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07 lathe

The document provides information about various types of lathes and machining operations performed on lathes. It discusses the history of lathe development from ancient times to modern CNC lathes. It describes different lathe components like beds, headstocks, toolholding devices, workholding devices and specifications. It explains common machining operations like turning, facing, grooving and threading. In under 3 sentences.

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LATHE
Bench lathe, 1911 Ancient India Bow lathe, Roman Era Pole lathe, 1250 Foot wheel lathe, Leonardo da Vinci 1480 Egypt, 300 BC Great wheel lathe, 1680 Lathe circa, 1850 2 LATHE-INTRODUCTION
 It is one of the most common and versatile metal cutting technologies. The machine is called lathe.  In turning, a workpiece is rotated about its axis (cutting movement) as single-point cutting tools are fed into it (feed and cutting depth movements), shearing away unwanted material and creating the desired part.  Typical geometries: Axially-symmetrical contoured part such as cylinders, cones and tapered shafts, spheres, threads, etc  Typical operations: Facing, Contour turning, Chamfering, Parting (Cut-off), Grooving, Threading, Drilling, Knurling,… LATHE-INTRODUCTION N N Spindle speed (rpm) Vc Cutting speed (m/min) fn ap Feed per revolution (mm/rev) Cutting depth (mm) r Positioning angle VIDEO
LATHE-INTRODUCTION
LATHE MACHINE
MACHINE TYPES Conventional lathes
MACHINE TYPES Conventional lathes • Manual movement execution. •Manual tool and part change. •Same part holding device for different parts.  Machining time: Important  Idle time: Important  Set-up time: small  Series: Unitary or up to 10 parts  Precision: IT7 , Ra:1.6 µm. 1.Bench / Center / Engine Lathe
MACHINE TYPES Conventional lathes  Turning of heavy and voluminous parts in diameter and/or length.  Several tools can work at a time.  Machining time: Important  Idle time: Important  Set-up time: Important (due to the weight of the parts)  Series: Unitary or small  Precision: IT7 , Ra:1.6 µm. 2.Vertical Lathe
MACHINE TYPES Conventional lathes • SEMIAUTOMATIC lathe. • Automatic tool change. • Several tools can work at a time. • Typical workholding device: collets • Machining time: Less than in a bench lathe. • Idle time: Less than in a bench lathe. • Set-up time: Important at the beginning (all the tools need to be adjusted). • Series: 25 parts or more. • Precision: IT 8 , Ra:1.6 µm. 3.Turret lathe  The distinguishing feature of this type of lathe is that the tailstock of an engine lathe is replaced by a hexagonal turret, on the face of which multiple tools may be fitted and fed into the work in proper sequence.  Due to this arrangement, several different types of operations can be done on a job without re-setting of work or tools, and a number of identical parts can be produced in the minimum time. hexagonal turret
MACHINE TYPES Conventional lathes 3. Capstan and Turret lathes  Capstan lathes generally deal with short or long rod type blanks held in collet, whereas turret lathes mostly work on chucking type jobs held in the quick acting chucks  In capstan lathe, the turret travels with limited stroke length within a saddle type guide block, called auxiliary bed, which is clamped on the main bed as indicated in Fig. 2, whereas in turret lathe, the heavy turret being mounted on the saddle which directly slides with larger stroke length on the main bed as indicated in Fig. 2. Fig.1 turret lathe. Fig.2 capstan lathe
MACHINE TYPES Conventional lathes • Automatic movements execution using cams. • Several tools can work at a time. • Automatic part feed and change. • Important toolholder cost • Machining time: Less than in a bench lathe. • Idle time: Almost zero. • Set-up time: Important (long tools set-up) • Series: 1000 parts or more • Precision: IT 8 , Ra:1.6 µm. 4.Single Spindle Automatic Lathe VIDEO
MACHINE TYPES Conventional lathes • Automatic movements execution. • Several tools can work at a time. • Automatic part feed and change. • Important toolholder cost. • Highly skilled workforce needed to set the machine. • 6 to 8 parts can be produced at a time. • Machining time: Very low • Idle time: Almost zero. • Set-up time: Very Important (long tools set-up) • Series: 10.000 parts or more • Precision: IT 7/8 , Ra:1.6 µm. 5.Multi Spindle Automatic Lathe
MACHINE TYPES Numerical Control Lathes (CNC)
MACHINE TYPES Numerical Control Lathes (CNC) • It is the evolution of an engine lathe being equipped with a CNC control. • They offer high stability, but slow tool indexing and changing. VIDEO 1.Flat bed lathe Video: Flat bed lathe
MACHINE TYPES Numerical Control Lathes (CNC) 2.Vertical lathe • It is used for large diameter heavy parts. • A gantry design with a ram is the base of construction. • Double ram offers a higher productivity. • Long tool change time and component loading/unloading. • Applications: railway wheels, gas/steam/wind turbines, aero engines,… VIDEO VIDEO
Video: Vertical lathe
MACHINE TYPES Numerical Control Lathes (CNC) • Used when machining from both sides is required (both spindles synchronize for part changing). • Higher productivity It may halve the cycle time compared to a single revolver machine: • Tandem turning (same side turning). • Machining operations on the sub-spindle at the same time as the main spindle. • Typically 3 turrets (2 for the main spindle and 1 for the sub-spindle), but 2 turrets also exist. • Typical applications: Long slender components like shafts and components machined on both sides. 3.Turning centre TWIN / DOUBLE / SUB SPINDLE VIDEO VIDEO
MACHINE TYPES Numerical Control Lathes (CNC) • Spindle has the axial movement for workpiece load and machining, not the tools. • Nearly always fitted with a bar-feeder ( 0.5mm - 40 mm). • Uses a headstock possible to machine long components and small diameters without using a secondary spindle. • Workpiece clamping system collet. • Application: complex, precise and small size parts. VIDEO VIDEO 4. Sliding head machine or Swiss type lathe (I)
Video: Sliding head machine or Swiss type lathe
MACHINE TYPES Numerical Control Lathes (CNC) Sliding head machine or Swiss type lathe VIDEO
