Lathe Machine and Accessories For Beginners

9/10/2014
MACHINE TOOLS
LATHE MACHINE
The Lathe
 Lathe is a machine tool which holds the work
between two rigid and strong supports, called
Introduction to Engine Lathe
centers, or in a chuck or face plate.

 The cutting tool is rigidly held and supported in
a tool post and is fed against the revolving
work.
 While the work revolves about its own axis, the
tool is made to move either parallel to
(Cylindrical surface) or at an angle with the
axis (Tapered surface) to cut the desired
material.
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Lathe Basics
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Parts of a Lathe
• Bed
• Head stock
• Tailstock
• Carriage
• Feed mechanism
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Lathe Basics
Headstock
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Lathe Basics
Bed
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Lathe Basics
Carriage/Apron
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Lathe Basics
Tailstock
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Engine Lathe
Figure: Diagram of an engine lathe, showing its principal components
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Lathe Basics
Spindle Tailstock
Nose Spindle
Tool Post
Clamp
Compound TAILSTOCK
HEADSTOCK
Rest
Saddle
Feed
Change
Lever
Lead
Feed BED Screw
Reverse WAYS
Lever Half Nut
APRON
Lever Bed
Gear Carriage
Box Hand
Wheel
Motor
Drive Cross
Slide
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Types of Lathe
1. Speed lathe
 Simplest of all types of lathe
 Contains Bed, Headstock, Tailstock, Tool post on adjustable slide
 No feed box, Lead screw, Carriage
 Headstock spindle speed:1200 to 3600 rpm
 Applications: Wood working, spinning, polishing etc.
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Types of Lathe …
2. Engine or Center lathe
 Most widely used
 Early lathes were driven by steam engines and so the name engine lathe
 Heavy duty
 Head stock is much more robust in construction
 Contains additional mechanism for multiple speeds
 Carriage, Feed rod and Lead screw are available and hence, longitudinal and
cross feeds are possible
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Types of Lathe …
3. Bench lathe
 Small lathe, mounted on a bench

 Just a scaled version of engine
lathe
 Used for small and precision work
4. Tool room lathe
 Greater accuracy
 More versatility
 Wide range of speeds and feeds
 Applications:
Precision work on tools, dies,
gauges
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Capstan and Turret Lathes

 Tailstock of an engine lathe is
replaced by a hexagonal turret
 Several tools fitted on the turret
are fed into work in proper
sequence to carryout different
operations in one setting
 Hence used for production work
 Capstan lathe
Turret with its saddle can move
for a short distance over the sub
bed.
Limitation: Length of a job to
be machined is limited
 Turret lathe:
Turret with its saddle slides
directly on bed-ways enabling
longer work to be machined
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Types of Lathe …
6. Special purpose lathes
 Used for special purposes
 Wheel lathe: For finishing journals, turning locomotive wheels
 Gap-bed lathe: A section of bed adjacent to tailstock is
removable thereby allowing very large diameter work to swing
 Duplicating lathe: To duplicate the shape of a template on to a
workpiece
Wheel lathe Machine Tools Duplicating lathe 15
Types of Lathe …
7. Automatic lathe
 Automatic control: Once the tools are
set and the machine starts, all the
operations will be performed
automatically
 Change of tools, speeds and feeds are
done automatically
 The jobs are made continuously one
after the other without the intervention of
operation
 High speed, Heavy duty and Mass
production lathe
 Single or multi spindle
 Capable of simultaneous cuts
Operator’s role:
 Loading the bar stock
 Setting the tools
 Machine maintenance
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Types of Lathe …
7. CNC lathe
 Computer Numerical Control
 Wide variety of process capability
 Multiple axes
 Indexing and contouring head
 On-line and off-line programming available
 Equipped with one or more turrets
 Each turret is equipped with a variety of tools
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The Bed
Diagonal ribs
• Rigid to withstand the
cutting forces
• Massive, sufficient to
Lathe
absorb vibration
• Resist the torsional

stresses set up.
• Should be seasoned
naturally to avoid
distortion.
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The Headstock
Main of parts of headstock are:
• Headstock spindle
Lathe
• Cone Pulley
• Backgears and backgear lever
• Gear Box
• Live center
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The Headstock Spindle

