sop of lathe machines

2. •A standard operating procedure (SOP) is a
set of step-by-step instructions compiled by
an organization to help workers carry out
routine operations.
•SOPs aim to achieve efficiency, quality
output, and uniformity of performance,
while reducing miscommunication and
failure to comply with industry regulations.

3. Lathe Machine

4. Lathe
Definition
Lathe is a machine, which removes the metal from a piece of work to the required
shape and size.
 Lathe is one of the most important machine tools in themetal working industry.A
lathe operates on the principle of a rotating workpiece and a fixed cuttingtool.
 The cutting tool is feed into the workpiece, which rotates about its ownaxis
causing the workpiece to be formed to the desired shape.
 Lathe machine is also known as “the mother/father of the entire tool family”.

5.  Henry Maudsley was born on an isolated farm
near Gigghleswick in North Yorkshire and
educated at University Collage London. He was
an outstandingly student, collecting ten Gold
Medals and graduating with an
M.D. degree in 1857.
INVENTOR OF CENTRE
LATHE

6. Function of lathe
Lathe is to remove excess material in the form of
chips by rotating the work piece against a stationary
cutting tool
Industrial revolution demanded
More production
More Precision
Changes in Manufacturing process
Lead to the Development of High speed
Special purpose lathes

7. MAIN PARTS
Lathe Machine is also known as “Centre Lathe”,
because it has two centres between which the job
can be held and rotated.
The main parts of centre lathe are:
 Bed,
 Head stock,
 Tail stock,
 Carriage,etc

8. Lathe

9. Lathes
Lathes are the oldest machine tools
Lathe Components
Bed: supports all major components
Carriage: slides along the ways and consists of the cross-
slide, tool post, apron
Headstock – Holds the jaws for the work piece, supplies
power to the jaws and has various drive speeds
Tailstock – supports the other end of the workpiece
Feed Rod and Lead Screw – Feed rod is powered by a set of
gears from the headstock

10. Working principle
of lathe

11. Working
principle of lathe
If the tool moves parallel
to work piece cylindrical
surface is formed

12. Working principle oflathe
If the tool moves
inclined to the axis it
produces a taper
surface and is called
taper turning.

13. Working principle
of lathe
It holds the work between two supports called centers.
Chuck or Face plate is also used for holding the work.
Chuck or face plate is mounted on machine spindle
Cutting tool is held and supported on a tool post.
Movement of the job is rotation about spindle axis
Tool is fed against the revolving work
Movement of the tool is either parallel to or at any inclination to the
work axis

14. Specifications of Lathe
1) a) Height of centers
b)type of bed(straight , semi gap, or gap)
c) center distance
2. a)swing over bed
b)swing over cross slide
c) swing in gap
d) gap in front of face place
3. a) spindle speeds range
b) spindle nose
c) spindle bore
d) taper nose

15. Specifications
of Lathe
4) a)Metric thread piches
b)lead screw pitch
c)longitudinal feeds
d)cross feeds
5) a) cross slide travel
b)top slide travel
c) tool section
6) a)tailstock sleeve travel
b)taper in sleeve bore
7) Motor horsepower and RPM
8) shipping dimensions ---
length*width*height*weight

16. Operating
Conditions
Machined
surface
Chip
Depth of cut
Chuck
N
Feed (f )
Tool
Cutting speed
Workpiece
Depth of cut (d)

17. LATHEOPERATIONS
 Turning: to remove material from the outside diameter of a workpieceto
obtain a finished surface.
 Facing: to produce a flat surface at the end of the workpiece or formaking
face grooves.
 Boring: to enlarge a hole or cylindrical cavity made by a previousprocess
or to produce circular internalgrooves.
 Drilling: to produce a hole on the workpiece.
 Reaming: to finishing the drilledhole.
 Threading: to produce external or internal threads on the workpiece.
 Knurling: to produce a regularly shaped roughness on theworkpiece.

18. LATHEOPERATIONS

19. Turning ..
Cylindrical job
Cutting
speed
Workpiece
Depth of cut (d)
Depth of cut
Feed
Tool
Chuck
N
Machined
surface
Chip

20. T
urning..
Excess Material is removed to reduce
Diameter
Cutting Tool: Turning Tool
Work is held in either chuck or between
centers.
Longitudinal feed is given to the tool either by
hand or power.

