Turning

Typical Parts Made with These

Processes

 Machine Components
 Engine Blocks and Heads
 Parts with Complex Shapes
 Parts with Close Tolerances
 Externally and Internally Threaded Parts
Products and Parts Made By These
Processes
Alternative Processes

 Precision Casting
 Powder Metallurgy
 Powder Injection
 Molding
 Abrasive Machining
 Thread Rolling
The Turning Process

Using Engine Lathes

 Operate on all Types of
Materials
 Use of single-point tools
 Skilled Labor
 Low Production Rate
Tool Geometry
 Rake Angle
 Side Rake Angle

 Cutting-Edge
Angle
 Relief Angle

 Nose Radius
Typical Lathe and Its Various Components
Lathe Components
 Bed: Usually made of cast iron. Provides a heavy
rigid frame on which all the main components are
mounted.
• Ways: Inner and outer guide railsn that are
precision machined parallel to assure accuracy of
movement.
• Headstock: mounted in a fixed position on the
inner ways, usually at the left end. Using a chuck, it
rotates the work.
• Gearbox: inside the headstock, providing multiple
speeds with a geometric ratio by moving levers.
• Spindle: Hole through the headstock to which bar
stock can be fed.
• Chuck: 3-jaw (self centering) or 4-jaw (independent)
to clamp part being machined.
• Tailstock: Fits on the inner ways of the bed and can
slide towards any position the headstock to fit the
length of the work piece. An optional taper turning
attachment would be mounted to it.
• Tailstock Quill: Has a Morse taper to hold a lathe
center, drill bit or other tool.
• Carriage: Moves on the outer ways. Used for
mounting and moving most the cutting tools.
• Cross Slide: Mounted on the traverse slide of the
carriage, and uses a handwheel to feed tools into
the workpiece.
• Tool Post: To mount tool holders in which the cutting
bits are clamped.
• Compound Rest: Mounted to the cross slide, it
pivots around the tool post.
• Apron: Attached to the front of the carriage, it has
the mechanism and controls for moving the carriage
and cross slide.
• Feed Rod: Has a keyway, with two reversing pinion
gears, either of which can be meshed with the
mating bevel gear to forward or reverse the carriage
using a clutch.
• Lead Screw: For cutting threads.
• Split Nut: When closed around the lead screw, the
carriage is driven along by direct drive without using
a clutch.
• Quick Change Gearbox: Controls the movement of
the carriage using levers.
• Steady Rest: Clamped to the lathe ways, it uses
adjustable fingers to contact the workpiece and align
it. Can be used in place of tailstock to support long
or unstable parts being machined.
• Follow Rest: Bolted to the lathe carriage, it uses
adjustable fingers to bear against the workpiece
opposite the cutting tool to prevent deflection.
Lathe Accessories
 Carriage and Cross Slide Stops
 Devices for Turning Parts with Various Tapers
 Milling, Sawing, Gear-Cutting, and Grinding
Attachments
 Various Attachments for Boring, Drilling, and
Thread Cutting
More Tool Geometry
Lathe Operations

 Form Tools
 Boring
 Drilling
 Parting
 Grooving
 Thread Cutting
 Knurling
Cutting Operations Performed on a Lathe
Above Left: Example of Boring Above Right: Example of Drilling

Below Left: Example of Thread Cutting Below Right: Example of Grooving

Types of Lathes

 Bench Lathes
 Special Purpose Lathes
 Tracer Lathes
 Automatic Lathes
 Automatic Bar Machines
 Turret Lathes
 Computer-Controlled Lathes
Turret Lathe
Computer-Controlled Lathe
Things to Remember About
Machining Parts on Lathes

 Takes considerable amount of time

 High Production Costs
 Wastes Material
 Not as Economical as Forming or Shaping
Boring and Boring Machines
What is Boring

 Performed to enlarge a hole made previously.

 Used for circular internal profiles in hollow
workpieces
Boring Machines

 Small pieces – lathe

 Large pieces – boring
mill
 Horizontal vs Vertical
 Boring mills
 Perform various
operations: TURNING,
FACING, GROOVING,
CHAMFERING
Horizontal Boring Mill
Vertical Boring Mill

 Large pieces can be

machined on a vertical
mill
Jig Boring Machines

 Vertical machines
 High precision bearings
 Used to make jigs and
fixtures
 Being replaced by CNC
boring machines
Considerations

 Through holes, rather than blind holes,

should be specified.
 Smaller length-bore diameter ratios
 Interrupted internal surfaces should be
avoided.
Milling and Milling Machines
Milling

 The Process of cutting away

material by feeding a
workpiece past a rotating
multiple tooth cutter.
Types of Milling
Peripheral Milling

 Peripheral Milling is when the cutter is longer than

the width of the cut.
 a.k.a.- Slab Milling
 The axis of the cutter is usually parallel to the work
piece surface.
Face Milling

 the cutter is mounted on a spindle having an

axis of rotation perpendicular to the
workpiece surface.
 Leaves feed marks on the machined surface.
End Milling

 The cutter generally rotates on an axis

vertical to the workpiece.
 It can be tilted to machine tapered surfaces.
Cutting teeth are located on both the end
face of the cutter and the periphery of the
cutter body.
 Can produce a variety of surfaces at any
depth.
Conventional Milling

 a.k.a- Up Milling
 The Direction of cutter rotation opposes the
feed motion.
Climb Milling

 a.k.a.- Down Milling

 The direction of cutter rotation is the same as
the feed motion.
Other Types of Milling

 Straddle Milling
 Form Milling
 Slotting and Slitting
 Uses circular cutters
Tool holders

 Arbor Cutters
 Mounted on an arbor
 Used in peripheral, face, straddle and form
milling.
Shank-Type Milling

 Cutter and shank are

one peice
 Design and Operating Guidelines

 Basic cutters should be used as much as

possible.
 Avoid expensive special cutters.

•Chamfers should be specified instead of

radii.
•Chamfer-A furrow or groove, as in a column.

•Avoid internal cavities and pockets with sharp

corners.
•Due to the difficulty of doing them.
Troubleshooting

 Tool Breakage Tool material lacks toughness,

improper angles.
 Excessive Tool Wear improper tool material, improper
tool fluids.
 Rough Surface Finish Feed per tooth too high, tool
chipped or worn.
 Chatter Marks Insufficient stiffness of system,
external vibrations.
 Breakout Lead angle too low, feed and
depth of cut too high.
Milling Machines

 First Milling Machine

 Built in 1820 by Eli Whitney
Column-and-Knee type

 Most common milling machines.

Basic Components

 Work Table
 Saddle
 Knee
 Overarm
 Head
Bed Type

 Work table is mounted is mounted directly on

the bed.
 Not versatile
 High Stiffness
 Used for high production work
Other Milling Machines

 Planer-Type
 Several heads and cutters able to mill different surfaces

•Rotary-Table
•One or more heads for face milling.
•Computer Numerical Control
•Able to mill, drill, bore and tap with repetitive accuracy
•Profile Milling Machines
•5 axes of movement.
Planning and Shaping

 Planning
 Large workpieces 25m X 15m
 Work piece is mounted on a table and travels back and
forth along a straight path.
 Cutting speeds can get up to 120 m/min with 150 hp
 Shaping
 Tool does the moving
 Small less than 1m X 2m
Gear milling
 Uses a rotating form
cutter
 Gear blanks are
indexed after each cut
 Is a low production
process
 Gear teeth are
produced individually