Production & Special purpose Lathes

Capstan Lathe Turret Lathe Automatic Lathe Duplicating Lathe

Engine Lathe

Limitations: Higher job setting time. Multi-machining is not possible. Higher Tool changing time Accuracy and precision is poor.

Improvements: Collect chuck, pneumatic chuck Automatic bar-feed mechanism, Auto-feeding of cutting tool, multi-tool arrangements, Automatic control of operation sequences

Break even analysis

Automation in Lathe

Production Lathes
Capstan and Turret lathe -- used for repetitive production of duplicate parts (i.e interchangeable products) Tailstock is replaced by a hexagonal turret, which is an indexable toolholder that allows multiple cutting operations to be performed, each with a different cutting tool.

Difference with centre Lathe

Aspects

Production lathe Centre lathe

Applied to different jobs

Nature of production Applied to quantity work production Constructional difference

Hexagonal turret, no Has a tailstock tailstock No such provision available more

No of tools handled at Multi tool holding, a time multi machining possible Tool set up/ changing less time Lead screw

Thread cutting Has one lead screw performed by die heads, no lead screw Very normal low high low

Degree of automation Semi or full automation Rate of production Labour cost Overhead cost high low high

Collet chuck

Difference between capstan & turret lathe

Aspects Turret position Turret Lathe Capstan lathe

Mounted directly on saddleMounted on an auxiliary slide, which can move on saddle Entire saddle is moved Very high Auxiliary slide (ram) is moved on saddle Lower due to overhung of the ram results tool deflection Lighter and smaller jobs only can machine Up to 60 mm diameter Limited tool travel Reach over type

Feeding of tools Extent of rigidity

Capability to handle job Maximum bar size Tool travel Type of carriage

Heavier job can be machined Up to 200 mm diameter Almost full length of bed Over hung type

Turret Lathe

Tool Layout

Production Lathes may be Classified by: size (small, medium, or large); method of control (manual, automated mechanically, or automated via computer (numerical control (NC) or computer numerical control (CNC)); and bed orientation (horizontal or vertical).

Semi-automatic turret lathes -- power feeds and automatic turret-indexing at the end of the return stroke. Automatic turret lathes (automatic screw machines) --can execute many part-cutting cycles without human intervention and thus, productivity increased significantly. ---use cams to automate the sliding and indexing of the turret and the opening and closing of the chuck. CNC turret lathes: The advent of electronics-based automation in machine tools via numerical control (NC) and then computer numerical control (CNC) displaced to a large extent. Vertical turret lathes: the headstock to sit on the floor and the faceplate to become a horizontal rotating table. --useful for the handling of very large, heavy, short workpieces

Multispindle lathes--have more than one spindle and automated control -- via cams or CNC). --production machines specializing in high-volume production. --smaller types are usually called screw machines, -- larger variants are called automatic chucking machines Screw machines usually work from bar stock, while chuckers automatically chuck up individual blanks from a magazine. Typical minimum profitable production lot size on a screw machine is in the thousands of parts due to the large setup time. Once set up, a screw machine can rapidly and efficiently produce thousands of parts on a continuous basis with high accuracy, low cycle time, and very little human intervention.

Automatic Lathes
Single- and multiple-spindle automatic lathes
Six or eight different operations may be performed on many parts at the same time Will produce parts for as long as required

Tracer lathes/ duplicating Lathe

Used where a few duplicate parts required cross-slide controlled by stylus bearing against round or flat template

 Programmable lathe
Operated as standard lathe or programmable lathe to automatically repeat machining operations 2-axis -- exact location of cutting tool and work-piece in X and Z axes

Computerized numerically controlled lathes

Cutting-tool movements controlled by computercontrolled program to perform sequence of operations automatically

Taper turning attachment

Duplicating Lathe

Transfer Machining
system of automatic machining, in which a number of machine tools are arranged in a series in the sequence of operations and linked together with transfer equipments. Application areas: mass production of identical parts.

Classification of TM
In-line transfer machine: 25 or more station,
pallet, guide-rails, conveyor system, auto-clamping devices at each station.

Rotary transfer machine: 6-8 stations, less floor

space required, round/ rotary table with indexing mechanism

Drum type transfer machine: rotary drum with

fixtures, front and rear slide machining head

Specific characteristics of TM

Automatic work loading mechanisms:

Electric hoist and conveyor (large work) Hopper and chutes (small work)

Automatic transfer mechanisms:

Pawl type, rotating bar and finger mechanism, walking beam mechanism etc.

Auxiliary equipments:
Electrical control system Automatic work lading and unloading devices control and disposal of unwanted chips

Advantages and Limitations

output, accuracy and precision increases But, high initial cost, complex control system, breakdown of one machine results complete stoppage, limited to high volume of production.