Lathe
1. Threaded end
2. Taper sleeve
3. Live center
4. Threaded nose
5. Spindle hole
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The Headstock
• Need for speed change
– Workpiece material
– Cutting tool material
Lathe
– Type of operation
– Workpiece size
– Surface finish
– Cutting fluid
– Rigidity of machine tool
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Methods to vary the speeds
1. By belt drive on cone pulley fitted

on the headstock spindle with or
without a back gear arrangement.
Lathe
2. By all gear drive using sliding

gears or clutches.
3. By variable speed motor.
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Belt Driven Backgeared Headstock

Spindle Cone Pulley
Lathe
In a belt driven back geared

headstock, multiple speeds can
be obtained
1. Direct speed or back gear out
Countershaft Cone
2. Indirect speed or back gear in
Pulley
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Speed Ratios
• Direct speeds:
Spindle speed =

• Indirect speeds:
Lathe
Spindle speed =

Back gear ratio =

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Geared Headstock
Fig. 9 speed all-geared headstock

1 – Fast Pulley
2 – Loose pulley
3 – Spindle shaft
4 to 13 – gears with
Z4 to Z13 teeth
10 – Intermediate shaft
14 – Gear box casting

Lathe
Preferred values for ‘r’,

= 1.12, 1.25, 1.4, 1.6 and 2

Speed distribution, r (GP Ratio)

15 – splined headstock spindle.
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Tailstock
Lathe
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Carriage
Lathe
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Single Screw Tool post
1 – screw
2 – body
3 – tool
Lathe
4 – convex
rocker
5 – concave
ring
Fig.: Single screw tool post

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Four way Tool post

1 – clamping
handle
2 – central
locking
bolt
Lathe
3 – set
screws
4 – tool
Figure: Four way Tool post
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Feed Mechanism
• Feed:
The distance advanced by the tool into or along
the workpiece for each revolution of the work.
 Units: mm/rev. or mm/min.
Lathe
• Types
– Longitudinal feed (cylindrical turning, thread
cutting, etc.)
– Cross feed (facing, parting, etc.)
– Angular feed (taper turning, chamfering, etc.)
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Feed Mechanism
Change gear
End of bed gearing
Mechanism
Feed rod &
lead screw
Apron
train
Power Train Tumbler gear Bevel gear
feed reverse feed reverse
mechanism mechanism
Feed gear box

Lathe
3. Gear
2. Sliding 4. Sliding 5. Combination
1. Sliding gear cone and
clutch key of two or more
mechanism Norton feed
mechanism mechanism of 1, 2, 3, 4
gear
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Feed Mechanisms …
Headstock spindle
Change Gears
Tumbler gear
Norton Gears
Sliding key
operating handle
Clutch handle
Lead screw
Sliding Key Mechanism

Feed rod
Figure: Layout diagram of feed drive
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Feed Reverse Mechanism

using Tumbler Gears
Tumbler gears are used to give the desired direction of movement to the
lathe carriage, via lead screw or feed rod.
Tumbler Gear Mechanism

Tumbler Gears
Two pinions B and C

are mounted on a
bracket.
Forward motion: A-B-D: Carriage moves towards headstock

Reverse motion: A-C-B-D: Carriage moves away from headstock
Drawback: Non-rigid construction, hence not suitable for heavy duty
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Feed Reverse Mechanism

using Bevel Gear Mechanism
Constructional details
1 – headstock spindle
2 – spindle gear
3 – driver gear keyed to stud shaft (7)
5 – gear on the lead screw (6)
8, 10, 12 – bevel gears with equal no. of teeth
11 – clutch (keyed to stud 7 by a feather key)
9 – lever (to engage clutch to gear 8 or 10 or
keep in neutral position)
(Gear 13-sleeve-bevel gear 8) rotate freely on

stud 7 as one unit
bevel gear 10 also rotates freely on stud 7
The clutch operated bevel gear feed reversing mechanism incorporated below the
headstock or in the apron provides sufficient rigidity in construction.
Feed Reverse Mechanism …

using Bevel Gear Mechanism
Operation:
When clutch is engaged to bevel gear 8:
Motion flow: gear 2 – Idler gear – (gear

13, sleeve, bevel gear 8) – (stud 7, gear 3)
Result: Gear 3 rotates in the same

direction as that of gear 2. Hence,
Forward motion, Carriage moves towards
headstock.
When clutch is engage to gear 10:
Motion flow: gear 2 – Idler – (gear 13,

sleeve, bevel gear 8) – bevel gear 12 –
bevel gear 10 – (stud 7, gear 3)
Result: Gear 3 rotates in opposite direction

to that of gear 2. Hence,
Reverse motion, Carriage moves away
from headstock.
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Feed Mechanisms …
Change gears are used in
Change Gears thread cutting to give
proper relative motion
between the work and tool
Change Gear Mechanism
E
G
Change Gears
Figure: Change gears
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Feed Mechanisms …
Norton Feed Gears
Norton Feed Gears
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Feed Mechanisms …

