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Turning

The document provides a comprehensive overview of turning technology in manufacturing, detailing various types of machines, workholding and toolholding devices, and safety guidelines. It covers both conventional and CNC lathes, explaining their functionalities, precision, and applications. The author emphasizes collaboration with sources in bibliographic references, enhancing the education around metal cutting and turning operations.

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BACHELOR OF ENGINEERING MANUFACTURING TECHNOLOGIES TURNING by Endika Gandarias
2by Endika Gandarias Dr. ENDIKA GANDARIAS MINTEGI Mechanical and Manufacturing department Mondragon Unibertsitatea - www.mondragon.edu (Basque Country) www.linkedin.com/in/endika-gandarias-mintegi-91174653 Further presentations: www.symbaloo.com/mix/manufacturingtechnology
3 CONTENTS  BIBLIOGRAPHY  INTRODUCTION  MACHINE TYPES  WORKHOLDING DEVICES  TOOLHOLDING DEVICES  TURNING OPERATIONS  SAFETY GUIDELINES  APPLICATIONS  GLOSSARY by Endika Gandarias
4 BIBLIOGRAPHY BIBLIOGRAPHY by Endika Gandarias
5 The author would like to thank all the bibliographic references and videos that have contributed to the elaboration of these presentations. For bibliographic references, please refer to: • http://www.slideshare.net/endika55/bibliography-71763364 (PDF file) • http://www.slideshare.net/endika55/bibliography-71763366 (PPT file) For videos, please refer to: • www.symbaloo.com/mix/manufacturingtechnology BIBLIOGRAPHY by Endika Gandarias
6 INTRODUCTION INTRODUCTION by Endika Gandarias
7 TURNING TECHNOLOGY INTRODUCTION  BASIC MOVEMENTS: – Mc  Cutting movement (regarding the part) – Ma  Feed movement (regarding the tool) – Mp  Cutting depth movement (regarding the tool) by Endika Gandarias Ma Mc Mp
8 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 INTRODUCTION by Endika Gandarias
9  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,… INTRODUCTION by Endika Gandarias N N Spindle speed (rpm) Vc Cutting speed (m/min) fn Feed per revolution (mm/rev) ap Cutting depth (mm) Κr Positioning angle VIDEO
10 INTRODUCTION by Endika Gandarias
11 INTRODUCTION Z X by Endika Gandarias
12 INTRODUCTION Headstock Carriage Tailstock by Endika Gandarias VIDEO VIDEO
13 MACHINE TYPES MACHINE TYPES by Endika Gandarias
14 MACHINE TYPES CONVENTIONALLATHES Bench / Center / Engine lathe Face lathe Vertical lathe Turret lathe Copy lathe Automatic lathe Single spindle Multi spindle by Endika Gandarias
15 • 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. • Turning of voluminous parts: Small length to diameter rate (rings, washers,…). • Machining time: Important • Idle time: Important • Set-up time: Important (due to the part size) • Series: Unitary o small • Precision: IT8/9 , Ra:1.6 µm. VIDEO MACHINE TYPES Conventional lathes Bench / Center / Engine Lathe Face Lathe by Endika Gandarias VIDEO
16 • 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. MACHINE TYPES Conventional lathes by Endika Gandarias Vertical Lathe
17 • 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. Tool turret MACHINE TYPES Conventional lathes Turret lathe by Endika Gandarias VIDEO
18 • Movement based on a template. It allows to copy difficult geometries. • One tool at a time. • Manual tool and part change. • Machining time: Less than in a bench lathe. • Idle time: Less than in a bench lathe. • Set-up time: Less than in turret lathe. • Series: 5 parts or more • Precision: IT 7 , Ra:1.6 µm. MACHINE TYPES Conventional lathes Copy lathe by Endika Gandarias VIDEOVIDEO
19 • 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. MACHINE TYPES Conventional lathes Single Spindle Automatic Lathe by Endika Gandarias VIDEO
20 MACHINE TYPES • 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. Conventional lathes by Endika Gandarias Multi Spindle Automatic Lathe
21 MACHINE TYPES NUMERICALCONTROLLATHES(CNC) Flat bed lathe Vertical lathe Turning centre HORIZONTAL Part loading automation Driven tool Y axis Twin / Double / Sub spindle VERTICAL Driven tool Y axisSliding head machine or Swiss type lathe Multitasking machine HORIZONTAL VERTICAL Automatic lathe Single spindle Multi spindle by Endika Gandarias
