhering to the chip underside and path to the work piece. That
process give to raise the poor surface finish on the machined surface and
accelerate wear on tool life. The formation of chip have some advantages
like as the rake face protected from the wear due to chip move and action
of heat. So it may be increase the tool life.
 If want to formation of this continuous with build up, to follow the blow
condition:
 Small rake angle
 Low cutting speed obtained
 Large amount of cutting thickness
 Coarse feed
 insufficient cutting fluid
Introduction to
Shaper Machine
The shaper process can be
defined as a process for
removing metal from the
surface in horizontal, vertical
and angular planes by the use
of a single point cutting tool
held in a ram that reciprocates
the tool in a linear direction
across the workpiece held on
the table of the machine. The
work is fed at right angles to the
direction of the ram in small
increments, at the end of the
return stroke.
Introduction
to Milling
Machine
Milling is the cutting operation
that removes metal by
feeding the work against a
rotating, cutter having single
or multiple cutting edges. Flat
or curved surfaces of many
shapes can be machined by
milling with good finish and
accuracy. A milling machine
may also be used for drilling,
slotting, making a circular
profile and gear cutting by
having suitable attachments.
Introduction to
Surface Grinding
Machine
A surface grinder is
a machine tool used to
provide precision ground
surfaces, either to a critical
size or for the surface finish.
The typical precision of a
surface grinder depends on
the type and usage, however
±0.002 mm (±0.0001 in) should
be achievable on most
surface grinders.