 It consists of a cone of gears
mounted on a hollow shaft.
 Gears rotate independently freely on the

I shaft.
 Steel washers are placed between the

3 gears to prevent simultaneous
engagement of adjacent gears.
II  With the help of sliding key (that

slides within the hollow shaft), any one of
the gears may be engaged to the cone
gears on the driven shaft.
I – driving shaft;
II – driven shaft  Motion is then transmitted finally to the
1 – sliding key operating handle lead screw or feed rod.
2 – sliding rod
3 – lever spring
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Apron Mechanism
1 – lead screw; 2- feed rod
3 – half-nut; 4 – cross feed screw
5, 6, 7 – Gear train for cross feed
9 – cone clutch for longitudinal feed
10, 11 – gear train for long. feed.
12 – gear for hand wheel
13 – pinion; 14 – apron
15 – rack; 16 – hand wheel
17 – knob for longitudinal feed
18 – cone clutch for cross feed
19 – knob for cross feed
20 – lever; 21 – cam
22 – sliding gear
23 – gear on worm shaft
24 – worm; 25 – cam plate
26 – half nut operating handle
Apron Mechanism
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Feed Rod & Lead Screw

Feed rod
Used to engage automatic tool feed during turning,

boring, facing etc.
Automatic tool feed is obtained by engaging feed rod so
as to transmit power from the lathe spindle to the apron
gears
lead screw
feed rod
Lead screw: Long threaded master screw

Engaged during thread cutting operation
In lathes without feed rod, lead screw may be used for turning, boring etc.
Split Half Nut

Mechanism
 Half Nut is engaged to the lead
screw during threading.
 The nut is made in two halves.
 Each of these halves carries a pin at

the back (P1 and P as shown in
2
Fig. a) which engages into the cam

slots provided in a plate at their back.
Fig. a) Half nut
 When this plate is rotated by
means of the lever L, it engages or
disengages the split half nut with the
lead screw depending upon the
direction of rotation of the lever.
1 – cam slot; 2 – frame; 3 – lead screw;

4 – hand lever; 5 – pin; 6 – circular plate;
7 – half nuts
Fig. b) Sectional views of Half Nut Mechanism
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Kinematic Structure of a Lathe

Lathe
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Specifications of a Lathe
A = Length between centers

B = Swing over gap (Gap bed lathes)
C = Height of centers
D = Swing over carriage
E = Swing over bed
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Turning Operation
FIGURE : Schematic illustration of a turning operation

showing depth of cut, d, and feed, f. cutting speed is the
surface speed of the workpiece at the tool tip.
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Lathe Operations
Fig: Various cutting operations that can be performed on a

lathe.
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Lathe Operations
Fig: Various cutting operations that can be performed on a lathe.
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Lathe – Accessories & Attachments

Accessories
Accessories & Attachments
Devices employed for holding

and supporting the work and the
tool.
Attachments
Devices to increase production
and efficiency and widen its scope
of use.
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Lathe – Accessories & Attachments

Accessories Attachments
Centers Bar Stops
Face & Angle Plates Thread Chasing Dials
Dogs or Carriers Taper turning
Chucks Milling
Grinding
Mandrels
Gear Cutting
Rests
Hydro-copying
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Centers
A – Ordinary Center E – Tipped (brazed) Center
B – Ball Center
F – Insert type Center
G - Pipe Center
C – Frictionless Center
1 – Insert type center
2 – Nut
D – Half Center
3 – Roller bearing H – Use of half center
4 – Thrust bearing 1 – Half center
5 - Housing 2 – Facing tool
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Driving Plates and Dogs

Boss Threaded Hole
Projected Pin
Fig: Driving Plate
Fig: Eccentric Turning
Fig. Straight dog
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Holding the work between Centers

Fig.: mounting the work between centers using a "dog”
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Chuck
1- concentric circle; 2 – chuck body;

3 – Jaw screw; 4 – jaw; 5 – gripping
surface; 6 – recess for back plate.
Fig: Four Jaw Chuck
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Chuck
Fig: Three Jaw Chuck
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Chuck
1-work; 2-magnetic material; 3-keepers;

4-face plates, 5-magnet
Fig: Magnetic Chuck
1-cylinder; 2-air passage; 3-head stock spindle; 4-piston;