22 Flat bed lathe Numerical Control Lathes (CNC) MACHINE TYPES • It is the evolution of an engine lathe being equipped with a CNC control. • They offer high stability, but slow tool indexing and changing. by Endika Gandarias VIDEO
23 Vertical lathe Numerical Control Lathes (CNC) MACHINE TYPES • 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 by Endika Gandarias VIDEOVIDEO
24 Turning centre MACHINE TYPES Numerical Control Lathes (CNC) Horizontal turning centre Vertical turning centre Z Z by Endika Gandarias VIDEOVIDEO
25 • Automatic movements execution. • Automatic tool change • One tool at a time • Manual or automatic bar feeder or part feeding (with robot or manipulators) • Same part holding device for different parts. • Possibility of power driven tools (live tools) • Machining time: Less than in a bench lathe. • Idle time: Usually small • Set-up time: Slightly important (Programming & setting-up) • Series: 10 to 1.000 parts (very flexible) • Precision: IT 7/8 , Ra:0.8 a 1.6 µm. VIDEO MACHINE TYPES Turning centre Numerical Control Lathes (CNC) by Endika Gandarias
26 BAR FEEDER • Suitable for bar diameters 1mm - 100mm, and bar lengths 12” (3-4 meters) or smaller  Attention: larger diameters and lengths represent more mass and more vibration when turned at high speeds. • A considerable workshop space is demanded. • Bar remnants produced by using short bars may be an economic issue. • Bar pushing types: 1. Servo driven  more accurate. 2. Pneumatic  a bar stop is needed. Thus, a tool position gets occupied with the stop. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre by Endika Gandarias VIDEO • It provides a simple and efficient way to automate part production  High volume production. • It is not necessary to have an operator loading/unloading any part. 1 PART LOADING AUTOMATION
27 GANTRY LOADER Numerical Control Lathes (CNC) Turning centre ROBOT LOADER PART LOADING AUTOMATION MACHINE TYPES by Endika Gandarias 32 • Both are systems for automation of chucked parts. • The gantry works as a manipulator to load and unload the machine tool and can move workpieces between operations. • Collaborative robots have recently appeared. VIDEO VIDEO VIDEOVIDEO
28 • Driven tools allow milling and drilling operations with C- axis control required on the main spindle (orientation and coupling to inhibit rotation or servo-controlled C axis). • Rotary tools are generally low powered and axis travel rates are slow compared to a stand-alone machining center. • Any milling or drilling off the machine's center line is not possible (a Y axis option is needed for that purpose). • Application: keyway slots, holes on the center line, spiral-milling cuts… MACHINE TYPES Numerical Control Lathes (CNC) Turning centre by Endika Gandarias VIDEOVIDEO DRIVEN TOOL or LIVE TOOL
29 • The Y-axis option was developed due to the need to use the driven tools for three axes, milling and drilling off center line. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre VIDEO by Endika Gandarias SIDE MILLING OFF-CENTRE GROOVING OFF-CENTRE DRILLING Z YX Y AXIS
30 • 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: a) Tandem turning (same side turning). b) 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. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre VIDEO by Endika Gandarias VIDEO TWIN / DOUBLE / SUB SPINDLE
31 • 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. Sliding head machine or Swiss type lathe (I) MACHINE TYPES Numerical Control Lathes (CNC) by Endika Gandarias VIDEOVIDEO
32 MACHINE TYPES Numerical Control Lathes (CNC) Sliding head machine or Swiss type lathe (II) by Endika Gandarias VIDEO
33 • 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. VIDEO MACHINE TYPES CNC machines Machining Centre MULTITASKING MACHINE – HORIZONTAL (I) by Endika Gandarias
34 MACHINE TYPES CNC machines Machining Centre MULTITASKING MACHINE – HORIZONTAL (II) by Endika Gandarias