21. Facing
Flat Surface/Reduce length
Depth of
cut
Feed
Workpiece
Chuck
Cutting
speed
Tool
d
Machined
Face

22. Facing ..
machine end of job  Flat surface or to Reduce Length
of Job
TurningTool
Feed: in direction perpendicular to workpieceaxis
Length of Tool Travel = radius ofworkpiece
Depth of Cut: in direction parallel to workpieceaxis

23. Knurling
Knurling tool
Tool post
Feed Movement
for depth
Knurled surface
Cutting
speed

24. Knurling
Produce rough textured surface
For Decorative and/or Functional Purpose
Knurling Tool
 A FormingProcess
MRR~0

25. Grooving ..
Shapeproduced
by formtool Groove
Grooving
tool
Feed or
depth ofcut
Formtool

26. Grooving
Produces a Groove on workpiece
Shape of tool  shape of groove
Carried out using Grooving Tool  A
form t
o
o
l
Also called Form Turning

27. Parting ..
Feed
Parting tool

28. Parting
Cutting workpiece into Two
Similar to grooving
Parting Tool
Tool rides over – at slow feed
Coolant use

29. Feed
Chamfering tool
Chamfering
Chamfer

30. Chamfering
 Beveling sharp machinededges
 Similar to form turning
 Chamfering tool – 45°
 T
o
Avoid Sharp Edges
Make AssemblyEasier
ImproveAesthetics

31. Drilling
• Drill – cutting tool – held inTS – feed fromTS
•Quill
Drill clamp moving
quill
Tail stock clamp
Tail stock
Feed

32. Lathe
Centers
Work to be turned between centers must have
center hole drilled in each end
Provides bearing surface
Support during cutting
Most common have
solid Morse taper shank
60º centers, steel with carbide tips
Care to adjust and lubricate occasionally

33. Chucks
Used extensively for holding work for machining
operations
Work large or unusual shape
Most commonly used lathe chucks
Three-jaw universal
Four-jaw independent
Collet chuck

34. TYPES OF
CHUCK
Three jaw
chuck
- Forholding cylindrical
stock centered.
- For facing/center
drilling,etc.
Four-Jaw
Chuck
- This is independent
chuck generally has four
jaws , which are adjusted
individually on thechuck
face by means of
adjusting screws

35. Turret Lathe
Capable of performing multiple
cutting operations on thesame
workpiece
Turning
Boring
Drilling
Thread cutting
Facing
Turret lathes are very versatile
Types of turret lathes
Ram-type: ram slides in a
separate base on thesaddle
Saddle type:
more heavily
constructed
Used to machinelarge
workpeiceces

36. Turret lathe

37. MachiningCalculations:
Turning
(rpm)
(mm/min -or-
Spindle Speed - N
v = cutting speed
Do = outerdiameter
Feed Rate - fr
in/min)
f = feed per rev
(mm/rev-or-
(min)
Depth of Cut -d
in/rev)
Do = outerdiameter
Df = finaldiameter
Machining Time -Tm
L = length of cut
Mat’l Removal Rate - MRR (mm3/min -or-in3/min)
o
π D
v
N 
 Df
d 
Do
r
m
f
T
2
 L
r
f N f
MRRv f d

38. STANDARD OPERATING PROCEDURE ‘S.O.P’
•
• All stock must be properly secured in the lathe chuck or
mounted prior to the machining process taking place. Use the
correct sized clamp or vise for the stock being machined.
• Turn the chuck or faceplate by hand to ensure there is no
binding or danger of the work striking any part of the lathe.
• Check to ensure the cutting tool will not run into the chuck or
lathe dog. If possible, feed away from the chuck or dogs.
• Before starting the lathe, ensure the spindle work has the cup
center embedded; tail, stock and tool rests are securely
clamped; and there is proper clearance for the rotating stock.
• Prior to starting the lathe, ensure that small diameter stock does
not project too far from the chuck without support from the tail
stock center.

39. • When roughing stock, do not force the tool in the work
piece or take too big a cut.
• The operator must always be aware of the direction and
speed of the carriage or cross-feed prior to engaging the
automatic feed.
• Never leave the key in the chuck. Do not let go of the key
until it is free of the chuck and secured in its proper
holding place.
• Select turning speed carefully. Large diameter stock must
be turned at a very low speed. Always use the lowest speed
to rough out the stock prior to final machining.
• The correct speed and feed for the specific material and
cutting tool must be used. Stop the machine before making
adjustments or measurements.