5-valves;; 6-piston rod; 7-link; 8-jaw; 9-guide; 10-sliding unit
Fig: Hydraulic Chuck
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Collet
Fig: Collet Chuck 1-Bearing; 2-Spindle; 3-Nut;

4-Key; 5-Chuck; 6-Collet
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Collet
Fig.: collet
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Face Plate & Angle Plate

Clamping Balance
Plate Weight
Packing Work
1-face plate; 2-balance weight; 3-elbow pipe;
Fig: Face Plate 4-clamping nut; 5-angle plate; 6-clamping nut
Fig: Angle Plate
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Face Plate
Fig.: face plate for non-cylindrical workparts
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Mandrels
Plain Mandrel
Collar Mandrel
Step Mandrel Threaded Mandrel
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Mandrels
1-solid cone; 2-sliding cone; 3-nut

1-fixed collar; 2-hollow workpieces;
Fig: Cone Mandrel 3-movable collar; 4-nut
Fig: Gang Mandrel
1-sleeve; 2-tapered pin
Fig: Expansion Mandrel

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Steady Rest
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Follower Rest
Fig.: Follower rest
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Thread Cutting - Terminology

Fig. Elements of external threads

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Thread Cutting - Terminology

Fig. Single Start Fig. Double Start
Fig. Triple Start

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Thread Cutting
Fig: General set-up of lathe for screw cutting
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Thread Cutting - Change Gear Ratio


,
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Cutting metric thread on

British standard lead screws or Vice Versa
To cut metric threads on lathes having

British standard lead screw:

5
127
To cut British standard threads to be cut on

a lathe having lead screw of metric pitch:
127
5
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Cutting R.H. and L.H. Threads

Right Hand threads:
 Threads slope up to the right when
screw is held vertically.

 The spindle and the lead screw will
rotate in the same direction.
Left Hand threads:
 Threads slope up to the left when
screw is held vertically.
 The spindle and the lead screw will
rotate in opposite direction.
This change of direction of rotation on
lathe is effected by tumbler gear or by
using proper number of idlers.
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Thread Cutting - Gear Trains

 Often lathes are equipped with a set of gears
ranging from 20T to 120T in steps of 5T.
 In addition, a gear of 127 teeth is also

provided which is known as translating gear.
Simple gear train Compound gear train

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Left Hand thread - Applications

Where the rotation of a shaft would cause a
conventional right-handed nut to loosen rather
than to tighten, e.g. on a left-hand bicycle

pedal.
In combination with right-handed threads in
turnbuckles.
In some gas supply connections to prevent

dangerous misconnections, for example in gas
welding the flammable gas supply uses left-
handed threads.
In Gold ornaments, e.g. ear studs.
MachineLH Thread
Tools RH Threa
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Examples:
Pb.: Calculate change gears for cutting R.H.
threads of 2 mm pitch on a lathe having
lead screw of 6 mm pitch.

Soln:
2 1

6 3
1 20 20
Simple train with one idler
3 20 60
1 25 25
3 25 75
1 30 30
3 30 90
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Examples:
Pb.: Calculate change gears for cutting L.H.
threads of 1.5 mm pitch on a lathe having

Soln:
1.5 1

6 4
1 20 20
4 20 80
1 25 20
4 25 100
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Examples:
Pb.: Calculate change gears for cutting R.H.B.S.W.
“V” threads of 12 TPI on a lathe having lead
screw of 8 TPI.
Soln:
1⁄12

1⁄8
8 2
12 3
2 20 20
3 20 60
2 25 25
3 25 75
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Examples:
Pb.: Calculate change gears for cutting R.H.
threads of 1 mm pitch on a lathe having

Soln:
1

8
1 20 20

8 20 160
1 1 1 1 1 20 1 30 20 30

8 4 2 4 2 4 20 2 30 80 60
Compound Gear train with no idler
Gear A = 20 Gear B = 80
Gear C=30 Gear D = 60
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Examples:
Pb.: Calculate change gears to cut R.H. threads
of 25 TPI on a lathe having lead screw of 6
TPI.
Soln: 6

25
6 2 3 2 20 3 15 40 45

25 5 5 5 20 5 15 100 75
Compound Gear train with no idler

Gear C = 45 Gear D = 75
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Examples:
Pb.: Calculate change gears to cut L.H. single
start threads of 0.25” pitch on a lathe having
lead screw of 8 mm lead.