35 • Parts normally larger in diameter than for a horizontal multi-task machine. • Does not require support via a steady rest, tailstock or sub-spindle. • It has evolved from 5 axis machining centers: a) High rpm capability of the C axis (turning table). b) Adopting the spindle for stationary operations. MACHINE TYPES CNC machines Machining Centre MULTITASKING MACHINE – VERTICAL by Endika Gandarias Trunnion table Combination type VIDEO
36 MACHINE TYPES by Endika Gandarias Single Spindle Automatic Lathe CNC machines VIDEO
37 MACHINE TYPES by Endika Gandarias Multiple Spindle Automatic Lathe CNC machines VIDEOVIDEO
38 WORKHOLDING DEVICES WORKHOLDING DEVICES by Endika Gandarias
39 WORKHOLDING DEVICES WORKHOLDINGDEVICES Jaw chuck (3 or 4 jaws) Jaw chuck and center Between centers Steady/Follow rest Mandrel Elastic collet VIDEO by Endika Gandarias
40 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 WORKHOLDING DEVICES by Endika Gandarias
41 Chucks: Manual Chucks: Power driven Pneumatic or Hydraulic WORKHOLDING DEVICES Magnetic operated  Centering is more complex.  Working with small workpieces is more difficult because they lack sufficient surface area. Independent jawsSelf-centering jaws by Endika Gandarias VIDEO VIDEO VIDEO
42 Chucks: Number of jaws Six jaw chuck WORKHOLDING DEVICES Four 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. by Endika Gandarias VIDEO
43 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. For cantilevers between 1.5Ø and 10Ø Live Center: Center contact point is mounted on bearings and allowed to spin with workpiece. It is mounted in the tailstock quill (60º vertex). WORKHOLDING DEVICES by Endika Gandarias VIDEO
44 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). WORKHOLDING DEVICES Dead Center: Solid steel tip that workpiece spins against. It is mounted in the spindle hole (60º vertex). by Endika Gandarias
45 Face Plates WORKHOLDING DEVICES by Endika Gandarias  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.
46 Steady and Follow rests Steady rest  Used in external or internal machining operations.  It stands stationary from a rigid mounting on the bed, and it supports the workpiece at the rest's center, typically with three contact points 120° apart. 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. WORKHOLDING DEVICES VIDEO by Endika Gandarias Cantilever L > 1.5Ø Cantilever L > 10Ø VIDEO VIDEOVIDEO
47 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. WORKHOLDING DEVICES by Endika Gandarias Gang mandrel
48 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. WORKHOLDING DEVICES by Endika Gandarias 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
49 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). One of the characteristics of this clamping system is the possiblity to clamp and unclamp the workpiece with no need to stop spinning. WORKHOLDING DEVICES by Endika Gandarias VIDEO
50 TOOLHOLDING DEVICES TOOLHOLDING DEVICES by Endika Gandarias
51 TOOLHOLDINGDEVICES TOOL HOLDING SYSTEM Tool post Turret Shank VDI CBI CDI Mini-turret TOOL INSERT HOLDING SYSTEM Rigid clamping Lever clamping Screw clamping Wedge clamping TOOLHOLDING DEVICES by Endika Gandarias
52 TOOLHOLDING DEVICES Tool holding system BORING BAR SHANK SPRING CLAMP by Endika Gandarias Tool post
53 TOOLHOLDING DEVICES Shank turret VDI turret (DIN 69880)  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 (longer gauge line). by Endika Gandarias Tool holding system Turret
54 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. by Endika Gandarias Tool holding system Turret
55 TOOLHOLDING DEVICES Four turning tools in one Two turning tools in one by Endika Gandarias Tool holding system Mini-turret
56 Type P  Negative inserts.  Chip flow with no obstacle.  Easy exchange. Type C & D  Negative inserts  Excellent fixation.  Easy exchange. Type S  Positive inserts.  Chip flow with no obstacle  Secure insert clamping. Type W  Negative inserts.  Excellent fixation. TOOLHOLDING DEVICES Rigid clamping Lever clamping Screw clamping Wedge clamping Tool insert holding system
57 MACHINING OPERATIONS MACHINING OPERATIONS by Endika Gandarias
58 TURNING. Machining operations MACHINING OPERATIONS INTERNAL TURNINGEXTERNAL TURNING by Endika Gandarias VIDEO
59 Turning Facing VIDEO MACHINING OPERATIONS Fr ↑ = higher tool vibration. Tool entry smoother. External turning by Endika Gandarias Fr = radial Ff = axial 95° Fr = radial Ff = axial 45° VIDEO