MACHINE TYPES Numerical Control Lathes (CNC) • Several technologies are integrated into one machine: turning, milling, drilling,… • It has evolved from turning machines. • The heart of the machine is the tool spindle (B spindle), which even can be tilted. It provides milling, drilling and tapping capability along with turning, facing, grooving and threading. • This spindle is serviced by an automatic tool changer that resides outside the cutting zone. • It may have a double spindle and one/two tool turrets. • Application: very complex parts. 5.MULTITASKING MACHINE – HORIZONTAL
MACHINE TYPES Numerical Control Lathes (CNC) MULTITASKING MACHINE – HORIZONTAL
Video: multitasking machine – horizontal
MACHINE TYPES Numerical Control Lathes (CNC) 6.Single Spindle Automatic Lathe VIDEO 24
MACHINE TYPES Numerical Control Lathes (CNC) 7.Multiple Spindle Automatic Lathe VIDEOVIDEO
Video: Multiple Spindle Automatic Lathe
WORK HOLDING DEVICES
WORK HOLDING DEVICES 1.Jaw chuck Part clamped within a chuck and with no additional support (maximum recommended cantilever 1.5 Diameter) Posibility to hold cylindrical or poligonal parts (side number equal or multiple to the number of jaws). Most common Chuck: Self-centering jaws Movement controlled by a single screw operated by a “T” shape key. The jaws move simultaneously and exactly the same amount of movement toward center. Cantilever L < 1.5Ø
WORK HOLDING DEVICES Chucks: Manual VIDEO Chucks: Power driven Pneumatic or Hydraulic Magnetic operated Centering is more complex. Working with small workpieces is more difficult because they lack sufficient surface area. Independent jawsSelf-centering jaws VIDEO VIDEO
WORK HOLDING DEVICES Chucks: Number of jaws Six jaw chuckFour jaw chuckThree jaw chuckTwo jaw chuck Eight jaw chuck Chucks: Ring and discs Holding with external part Holding with inverted jaws Chucks: Soft jaws • To hold cylindrical parts precisely as well as irregular parts. • Soft material jaws, without being thermically treated. VIDEO
Video: Self-centering jaws Video: Independent jaws
WORK HOLDING DEVICES 2.Jaw Chuck and Center • Part held on one side within a chuck and on the other side with a live center. • A lathe center holds the end of the workpiece, providing support to preventing the workpiece from deflecting during machining. Live Center: • Center contact point is mounted on bearings and allowed to spin with workpiece. It is mounted in the tailstock quill (60º vertex). VIDEO
WORK HOLDING DEVICES Between Centers • Part hold within two centers (live center and dead center). • Rotation is produced thanks to a dog. It is not an energetic holding but it offers an excellent centering (finishing operations). Dead Center: • Solid steel tip that workpiece spins against. It is mounted in the spindle hole (60º vertex).
WORK HOLDING DEVICES 3.Face Plates • It is used to grasp parts with irregular shapes. • It is used when no other clamping system is valid. • It is a custom-designed clamp for a particular geometry.
WORK HOLDING DEVICES 4.Steady and Follow rests Steady rest • Used in external or internal machining operations. • It stands stationary from a rigid mounti • on the bed, and it supports the workpiece at the rest's center, typically with three contact points 120° apart. ng Follow rest • External machining of parts mounted within a chuck and center. • It is similar to the steady rest, but it is mounted to the carriage rather than the bed, which means that as the tool bit moves, the follower rest follows along. VIDEO VIDEOVIDEO
Video: Follow rest
Video: Steady rest
WORK HOLDING DEVICES 5.Mandrel • For external/internal concentric machining operations. • Mandrel: It is a hardened and ground cylindrical piece having undercut centerholes on both ends. It is used for holding hollow workpieces, or those that have been drilled or bored previously. Solid mandrel • Mandrels have a slight taper (1:2000). The workpiece is just fixed by friction. The ends of the mandrel have machined flats for the lathe dog to grip. • Since solid machine mandrels have a very slight taper, they are limited to workpieces with specific inside diameters. • The workpiece is mounted on a cylindrical shaft and is axially fixed using nuts. • The coaxiality between the inner and outer diameter of the workpiece depends on the workpiece and mandrel adjustment. Gang mandrel
WORK HOLDING DEVICES Cone mandrel • The workpice is fixed by means of an elastic collet (B). The collet is expanded by pressing the nut (D) against the taper shaft (M). • On the same mandrel different size elastic collets can be mounted to fix different diameter workpieces. Expansion mandrel • It is a very effective device for holding a part that has a hole drilled through it. • The part is secured between the tapers of the mandrel. VIDEO
WORK HOLDING DEVICES 6.Elastic collets • Commonly used in turret lathes and automatic lathes. • Collet: Taper body with an axial hole where the workpiece to be machined is introduced (cylindrical, rectangular, hexagonal,… bars). • Longitudinal cuts offer elasticity to the collet and a uniform fixture is obtained. The taper body is pulled manually or automatically against the machine frame and the workpiece is fixed by pressure (axial movement is needed to clamp/unclamp the workpiece). VIDEO
TOOLHOLDING DEVICES
TOOLHOLDING DEVICES Tool holding system 1.Tool post BORING BAR SHANK SPRING CLAMP
TOOLHOLDING DEVICES Shank turret VDI turret (Verein Deutscher Ingenieure) Designed for shank and cylindrical holders. Driven solutions can not be used. It has been the standard quick change solution. Driven units can be adopted, although the bearings are always outside the turret. Tool holding system 2.Turret
TOOLHOLDING DEVICES Coromant Capto Interface (CBI) turret VIDEO Coromant Capto Disc Interface (CDI) turret Driven solutions can be mounted inside or outside the turret. New solution to replace shank and VDI turrets Driven tool holder (DTH) bearings mounted inside the turret. Tool holding system Turret 44
TOOLHOLDING DEVICES Four turning tools in one Two turning tools in one Tool holding system Mini-turret
Lathe Specifications