Soln: 1
0.25"
4
127 1⁄4

5 8
127 127 127 1 50 127 50
⇒
5 32 5 16 2 80 2 50 80 100
Compound Gear train with one idler
Gear C = 50 Gear D = 100
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Setting of Tools for Threading

Fig. Setting threading tool

for external threading
Fig. Setting threading tool

for internal threading
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Feeding the Tool in Threading

Fig: Straight Thread

Fig: Inclined feed
Fig: Inclined feed using a form tool

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Thread Cutting
Fig.: Cutting a screw thread on a lathe

Inset shows face of threading dial
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Providing undercut
Fig.: Under Cut
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Cutting Square and Acme Threads

Lead .of .thread

tan  
Circumference
Fig. Tool setting for square

threads
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Thread Cutting Cycle

Fig.: Threading cycle to produce threads
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Thread Chasing Dial

Fig: Thread Chasing Dial
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Taper Turning
1
1 100
100
⁄2
tan
2
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Tail Stock Set-over Method

Let,
H = set-over required
D = larger diameter
d = smaller diameter
L = total length of work
l = length of taper
(all dimensions in ‘mm’)
sin
α is very small and hence, sin tan
But, tan ∴
2 2
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Swiveling the Compound Rest

Fig. Turning taper by swiveling the compound rest
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Taper turning attachment

Fig. Use of taper turning attachment

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Form or Broad Nose Tool

Fig. Turning short taper by a form (broad nose) tool
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Machining Time Calculations in Turning

Cutting speed: /
1000
where d = diameter of the work in mm;

N = speed of the work in rpm.
Feed: mm / rev. or mm / min.
f (mm / min) = f (mm / rev) X N (rev / min)
Machining time:
where l = length of the job, mm
f = feed in mm/rev.;
N = speed in rpm.
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References
• Materials and Processes in Manufacturing,
by E. Paul DeGarmo, et al, Wiley
• Manufacturing Engineering and Technology,
by S Kalpakjian and Steven R Schmid, Pearson
Text Books
• Machining Technology – Machine Tools and

Operations, by Helmi A Youssef and Hassan
El-Hofy, CRC Press
• Manufacturing Science, by A Ghosh and AK
Mallik, EWP
• Machining & Machine Tools, by AB
Chattopadhyay, Wiley
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Lathe Machine and Accessories For Beginners

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9/10/2014

centers, or in a chuck or face plate.

Figure: Diagram of an engine lathe, showing its principal components

 Small lathe, mounted on a bench

4. Tool room lathe

Capstan and Turret Lathes

Wheel lathe Machine Tools Duplicating lathe 15

 Computer Numerical Control

 Wide variety of process capability

 Indexing and contouring head

 On-line and off-line programming available

 Equipped with one or more turrets

 Each turret is equipped with a variety of tools

• Resist the torsional

Main of parts of headstock are:

The Headstock Spindle

Methods to vary the speeds

1. By belt drive on cone pulley fitted

2. By all gear drive using sliding

3. By variable speed motor.

Belt Driven Backgeared Headstock

In a belt driven back geared

Fig. 9 speed all-geared headstock

14 – Gear box casting

Preferred values for ‘r’,

Single Screw Tool post

Fig.: Single screw tool post

Four way Tool post

Figure: Four way Tool post

Feed gear box

Sliding Key Mechanism

Figure: Layout diagram of feed drive

Feed Reverse Mechanism

Tumbler Gear Mechanism

Two pinions B and C

Forward motion: A-B-D: Carriage moves towards headstock

Feed Reverse Mechanism

(Gear 13-sleeve-bevel gear 8) rotate freely on

bevel gear 10 also rotates freely on stud 7

Feed Reverse Mechanism …

Motion flow: gear 2 – Idler gear – (gear

Result: Gear 3 rotates in the same

When clutch is engage to gear 10:

Motion flow: gear 2 – Idler – (gear 13,

Result: Gear 3 rotates in opposite direction

Figure: Layout diagram of feed drive

Change Gear Mechanism

Figure: Change gears

Norton Feed Gears

Figure: Layout diagram of feed drive

Norton Feed Gears

Sliding Key Mechanism

Figure: Layout diagram of feed drive

Sliding Key Mechanism

 Gears rotate independently freely on the

 Steel washers are placed between the

II  With the help of sliding key (that

Feed Rod & Lead Screw

Used to engage automatic tool feed during turning,

Lead screw: Long threaded master screw

Split Half Nut

 The nut is made in two halves.

 Each of these halves carries a pin at