60 1. The compound rest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). 2. By offsetting the tailstock (Long and slim tapers, up to 10-15%). VIDEO 3. CNC lathes – 2 axes Interpolation MACHINING OPERATIONS Taper turning External turning by Endika Gandarias VIDEO VIDEO
61 MACHINING OPERATIONS Grooving External turning Two types of grooving: Outer Diameter (OD) grooving Face grooving by Endika Gandarias VIDEOVIDEO
62 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 MACHINING OPERATIONS Grooving External turning by Endika Gandarias
63 MACHINING OPERATIONS Grooving External turning The correct curve on the tool is dependent on the radius of the workpiece. FACE GROOVING: by Endika Gandarias 2 VIDEO Left hand (L) tool Right hand (R) tool
64  Similar to grooving, but the cutter moves radially until the center or inner diameter of the workpiece.  Reduce feed by 75% when approaching the centre, around 2 mm before the part comes off  vibration ↓ and tool life ↑. Stop the feed 0.5mm before the centre and the part will drop down.  Chip evacuation is a critical factor in parting operations. MACHINING OPERATIONS Parting or Cut-off External turning 1 2 3 by Endika Gandarias Type of tool: 1. Insert type (shallow groove) 2. Screw-clamp (medium groove) 3. Spring-clamp (deep groove) VIDEO VIDEO VIDEO
65  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. MACHINING OPERATIONS  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. Form turning Profiling or Contour turning External turning by Endika Gandarias VIDEOVIDEO
66 Profiling or Contour turning MACHINING OPERATIONS External turning by Endika Gandarias VIDEO Insert radius = component radius Insert radius < component radius  Typically used on Heat resistant super alloys (HRSA).  Machinng strategy:  Roll into cut with reduced feed  Increase feed to max fn for linear cuts  Roll out of cut with reduced feed reduced fn max reduced fn maxfn max THROCHOIDAL TURNING
67  Machining of an angle on the corner of the cylinder with not much precision, forming a "chamfer“.  OBJECTIVE: Eliminate the sharp edge for part handling, ease assemblying, thread inlets, etc.  Machining of a groove that facilitates the tool outlet for further operations: threading, grinding, etc.  Round cutting edges are required. MACHINING OPERATIONS Chamfering Notch machining or undercutting External turning by Endika Gandarias
68  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. Knurling tool Knurling wheels or Knurls Knurled part VIDEO MACHINING OPERATIONS Knurling External turning by Endika Gandarias
69  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. MACHINING OPERATIONS Insert types Infeed strategies Threading External turning Each insert can only cut one pitch. Can result in burr formation that needs to be taken away. Reduced number of infeeds  Productivity ↑ by Endika Gandarias VIDEOVIDEOVIDEO VIDEOVIDEO
70 MACHINING OPERATIONS Threading External turning by Endika Gandarias RIGHT SIDE LEFT SIDE CNC thread generator: http://vargen.vargus.com/VargusGenWeb/Pages/ThreadSelection.aspx
71 MACHINING OPERATIONS Threading External turning by Endika Gandarias BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales NUT SCREW
72 Internal threads -- 6H External threads – 6g MACHINING OPERATIONS Threading External turning by Endika Gandarias Tolerances: BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales The absence of tolerance class designation means: The absence of the designation for the group of length of thread engagement means the group "normal" N is specified.  M-10x1 – 5H 6H – L Pitch value Pitch diameter (D2) tolerance Minor diameter (D1) tolerance Length of thread engagement (S, N or L)  M-10 – 6H Pitch & minor (D2, D1) diameter tolerance  M-10x1 – 5g 6g – N Pitch diameter (d2) tolerance Major diameter (d) tolerance Length of thread engagement (S, N or L)  M-10 – 6g Pitch & minor (d2, d) diameter tolerance INTERNALTHREADEXTERNALTHREAD
73 MACHINING OPERATIONS Threading External turning by Endika Gandarias BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales
74 MACHINING OPERATIONS Threading External turning by Endika Gandarias Example: Internal thread (nut) M-10 Pitch value: default value 1.5mm Pitch diameter (D2) tolerance: default value 6H  Tolerance [0, +180] µm  Theoretical D2 value = d -0.649p = 10 – 0.649*1.5 = 9.026 mm D2 = [ 9.026, 9.206] mm Minor diameter (D1) tolerance: default value 6H  Tolerance [0, +300] µm  Theoretical D1 value = d -1.082p = 10 – 1.082*1.5 = 8.377 mm D1 = [ 8.377, 8.677] mm External thread (screw) M-10 Pitch value: default value 1.5mm Pitch diameter (d2) tolerance: default value 6g  Tolerance [-32, -164] µm  Theoretical d2 value = d -0.649p = 10 – 0.649*1.5 = 9.026 mm d2 = [ 8.862, 8.994] mm Major diameter (d) tolerance: default value 6g  Tolerance [-32, -268] µm  Theoretical d value = 10 mm d = [ 9.732, 9.968] mm BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales
75  It consists on increasing a previously drilled workpiece diameter. This operation is accomplished moving the tool using the longitudinal carriage. VIDEO MACHINING OPERATIONS VIDEO Turning or boring Internal turning by Endika Gandarias
76  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,… MACHINING OPERATIONS Facing Internal turning Grooving by Endika Gandarias
77  It consists on machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. MACHINING OPERATIONS Profiling Internal turning by Endika Gandarias • The compound rest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). • CNC lathes – 2 axes Interpolation Taper turning VIDEO
78  It consists on creating a blind hole or a through hole using a drill.  Two ways to obatain a hole: 1. The part spins and the drill has no rotation, only an axial displacement thanks to the tailstock. 2. Using a live tool. VIDEO MACHINING OPERATIONS Drilling Internal turning by Endika Gandarias WC HSS Solid carbide drills Indexable insert drills Exchangeable tip drills  It needs to be minimized for best performance. TIR (Total Indicator Runout) 0,02 mm 0,03 mm 0,02 mm VIDEO
79  It is a special drilling and countersank (60º) operation done with a center drill to fit later a live or dead center. MACHINING OPERATIONS Center hole machining Internal turning by Endika Gandarias  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).  The tool is called “reamer”. VIDEO Reaming
80 MACHINING OPERATIONS Threading Internal turning by Endika Gandarias RIGHT SIDE LEFT SIDE VIDEO 1 SINGLE POINT THREADING TOOL
81 MACHINING OPERATIONS WHIRLING RING2 by Endika Gandarias Threading Internal turning VIDEO
82 MACHINING OPERATIONS 1 – Jaws 2 - Chuck 3 - Stock 1 - External facing 2 - External turning (Rough/Finish) 3 - External Grooving 4 - External threading 5 - Pecking 6 - Drilling 7 - Boring or internal turning 8 - Cut-off EXERCISE EXAMPLE: by Endika Gandarias
83 SAFETY GUIDELINES by Endika Gandarias SAFETY GUIDELINES
84by Endika Gandarias Goggles Ear muff or Ear plug Gloves Clothing Shoes safety guards or machine encapsulation SAFETY GUIDELINES
85 TURNING APPLICATIONS TURNING APPLICATIONS by Endika Gandarias
86 AEROSPACE APPLICATIONS by Endika Gandarias 4 – FAN CASTING – Titanium 7 – COMBUSTION CASING – Heat Resistant Super Alloy 6 – TURBINE DISC – Heat Resistant Super Alloy VIDEO
87 AUTOMOTIVE APPLICATIONS GEAR WHEEL– Hardened Steel SHAFT – Cast iron or steel by Endika Gandarias
88 BIOMEDICAL APPLICATIONS by Endika Gandarias TULIP HEAD – Titanium BONE SCREW – Titanium or Stainless Steel DENTAL SCREW – Titanium VIDEO VIDEO
89 BIOMEDICAL APPLICATIONS VIDEO VIDEO by Endika Gandarias FEMORAL HEAD & ACETABULAR CUP – Titanium or Stainless Steel
90 OIL & GAS APPLICATIONS by Endika Gandarias SPOOL BODY – Steel or inconel TUBING HANGER – Steel or inconel MANDREL – Steel
91by Endika Gandarias POWER GENERATION APPLICATIONS STEAM TURBINE DIAPHRAGM Stainless steel
92by Endika Gandarias 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)
93 WIND POWER APPLICATIONS by Endika Gandarias 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
94 GLOSSARY GLOSSARY by Endika Gandarias