Lathe Specifications 1. Length between the centers • It is the measure of the maximum length of the workpiece that can be fixed between the lathe centers 2. Height of the centers • It is the distance between the lathe axis and the lathe bed
Lathe Specifications 3. Swing diameter over the bed • It is the maximum diameter of the workpiece that can be turned on a lathe without hitting the lathe bed 4. Swing diameter over the carriage • It is the maximum diameter of the workpiece that can be turned on a lathe without hitting the carriage 5. Maximum bar diameter • It is the maximum diameter of the workpiece that can be passed through the hole in the headstock
MACHINING OPERATIONS
MACHINING OPERATIONS 1.Turning Fr  = higher tool vibration. Tool entry smoother. Fr = radial Fr =radial Ff = axial 95° Ff =axial 45° • Turning is the operation of removing the excess material from the workpiece to produce a cylindrical surface to the desired length. External turning
MACHINING OPERATIONS 2.Facing VIDEO VIDEO • It is an operation of reducing the length of the workpiece by feeding the perpendicular to the lathe axis. • This operation of reducing a flat surface on the end of the workpiece. External turning
MACHINING OPERATIONS 3.Chamfering VIDEO • It is the operation of getting a bevelled surface at the edge of a cylindrical workpiece. This operation is done in case of bolt ends and shaft ends. • Chamfering helps to avoid damage to the sharp edges and protect the operation getting hurt during other operations. External turning
MACHINING OPERATIONS 4.Grooving Outer Diameter (OD) grooving Face grooving VIDEO • It is the process of reducing the diameter of a workpiece over a very narrow surface. It is done by groove tool. A grooving tool is similar to the parting-off tool. It is often done at the end of a thread or adjacent to a shoulder to leave a small margin. Two types of grooving: External turning
MACHINING OPERATIONS Positioning of the tool Type of tool: 1.Insert type (shallow groove) 2.Screw-clamp (medium groove) 3.Spring-clamp (deep groove) 1 2 3 OD GROOVING: VIDEO 1 Grooving External turning
MACHINING OPERATIONS The correct curve on the tool is dependent on the radius of the workpiece. FACE GROOVING:2 VIDEO Left hand (L) tool Right hand (R) tool External turning
MACHINING OPERATIONS  Cutting tool has a shape that is imparted to the workpiece by plunging the tool into the workpiece.  In form turning, cutting tool is complex and expensive but feed is linear and does not require special machine tools or devices.  Cutting tool has a simple shape, but the feed motion is complex; cutting tool is fed along a contour thus creating a contoured shape on the workpiece.  Not possible to be done efficiently in manual lathes. 5.Form turning 6.Profiling or Contour turning VIDEO VIDEO External turning
MACHINING OPERATIONS • This is not a machining operation but a plastic deformation operation using a knurling tool. • Criss-cross pattern knurls are the most typical (ocasionally straight knurls are used too). • OBJECTIVE: Knurling allows hands or fingers to get a better grip. VIDEO 7.Knurling Knurling tool Knurling wheels or Knurls Knurled part • It is an operation of obtaining a diamond shape on the workpiece for the gripping purpose. External turning
MACHINING OPERATIONS 8. Threading • It is the important operation in the lathe to obtain the continuous ”helical grooves” or ” threads’‘. • When the threads or helical grooves are formed on the out surface of the workpiece is called external thread cutting. When the threads or helical grooves are formed on the inner surface of the workpiece is called internal thread cutting. External turning
MACHINING OPERATIONS  Spindle revolution (N) and feed per revolution (fn) must keep a relation.  A single-point threading tool, typically with a 60 degree pointed nose, moves axially along the side of the workpiece, cutting threads into the outer surface.  The threads can be cut to a specified length and pitch, and may require multiple passes to be formed. Insert types Infeed strategies 8. Threading Each insert can only cut one pitch. Can result in burr formation that needs to be taken away. Reduced number of infeeds Productivity ↑ VIDEOVIDEOVIDEO VIDEOVIDEO External turning
MACHINING OPERATIONS 1. Using a compound slide 2. Using form tools 3. Offsetting the tailstock 4. Using taper turning attachment 1. The compound rest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). VIDEO 2. By offsetting the tailstock (Long and slim tapers, up to 10-15%). 9. Taper turning External turning Taper Turning Methods
1. Using a compound slide • Limited movement of the compound slide. • Feeding is by hand and is non-uniform. • This is responsible for low productivity and poor surface finish. • Short and steep tapers can be easily done. MACHINING OPERATIONS Taper turning D d ℓ θ tan 2 D d l    , 2 c D d Noof cuts n d   / L Time cut f N 
2. Using form tools • Useful for short tapers, where the steepness is of no consequence such as for chamfering. • When turning long tapers with form tools, the tool would likely to chatter (vibrate) resulting in poor surface finish. • However care of the form tools is a careful exercise. MACHINING OPERATIONS Taper turning Video: form tools
3. Offsetting the tailstock tan 2 D d l        tan certain part length only tobe tapered , tan entirepart length tobe tapered 2 2 2 L offset s l D d L l D d D d l l                MACHINING OPERATIONS Taper turning For tapers on longer shafts, you can offset the tailstock from the centre line. The limitations are on the size of taper, it will only be a shallow taper. Calculations on the offset will be needed. Video: Offsetting the tailstock
4. Using taper turning attachment MACHINING OPERATIONS Taper turning For longer tapers you can use a Taper Turning Attachment. Video: taper turning attachment
4. Using taper turning attachment • Long Tapers • Power feed • Taper angle limited to 6 – 7° • Attachment • Guide bar • Sliding block MACHINING OPERATIONS Taper turning l GL x 2 d-D setoverbarGuide  For longer tapers you can use a Taper Turning Attachment.  They attach to the lathe bed.  Having set the angle on the attachment, the cross slide is moved producing the taper as the saddle moves along the bed.