40. • Do not remove metal or wood chips from the table or stock
by hand. Use a brush or other tool to properly remove
chips or shavings from the table or stock.
• Never attempt to run the chuck on or off the spindle head
by engaging the power.
• Do not stop the rotation of the chuck by reversing the
power to the lathe unless tapping holes.
• Do not leave tools, bits or excess pieces of stock on the
lathe bed.
• All belts and pulleys must be guarded. If frayed belts or
pulleys are observed, the lathe must be taken out of service
and the belts or pulleys replaced.

41. • Stop the machine immediately if odd noise or excessive
vibration occurs.
• Only properly sharpened drill bits and cutting tools in good
condition should be used. Dull drill bits and chipped or
broken cutting tools must be removed from service.
• When an operator has finished working on the lathe, and
before leaving the lathe for any reason, the power must be
shut off and the machine must come to a complete stop.

42. • CONTROL PLAN: • Read and become familiar with machine’s
operating procedures before operating • Always know where
the power off switch is located in case of emergency • Always
turn switch to off position when not operating machine •
Always disconnect the machine from the power source before
servicing, repairing, or making any adjustments •Wear safety
glasses at all times while operating the lathe to protect eyes
from any dust or debris •Wear a dust or face mask to prevent
the inhalation of dust from operating the machine • Do not
wear gloves, necktie, jewelry, or loose clothing, as they could
get caught in the rotating elements of the machine •Tie up
long hair or wear protective hair covering to prevent hair from
getting caught in the rotating elements of the machine •
Always clamp work piece. Never operate on loose work. Never
secure the work piece with your hands. • Always use guards in
the appropriate position when operating the lathe. • Always
use recommended speed and specifications for lathe and
accessories

43. • EXPERIMENTAL PROCEDURES: • Put on all safety
equipment and tie back loose hair or clothing before
operating machine Check to make sure all parts of
machine are working and functioning properly • Double
check all measurements for operating machine on work
piece • Adjust machine to correct speed for machining
process • Put work piece into chuck • Use chuck key to
loosen and tighten the chuck • Remove chuck key from
chuck and place out of chuck path of rotation • Make sure
all safety equipment is on correctly and put safety guards
into position • Start machine by turning black knob into
on position • During operation, keep hands a safe
distance away and only use adjustment tools on lathe to
maneuver work piece. •When finished, turn off the lathe
right away •Wait until rotating chuck has completely
stopped before handling work piece • Clean machine
after use and dispose of debris (seeWaste Management
Procedures)

46. A standard maintenance
procedure (SMP) is a detailed list
of written instructions that
describes how a maintenance
task is to be performed.

47. SMP of Steel Transfer Car (STC)
Gear Box OUTPUT SHAFT

48. STEEL TRANSFER CAR

49. STEEL TRANSFER CAR
STEEL TRANSFER CAR (STC) AT SMS-1

50. MAIN COMPONENTS OF STEEL TRANSFER CAR
STEEL TRANSFER CAR GEAR BOX LOCATION
STEEL TRANSFER CAR GEAR BOX

51. GEAR BOX
OUTPUT
SHAFT
STEEL TRANSFER CAR GEAR BOX OUTPUT SHAFT ASSEMBLY
DAMAGED GEAR BOX OF STEEL TRANSFER CAR

52. GEAR BOX DRAWING

53. MAIN COMPONENTS OF STC GEAR BOX OUTPUT SHAFT ASSEMBLY

55. Dismantling
Fixing Bottom base plate Fixing Split plates on Bottom plate
Adjusting the Split plates before
gear coupling
Tightening the Split Plates
to the Bottom Plate
Fixing of
special fixture
to the output
shaft

56. Placing the output shaft along with special fixture into the modified Stand fixture
Universal Fixture
Output shaft assembly along with special
fixture seating into the Universal fixture

57. Dismantle of gear coupling from the output shaft at 630 T
Horizontal Hydraulic press
Placing Puller Rod between gear
coupling and Ram of 630T
Hydraulic Press
Puller Rod
Successfully
Dismantled Gear
coupling from the
output shaft VERY
EASILY

58. ASSEMBLY