95 GLOSSARY by Endika Gandarias ENGLISH SPANISH BASQUE Bar Barra Baraila Bench / Center / Engine lathe Torno paralelo Tornu paraleloa Between centers Entre puntos Puntuen artean Bone Hueso Hazur Boring Mandrinado Mandrinaketa Boring bar Barra de mandrinado Mandrinatzeko barra Bow Arco Arkua Cam Leva Espeka Cantilever Voladizo Hegalkin Carriage Carro Orga Center Punto Puntua Center hole machining Punteado Punteaketa Chamfering Achaflanado Alakaketa Clamp Amarrar Lotu Collet Pinza Pintza Compound rest Carro orientable Orga birakorra Countersank Avellanado Abeilanatu Cross slide Carro transversal Zeharkako orga Cutting depth Profundidad de pasada axial Sakontze sakonera Cutting speed Velocidad de corte Ebaketa abiadura Dead center Punto Puntu finkoa Dog Perro de arrastre Arraste txakurra Dog plate Plato de arrastre Arrastratze platerra Drilling Taladrado Zulaketa Ear muff / Ear plug Orejera de casco Entzumen kaskoak Face lathe Torno al aire Tornu airean Face plate Plato plano Plater laua Facing Refrentado Aurpegiketa
96 GLOSSARY by Endika Gandarias ENGLISH SPANISH BASQUE Fan Ventilador Haizegailu Feed Avance por minuto Aitzinamendu abiadura Feeder Alimentador Elikatzaile Form turning Torneado de forma Forma torneaketa Follow rest Luneta móvil Luneta mugikorra Gear wheel Rueda de engranaje Engranai gurpila Gearbox Caja de cambios Abiadura kaxa Gloves Guantes Eskularruak Goggles Gafas de seguridad Segurtasun betaurrekoak Grasp Amarrar Lotu / Heldu Groove Ranura Arteka Headstock Cabezal Buru High Speed Steel Acero rápido Altzairu lasterra Idle time Tiempos no productivos Denbora ez produktiboa Insert Plaquita Plakatxo Jaw chuck Plato de garras Atzapardun platera Knurling Moleteado Moletaketa Lathe Torno Tornua Lever clamping Amarre por palanca Palanka bidezko lotze sistema Live center Punto rotatorio Puntu birakorra Live tool = Driven tool Herramienta motorizada Erraminta motorizatua Loading Carga Karga Mandrel Mandrino Mandrino Multitasking machine Máquina multitarea Ataza anitzeko makina Notch machining Entallado Hozkadura Nut Tuerca Azkoina Off-centre Descentrado Deszentratu Offset Descentrar Deszentratu
97 GLOSSARY by Endika Gandarias ENGLISH SPANISH BASQUE Part feeding Alimentación de piezas Piezen elikatze Parting / Cutting-off Tronzado Trontzaketa Pecking Punteado Punteaketa Pitch Paso Neurri Pole Poste Zutoin Profiling Perfilado Perfilaketa Ram Carnero Ahari Reamer Escariador Otxabu Reaming Escariado Otxabuketa Remnant Resto / Remanente Hondar / Soberakin Runout Excentricidad Eszentrikotasun Safety guidelines Normas de seguridad Segurtasun arauak Screw Tornillo Torloju Self-centering jaws Garras auto-centrante Atzapar autozentranteak Set-up time Tiempo de puesta a punto Prestaketa denbora Shaft Eje Ardatza Shallow Superficial Azaleko Shank Mango Kirten Single spindle / Multi spindle Monohusillo / Multihusillo Ardatz bakarra / Ardatz aniztun Slender Esbelto Lerden Sliding head machine Máquina de cabezal móvil Buru mugikorreko makina Soft jaw Garra blanda Atzapar biguna Solid mandrel Mandril fijo Mandril finkoa Spindle speed Velocidad de giro Biraketa abiadura Spool body Cuerpo de carrete Txirrika gorputza Spring clamp Amarre por deformación Deformazio bidezko lotzea Stainless steel Acero inoxidable Altzairu erdoilgaitza Steady rest Luneta fija Luneta finkoa
98 GLOSSARY by Endika Gandarias ENGLISH SPANISH BASQUE Steam turbine diaphragm Turbina de vapor Lurrun turbina Tailstock Contrapunto Kontrapuntu Taper turning Torneado cónico Torneaketa konikoa Template Plantilla Txantiloi Threading Roscado Hariztaketa Tip Punta Punta Tool post Torreta portaherramienta Erreminta-etxe dorretxo Tool turret Torreta portaherramientas Erreminta-etxe dorretxoa Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak Tubing hanger Soporte de tubería Tutu euskarria Tulip Tulipa Tulipa Turning Torneado Torneaketa Turning centre Centro de torneado Torneaketa zentrua Turning operation Operación de cilindrado Zilindraketa operazioa Turret lathe Torno revolver Tornu errebolberra Twin / Double / Sub spindle Doble cabezal Buru bikoitza Unloading Descarga Deskarga / Huste Washer Arandela Zirrindola WC (Hard metal) Metal duro Metal gogorra Whirling ring Cabezal giratorio Buru birakorra

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Turning

  • 1.
    BACHELOR OF ENGINEERING MANUFACTURINGTECHNOLOGIES TURNING by Endika Gandarias
  • 2.