MACHINING OPERATIONS  It consists on increasing a previously drilled workpiece diameter. This operation is accomplished moving the tool using the longitudinal carriage. VIDEO VIDEO 1.Turning or boring Internal turning
MACHINING OPERATIONS  It consists on machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. Tool movement using the cross-slide to allow thread exits, outlet for the use of grinding wheels,… 2.Facing 3.Grooving Internal turning
MACHINING OPERATIONS  It consists on machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. 4. Profiling 5.Taper turning •The compound rest may be swiveled on the cross- slide to any angle in the horizontal plane (short tapers). • CNC lathes – 2 axes Interpolation VIDEO Internal turning
MACHINING OPERATIONS It consists on creating a blind hole or a through hole using a drill. Two ways to obatain a gole: 1. The part spins and the drill has no rotation, only an axial displacement thanks to the tailstock. 2. Using a live tool. VIDEO 6. Drilling WC HSS Solid carbide drills Indexable insert drills Exchangeable tip drills TIR(TotalIndicatorRunout) 0,02 mm 0,03 mm 0,02 mm VIDEO Internal turning
MACHINING OPERATIONS  It is a special drilling and countersank (60º) operation done with a center drill to fit later a live or dead center. 7. Center hole machining  The reaming is a finishing operation to achieve good dimensional (H6,H7,H8) and surface tolerances depending on the ream.  Two ways to ream within the lathe:  Keeping the part stationary and spinning the ream handle manually (the handle is supported in the tailstock).  Spinning the part (Mc) and moving the ream axially (Ma) (held within a drill chuck). VIDEO 8.Reaming Internal turning
MACHINING OPERATIONS 9.Threading RIGHT SIDE LEFT SIDE VIDEO 1 SINGLE POINT THREADING TOOL Internal turning
LATHE MACHINE APPLICATIONS
LATHE MACHINE APPLICATIONS AEROSPACE APPLICATIONS 4 – FAN CASTING – Titanium 7 – COMBUSTION CASING – Heat Resistant Super Alloy 6 – TURBINE DISC – Heat Resistant Super Alloy
LATHE MACHINE APPLICATIONS AUTOMOTIVE APPLICATIONS GEAR WHEEL– Hardened Steel SHAFT – Cast iron or steel
LATHE MACHINE APPLICATIONS BIOMEDICALAPPLICATIONS TULIP HEAD – Titanium VIDEO BONE SCREW – Titanium or Stainless Steel DENTAL SCREW – TitaniumVIDEO
LATHE MACHINE APPLICATIONS OIL & GAS APPLICATIONS SPOOL BODY – Steel or inconel TUBING HANGER – Steel or inconel MANDREL – Steel
LATHE MACHINE APPLICATIONS POWER GENERATION APPLICATIONS STEAM TURBINE DIAPHRAGM Stainless steel
LATHE MACHINE APPLICATIONS POWER GENERATION APPLICATIONS GAS TURBINE DISC Inconel or steel OPERATION OVERVIEW 1.Rough turning: outer diameter, facing 2.Pocketing 3.Grooving 4.Profiling 5.Finishing turning: O.D, I.D, faces 6.Drilling 7.Chamfering (front & back)
LATHE MACHINE APPLICATIONS WIND POWER APPLICATIONS GEARBOX SHAFT Steel MAIN SHAFT Steel OPERATION OVERVIEW 1.Turning – Heavy duty roughing 2.Turning – Semi roughing 3.Turning – Finishing 4.Drilling – Deep hole 5.Drilling – Short hole

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07 lathe

  • 1.
  • 2.
    Bench lathe, 1911 AncientIndia Bow lathe, Roman Era Pole lathe, 1250 Foot wheel lathe, Leonardo da Vinci 1480 Egypt, 300 BC Great wheel lathe, 1680 Lathe circa, 1850 2 LATHE-INTRODUCTION
  • 3.
     It isone of the most common and versatile metal cutting technologies. The machine is called lathe.  In turning, a workpiece is rotated about its axis (cutting movement) as single-point cutting tools are fed into it (feed and cutting depth movements), shearing away unwanted material and creating the desired part.  Typical geometries: Axially-symmetrical contoured part such as cylinders, cones and tapered shafts, spheres, threads, etc  Typical operations: Facing, Contour turning, Chamfering, Parting (Cut-off), Grooving, Threading, Drilling, Knurling,… LATHE-INTRODUCTION N N Spindle speed (rpm) Vc Cutting speed (m/min) fn ap Feed per revolution (mm/rev) Cutting depth (mm) r Positioning angle VIDEO
  • 4.
  • 5.
  • 6.
  • 7.
    MACHINE TYPES Conventional lathes •Manual movement execution. •Manual tool and part change. •Same part holding device for different parts.  Machining time: Important  Idle time: Important  Set-up time: small  Series: Unitary or up to 10 parts  Precision: IT7 , Ra:1.6 µm. 1.Bench / Center / Engine Lathe
  • 8.
    MACHINE TYPES Conventional lathes Turning of heavy and voluminous parts in diameter and/or length.  Several tools can work at a time.  Machining time: Important  Idle time: Important  Set-up time: Important (due to the weight of the parts)  Series: Unitary or small  Precision: IT7 , Ra:1.6 µm. 2.Vertical Lathe
  • 9.
    MACHINE TYPES Conventional lathes •SEMIAUTOMATIC lathe. • Automatic tool change. • Several tools can work at a time. • Typical workholding device: collets • Machining time: Less than in a bench lathe. • Idle time: Less than in a bench lathe. • Set-up time: Important at the beginning (all the tools need to be adjusted). • Series: 25 parts or more. • Precision: IT 8 , Ra:1.6 µm. 3.Turret lathe  The distinguishing feature of this type of lathe is that the tailstock of an engine lathe is replaced by a hexagonal turret, on the face of which multiple tools may be fitted and fed into the work in proper sequence.  Due to this arrangement, several different types of operations can be done on a job without re-setting of work or tools, and a number of identical parts can be produced in the minimum time. hexagonal turret
  • 10.
    MACHINE TYPES Conventional lathes 3.Capstan and Turret lathes  Capstan lathes generally deal with short or long rod type blanks held in collet, whereas turret lathes mostly work on chucking type jobs held in the quick acting chucks  In capstan lathe, the turret travels with limited stroke length within a saddle type guide block, called auxiliary bed, which is clamped on the main bed as indicated in Fig. 2, whereas in turret lathe, the heavy turret being mounted on the saddle which directly slides with larger stroke length on the main bed as indicated in Fig. 2. Fig.1 turret lathe. Fig.2 capstan lathe
  • 11.
    MACHINE TYPES Conventional lathes •Automatic movements execution using cams. • Several tools can work at a time. • Automatic part feed and change. • Important toolholder cost • Machining time: Less than in a bench lathe. • Idle time: Almost zero. • Set-up time: Important (long tools set-up) • Series: 1000 parts or more • Precision: IT 8 , Ra:1.6 µm. 4.Single Spindle Automatic Lathe VIDEO
  • 12.
    MACHINE TYPES Conventional lathes •Automatic movements execution. • Several tools can work at a time. • Automatic part feed and change. • Important toolholder cost. • Highly skilled workforce needed to set the machine. • 6 to 8 parts can be produced at a time. • Machining time: Very low • Idle time: Almost zero. • Set-up time: Very Important (long tools set-up) • Series: 10.000 parts or more • Precision: IT 7/8 , Ra:1.6 µm. 5.Multi Spindle Automatic Lathe
  • 13.
  • 14.
    MACHINE TYPES Numerical ControlLathes (CNC) • It is the evolution of an engine lathe being equipped with a CNC control. • They offer high stability, but slow tool indexing and changing. VIDEO 1.Flat bed lathe Video: Flat bed lathe
  • 15.
    MACHINE TYPES Numerical ControlLathes (CNC) 2.Vertical lathe • It is used for large diameter heavy parts. • A gantry design with a ram is the base of construction. • Double ram offers a higher productivity. • Long tool change time and component loading/unloading. • Applications: railway wheels, gas/steam/wind turbines, aero engines,… VIDEO VIDEO
  • 16.
  • 17.
    MACHINE TYPES Numerical ControlLathes (CNC) • Used when machining from both sides is required (both spindles synchronize for part changing). • Higher productivity It may halve the cycle time compared to a single revolver machine: • Tandem turning (same side turning). • Machining operations on the sub-spindle at the same time as the main spindle. • Typically 3 turrets (2 for the main spindle and 1 for the sub-spindle), but 2 turrets also exist. • Typical applications: Long slender components like shafts and components machined on both sides. 3.Turning centre TWIN / DOUBLE / SUB SPINDLE VIDEO VIDEO
  • 18.
    MACHINE TYPES Numerical ControlLathes (CNC) • Spindle has the axial movement for workpiece load and machining, not the tools. • Nearly always fitted with a bar-feeder ( 0.5mm - 40 mm). • Uses a headstock possible to machine long components and small diameters without using a secondary spindle. • Workpiece clamping system collet. • Application: complex, precise and small size parts. VIDEO VIDEO 4. Sliding head machine or Swiss type lathe (I)
  • 19.