    2by Endika Gandarias Dr.ENDIKA GANDARIAS MINTEGI Mechanical and Manufacturing department Mondragon Unibertsitatea - www.mondragon.edu (Basque Country) www.linkedin.com/in/endika-gandarias-mintegi-91174653 Further presentations: www.symbaloo.com/mix/manufacturingtechnology
  • 3.
    3 CONTENTS  BIBLIOGRAPHY  INTRODUCTION MACHINE TYPES  WORKHOLDING DEVICES  TOOLHOLDING DEVICES  TURNING OPERATIONS  SAFETY GUIDELINES  APPLICATIONS  GLOSSARY by Endika Gandarias
  • 4.
  • 5.
    5 The author wouldlike to thank all the bibliographic references and videos that have contributed to the elaboration of these presentations. For bibliographic references, please refer to: • http://www.slideshare.net/endika55/bibliography-71763364 (PDF file) • http://www.slideshare.net/endika55/bibliography-71763366 (PPT file) For videos, please refer to: • www.symbaloo.com/mix/manufacturingtechnology BIBLIOGRAPHY by Endika Gandarias
  • 6.
  • 7.
    7 TURNING TECHNOLOGY INTRODUCTION  BASICMOVEMENTS: – Mc  Cutting movement (regarding the part) – Ma  Feed movement (regarding the tool) – Mp  Cutting depth movement (regarding the tool) by Endika Gandarias Ma Mc Mp
  • 8.
    8 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 INTRODUCTION by Endika Gandarias
  • 9.
    9  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,… INTRODUCTION by Endika Gandarias N N Spindle speed (rpm) Vc Cutting speed (m/min) fn Feed per revolution (mm/rev) ap Cutting depth (mm) Κr Positioning angle VIDEO
  • 10.
  • 11.
  • 12.
  • 13.
  • 14.
    14 MACHINE TYPES CONVENTIONALLATHES Bench /Center / Engine lathe Face lathe Vertical lathe Turret lathe Copy lathe Automatic lathe Single spindle Multi spindle by Endika Gandarias
  • 15.
    15 • Manual movementexecution. • 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. • Turning of voluminous parts: Small length to diameter rate (rings, washers,…). • Machining time: Important • Idle time: Important • Set-up time: Important (due to the part size) • Series: Unitary o small • Precision: IT8/9 , Ra:1.6 µm. VIDEO MACHINE TYPES Conventional lathes Bench / Center / Engine Lathe Face Lathe by Endika Gandarias VIDEO
  • 16.
    16 • Turning ofheavy 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. MACHINE TYPES Conventional lathes by Endika Gandarias Vertical Lathe
  • 17.
    17 • 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. Tool turret MACHINE TYPES Conventional lathes Turret lathe by Endika Gandarias VIDEO
  • 18.
    18 • Movement basedon a template. It allows to copy difficult geometries. • One tool at a time. • Manual tool and part change. • Machining time: Less than in a bench lathe. • Idle time: Less than in a bench lathe. • Set-up time: Less than in turret lathe. • Series: 5 parts or more • Precision: IT 7 , Ra:1.6 µm. MACHINE TYPES Conventional lathes Copy lathe by Endika Gandarias VIDEOVIDEO
  • 19.
    19 • Automatic movementsexecution 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. MACHINE TYPES Conventional lathes Single Spindle Automatic Lathe by Endika Gandarias VIDEO
  • 20.
    20 MACHINE TYPES • Automaticmovements 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. Conventional lathes by Endika Gandarias Multi Spindle Automatic Lathe
  • 21.
    21 MACHINE TYPES NUMERICALCONTROLLATHES(CNC) Flat bedlathe Vertical lathe Turning centre HORIZONTAL Part loading automation Driven tool Y axis Twin / Double / Sub spindle VERTICAL Driven tool Y axisSliding head machine or Swiss type lathe Multitasking machine HORIZONTAL VERTICAL Automatic lathe Single spindle Multi spindle by Endika Gandarias
  • 22.
    22 Flat bed lathe NumericalControl Lathes (CNC) MACHINE TYPES • It is the evolution of an engine lathe being equipped with a CNC control. • They offer high stability, but slow tool indexing and changing. by Endika Gandarias VIDEO
  • 23.
    23 Vertical lathe Numerical ControlLathes (CNC) MACHINE TYPES • 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 by Endika Gandarias VIDEOVIDEO
  • 24.
    24 Turning centre MACHINE TYPES NumericalControl Lathes (CNC) Horizontal turning centre Vertical turning centre Z Z by Endika Gandarias VIDEOVIDEO
  • 25.