    Video: Sliding headmachine or Swiss type lathe
  • 20.
    MACHINE TYPES Numerical ControlLathes (CNC) Sliding head machine or Swiss type lathe VIDEO
  • 21.
    MACHINE TYPES Numerical ControlLathes (CNC) • Several technologies are integrated into one machine: turning, milling, drilling,… • It has evolved from turning machines. • The heart of the machine is the tool spindle (B spindle), which even can be tilted. It provides milling, drilling and tapping capability along with turning, facing, grooving and threading. • This spindle is serviced by an automatic tool changer that resides outside the cutting zone. • It may have a double spindle and one/two tool turrets. • Application: very complex parts. 5.MULTITASKING MACHINE – HORIZONTAL
  • 22.
    MACHINE TYPES Numerical ControlLathes (CNC) MULTITASKING MACHINE – HORIZONTAL
  • 23.
  • 24.
    MACHINE TYPES Numerical ControlLathes (CNC) 6.Single Spindle Automatic Lathe VIDEO 24
  • 25.
    MACHINE TYPES Numerical ControlLathes (CNC) 7.Multiple Spindle Automatic Lathe VIDEOVIDEO
  • 26.
    Video: Multiple SpindleAutomatic Lathe
  • 27.
  • 28.
    WORK HOLDING DEVICES 1.Jawchuck Part clamped within a chuck and with no additional support (maximum recommended cantilever 1.5 Diameter) Posibility to hold cylindrical or poligonal parts (side number equal or multiple to the number of jaws). Most common Chuck: Self-centering jaws Movement controlled by a single screw operated by a “T” shape key. The jaws move simultaneously and exactly the same amount of movement toward center. Cantilever L < 1.5Ø
  • 29.
    WORK HOLDING DEVICES Chucks:Manual VIDEO Chucks: Power driven Pneumatic or Hydraulic Magnetic operated Centering is more complex. Working with small workpieces is more difficult because they lack sufficient surface area. Independent jawsSelf-centering jaws VIDEO VIDEO
  • 30.
    WORK HOLDING DEVICES Chucks:Number of jaws Six jaw chuckFour jaw chuckThree jaw chuckTwo jaw chuck Eight jaw chuck Chucks: Ring and discs Holding with external part Holding with inverted jaws Chucks: Soft jaws • To hold cylindrical parts precisely as well as irregular parts. • Soft material jaws, without being thermically treated. VIDEO
  • 31.
    Video: Self-centering jawsVideo: Independent jaws
  • 32.
    WORK HOLDING DEVICES 2.JawChuck and Center • Part held on one side within a chuck and on the other side with a live center. • A lathe center holds the end of the workpiece, providing support to preventing the workpiece from deflecting during machining. Live Center: • Center contact point is mounted on bearings and allowed to spin with workpiece. It is mounted in the tailstock quill (60º vertex). VIDEO
  • 33.
    WORK HOLDING DEVICES BetweenCenters • Part hold within two centers (live center and dead center). • Rotation is produced thanks to a dog. It is not an energetic holding but it offers an excellent centering (finishing operations). Dead Center: • Solid steel tip that workpiece spins against. It is mounted in the spindle hole (60º vertex).
  • 34.
    WORK HOLDING DEVICES 3.FacePlates • It is used to grasp parts with irregular shapes. • It is used when no other clamping system is valid. • It is a custom-designed clamp for a particular geometry.
  • 35.
    WORK HOLDING DEVICES 4.Steadyand Follow rests Steady rest • Used in external or internal machining operations. • It stands stationary from a rigid mounti • on the bed, and it supports the workpiece at the rest's center, typically with three contact points 120° apart. ng Follow rest • External machining of parts mounted within a chuck and center. • It is similar to the steady rest, but it is mounted to the carriage rather than the bed, which means that as the tool bit moves, the follower rest follows along. VIDEO VIDEOVIDEO
  • 36.
  • 37.
  • 38.
    WORK HOLDING DEVICES 5.Mandrel •For external/internal concentric machining operations. • Mandrel: It is a hardened and ground cylindrical piece having undercut centerholes on both ends. It is used for holding hollow workpieces, or those that have been drilled or bored previously. Solid mandrel • Mandrels have a slight taper (1:2000). The workpiece is just fixed by friction. The ends of the mandrel have machined flats for the lathe dog to grip. • Since solid machine mandrels have a very slight taper, they are limited to workpieces with specific inside diameters. • The workpiece is mounted on a cylindrical shaft and is axially fixed using nuts. • The coaxiality between the inner and outer diameter of the workpiece depends on the workpiece and mandrel adjustment. Gang mandrel
  • 39.
    WORK HOLDING DEVICES Conemandrel • The workpice is fixed by means of an elastic collet (B). The collet is expanded by pressing the nut (D) against the taper shaft (M). • On the same mandrel different size elastic collets can be mounted to fix different diameter workpieces. Expansion mandrel • It is a very effective device for holding a part that has a hole drilled through it. • The part is secured between the tapers of the mandrel. VIDEO
  • 40.
    WORK HOLDING DEVICES 6.Elasticcollets • Commonly used in turret lathes and automatic lathes. • Collet: Taper body with an axial hole where the workpiece to be machined is introduced (cylindrical, rectangular, hexagonal,… bars). • Longitudinal cuts offer elasticity to the collet and a uniform fixture is obtained. The taper body is pulled manually or automatically against the machine frame and the workpiece is fixed by pressure (axial movement is needed to clamp/unclamp the workpiece). VIDEO
  • 41.
  • 42.
    TOOLHOLDING DEVICES Tool holdingsystem 1.Tool post BORING BAR SHANK SPRING CLAMP
  • 43.
    TOOLHOLDING DEVICES Shank turret VDIturret (Verein Deutscher Ingenieure) Designed for shank and cylindrical holders. Driven solutions can not be used. It has been the standard quick change solution. Driven units can be adopted, although the bearings are always outside the turret. Tool holding system 2.Turret
  • 44.
    TOOLHOLDING DEVICES Coromant CaptoInterface (CBI) turret VIDEO Coromant Capto Disc Interface (CDI) turret Driven solutions can be mounted inside or outside the turret. New solution to replace shank and VDI turrets Driven tool holder (DTH) bearings mounted inside the turret. Tool holding system Turret 44
  • 45.
    TOOLHOLDING DEVICES Four turningtools in one Two turning tools in one Tool holding system Mini-turret
  • 46.
  • 47.
    Lathe Specifications 1. Lengthbetween the centers • It is the measure of the maximum length of the workpiece that can be fixed between the lathe centers 2. Height of the centers • It is the distance between the lathe axis and the lathe bed
  • 48.
    Lathe Specifications 3. Swingdiameter over the bed • It is the maximum diameter of the workpiece that can be turned on a lathe without hitting the lathe bed 4. Swing diameter over the carriage • It is the maximum diameter of the workpiece that can be turned on a lathe without hitting the carriage 5. Maximum bar diameter • It is the maximum diameter of the workpiece that can be passed through the hole in the headstock
  • 49.
  • 50.
    MACHINING OPERATIONS 1.Turning Fr = higher tool vibration. Tool entry smoother. Fr = radial Fr =radial Ff = axial 95° Ff =axial 45° • Turning is the operation of removing the excess material from the workpiece to produce a cylindrical surface to the desired length. External turning
  • 51.
    MACHINING OPERATIONS 2.Facing VIDEO VIDEO • Itis an operation of reducing the length of the workpiece by feeding the perpendicular to the lathe axis. • This operation of reducing a flat surface on the end of the workpiece. External turning
  • 52.
    MACHINING OPERATIONS 3.Chamfering VIDEO • Itis the operation of getting a bevelled surface at the edge of a cylindrical workpiece. This operation is done in case of bolt ends and shaft ends. • Chamfering helps to avoid damage to the sharp edges and protect the operation getting hurt during other operations. External turning
  • 53.
    MACHINING OPERATIONS 4.Grooving Outer Diameter(OD) grooving Face grooving VIDEO • It is the process of reducing the diameter of a workpiece over a very narrow surface. It is done by groove tool. A grooving tool is similar to the parting-off tool. It is often done at the end of a thread or adjacent to a shoulder to leave a small margin. Two types of grooving: External turning
  • 54.
    MACHINING OPERATIONS Positioning of thetool Type of tool: 1.Insert type (shallow groove) 2.Screw-clamp (medium groove) 3.Spring-clamp (deep groove) 1 2 3 OD GROOVING: VIDEO 1 Grooving External turning
  • 55.
    MACHINING OPERATIONS The correctcurve on the tool is dependent on the radius of the workpiece. FACE GROOVING:2 VIDEO Left hand (L) tool Right hand (R) tool External turning
  • 56.
    MACHINING OPERATIONS  Cuttingtool has a shape that is imparted to the workpiece by plunging the tool into the workpiece.  In form turning, cutting tool is complex and expensive but feed is linear and does not require special machine tools or devices.  Cutting tool has a simple shape, but the feed motion is complex; cutting tool is fed along a contour thus creating a contoured shape on the workpiece.  Not possible to be done efficiently in manual lathes. 5.Form turning 6.Profiling or Contour turning VIDEO VIDEO External turning
  • 57.
    MACHINING OPERATIONS • Thisis not a machining operation but a plastic deformation operation using a knurling tool. • Criss-cross pattern knurls are the most typical (ocasionally straight knurls are used too). • OBJECTIVE: Knurling allows hands or fingers to get a better grip. VIDEO 7.Knurling Knurling tool Knurling wheels or Knurls Knurled part • It is an operation of obtaining a diamond shape on the workpiece for the gripping purpose. External turning
  • 58.
    MACHINING OPERATIONS 8. Threading •It is the important operation in the lathe to obtain the continuous ”helical grooves” or ” threads’‘. • When the threads or helical grooves are formed on the out surface of the workpiece is called external thread cutting. When the threads or helical grooves are formed on the inner surface of the workpiece is called internal thread cutting. External turning
  • 59.
    MACHINING OPERATIONS  Spindlerevolution (N) and feed per revolution (fn) must keep a relation.  A single-point threading tool, typically with a 60 degree pointed nose, moves axially along the side of the workpiece, cutting threads into the outer surface.  The threads can be cut to a specified length and pitch, and may require multiple passes to be formed. Insert types Infeed strategies 8. Threading Each insert can only cut one pitch. Can result in burr formation that needs to be taken away. Reduced number of infeeds Productivity ↑ VIDEOVIDEOVIDEO VIDEOVIDEO External turning
  • 60.
    MACHINING OPERATIONS 1. Usinga compound slide 2. Using form tools 3. Offsetting the tailstock 4. Using taper turning attachment 1. The compound rest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). VIDEO 2. By offsetting the tailstock (Long and slim tapers, up to 10-15%). 9. Taper turning External turning Taper Turning Methods
  • 61.
    1. Using acompound slide • Limited movement of the compound slide. • Feeding is by hand and is non-uniform. • This is responsible for low productivity and poor surface finish. • Short and steep tapers can be easily done. MACHINING OPERATIONS Taper turning D d ℓ θ tan 2 D d l    , 2 c D d Noof cuts n d   / L Time cut f N 
  • 62.
    2. Using formtools • Useful for short tapers, where the steepness is of no consequence such as for chamfering. • When turning long tapers with form tools, the tool would likely to chatter (vibrate) resulting in poor surface finish. • However care of the form tools is a careful exercise. MACHINING OPERATIONS Taper turning Video: form tools
  • 63.
    3. Offsetting thetailstock tan 2 D d l        tan certain part length only tobe tapered , tan entirepart length tobe tapered 2 2 2 L offset s l D d L l D d D d l l                MACHINING OPERATIONS Taper turning For tapers on longer shafts, you can offset the tailstock from the centre line. The limitations are on the size of taper, it will only be a shallow taper. Calculations on the offset will be needed. Video: Offsetting the tailstock
  • 64.
    4. Using taperturning attachment MACHINING OPERATIONS Taper turning For longer tapers you can use a Taper Turning Attachment. Video: taper turning attachment
  • 65.
    4. Using taperturning attachment • Long Tapers • Power feed • Taper angle limited to 6 – 7° • Attachment • Guide bar • Sliding block MACHINING OPERATIONS Taper turning l GL x 2 d-D setoverbarGuide  For longer tapers you can use a Taper Turning Attachment.  They attach to the lathe bed.  Having set the angle on the attachment, the cross slide is moved producing the taper as the saddle moves along the bed.
  • 66.
    MACHINING OPERATIONS  Itconsists on increasing a previously drilled workpiece diameter. This operation is accomplished moving the tool using the longitudinal carriage. VIDEO VIDEO 1.Turning or boring Internal turning
  • 67.
    MACHINING OPERATIONS  Itconsists on machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. Tool movement using the cross-slide to allow thread exits, outlet for the use of grinding wheels,… 2.Facing 3.Grooving Internal turning
  • 68.
    MACHINING OPERATIONS  Itconsists on machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. 4. Profiling 5.Taper turning •The compound rest may be swiveled on the cross- slide to any angle in the horizontal plane (short tapers). • CNC lathes – 2 axes Interpolation VIDEO Internal turning
  • 69.
    MACHINING OPERATIONS It consistson creating a blind hole or a through hole using a drill. Two ways to obatain a gole: 1. The part spins and the drill has no rotation, only an axial displacement thanks to the tailstock. 2. Using a live tool. VIDEO 6. Drilling WC HSS Solid carbide drills Indexable insert drills Exchangeable tip drills TIR(TotalIndicatorRunout) 0,02 mm 0,03 mm 0,02 mm VIDEO Internal turning
  • 70.
    MACHINING OPERATIONS  Itis a special drilling and countersank (60º) operation done with a center drill to fit later a live or dead center. 7. Center hole machining  The reaming is a finishing operation to achieve good dimensional (H6,H7,H8) and surface tolerances depending on the ream.  Two ways to ream within the lathe:  Keeping the part stationary and spinning the ream handle manually (the handle is supported in the tailstock).  Spinning the part (Mc) and moving the ream axially (Ma) (held within a drill chuck). VIDEO 8.Reaming Internal turning
  • 71.
    MACHINING OPERATIONS 9.Threading RIGHT SIDELEFT SIDE VIDEO 1 SINGLE POINT THREADING TOOL Internal turning
  • 72.
  • 73.
    LATHE MACHINE APPLICATIONS AEROSPACEAPPLICATIONS 4 – FAN CASTING – Titanium 7 – COMBUSTION CASING – Heat Resistant Super Alloy 6 – TURBINE DISC – Heat Resistant Super Alloy
  • 74.
    LATHE MACHINE APPLICATIONS AUTOMOTIVEAPPLICATIONS GEAR WHEEL– Hardened Steel SHAFT – Cast iron or steel
  • 75.
    LATHE MACHINE APPLICATIONS BIOMEDICALAPPLICATIONS TULIPHEAD – Titanium VIDEO BONE SCREW – Titanium or Stainless Steel DENTAL SCREW – TitaniumVIDEO
  • 76.
    LATHE MACHINE APPLICATIONS OIL& GAS APPLICATIONS SPOOL BODY – Steel or inconel TUBING HANGER – Steel or inconel MANDREL – Steel
  • 77.
    LATHE MACHINE APPLICATIONS POWERGENERATION APPLICATIONS STEAM TURBINE DIAPHRAGM Stainless steel
  • 78.
    LATHE MACHINE APPLICATIONS POWERGENERATION APPLICATIONS GAS TURBINE DISC Inconel or steel OPERATION OVERVIEW 1.Rough turning: outer diameter, facing 2.Pocketing 3.Grooving 4.Profiling 5.Finishing turning: O.D, I.D, faces 6.Drilling 7.Chamfering (front & back)
  • 79.
    LATHE MACHINE APPLICATIONS WINDPOWER APPLICATIONS GEARBOX SHAFT Steel MAIN SHAFT Steel OPERATION OVERVIEW 1.Turning – Heavy duty roughing 2.Turning – Semi roughing 3.Turning – Finishing 4.Drilling – Deep hole 5.Drilling – Short hole