    25 • Automatic movementsexecution. • Automatic tool change • One tool at a time • Manual or automatic bar feeder or part feeding (with robot or manipulators) • Same part holding device for different parts. • Possibility of power driven tools (live tools) • Machining time: Less than in a bench lathe. • Idle time: Usually small • Set-up time: Slightly important (Programming & setting-up) • Series: 10 to 1.000 parts (very flexible) • Precision: IT 7/8 , Ra:0.8 a 1.6 µm. VIDEO MACHINE TYPES Turning centre Numerical Control Lathes (CNC) by Endika Gandarias
  • 26.
    26 BAR FEEDER • Suitablefor bar diameters 1mm - 100mm, and bar lengths 12” (3-4 meters) or smaller  Attention: larger diameters and lengths represent more mass and more vibration when turned at high speeds. • A considerable workshop space is demanded. • Bar remnants produced by using short bars may be an economic issue. • Bar pushing types: 1. Servo driven  more accurate. 2. Pneumatic  a bar stop is needed. Thus, a tool position gets occupied with the stop. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre by Endika Gandarias VIDEO • It provides a simple and efficient way to automate part production  High volume production. • It is not necessary to have an operator loading/unloading any part. 1 PART LOADING AUTOMATION
  • 27.
    27 GANTRY LOADER Numerical ControlLathes (CNC) Turning centre ROBOT LOADER PART LOADING AUTOMATION MACHINE TYPES by Endika Gandarias 32 • Both are systems for automation of chucked parts. • The gantry works as a manipulator to load and unload the machine tool and can move workpieces between operations. • Collaborative robots have recently appeared. VIDEO VIDEO VIDEOVIDEO
  • 28.
    28 • Driven toolsallow milling and drilling operations with C- axis control required on the main spindle (orientation and coupling to inhibit rotation or servo-controlled C axis). • Rotary tools are generally low powered and axis travel rates are slow compared to a stand-alone machining center. • Any milling or drilling off the machine's center line is not possible (a Y axis option is needed for that purpose). • Application: keyway slots, holes on the center line, spiral-milling cuts… MACHINE TYPES Numerical Control Lathes (CNC) Turning centre by Endika Gandarias VIDEOVIDEO DRIVEN TOOL or LIVE TOOL
  • 29.
    29 • The Y-axisoption was developed due to the need to use the driven tools for three axes, milling and drilling off center line. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre VIDEO by Endika Gandarias SIDE MILLING OFF-CENTRE GROOVING OFF-CENTRE DRILLING Z YX Y AXIS
  • 30.
    30 • Used whenmachining 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: a) Tandem turning (same side turning). b) 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. MACHINE TYPES Numerical Control Lathes (CNC) Turning centre VIDEO by Endika Gandarias VIDEO TWIN / DOUBLE / SUB SPINDLE
  • 31.
    31 • Spindle hasthe 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. Sliding head machine or Swiss type lathe (I) MACHINE TYPES Numerical Control Lathes (CNC) by Endika Gandarias VIDEOVIDEO
  • 32.
    32 MACHINE TYPES Numerical ControlLathes (CNC) Sliding head machine or Swiss type lathe (II) by Endika Gandarias VIDEO
  • 33.
    33 • Several technologiesare 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. VIDEO MACHINE TYPES CNC machines Machining Centre MULTITASKING MACHINE – HORIZONTAL (I) by Endika Gandarias
  • 34.
    34 MACHINE TYPES CNC machines MachiningCentre MULTITASKING MACHINE – HORIZONTAL (II) by Endika Gandarias
  • 35.
    35 • Parts normallylarger in diameter than for a horizontal multi-task machine. • Does not require support via a steady rest, tailstock or sub-spindle. • It has evolved from 5 axis machining centers: a) High rpm capability of the C axis (turning table). b) Adopting the spindle for stationary operations. MACHINE TYPES CNC machines Machining Centre MULTITASKING MACHINE – VERTICAL by Endika Gandarias Trunnion table Combination type VIDEO
  • 36.
    36 MACHINE TYPES by EndikaGandarias Single Spindle Automatic Lathe CNC machines VIDEO
  • 37.
    37 MACHINE TYPES by EndikaGandarias Multiple Spindle Automatic Lathe CNC machines VIDEOVIDEO
  • 38.
  • 39.
    39 WORKHOLDING DEVICES WORKHOLDINGDEVICES Jaw chuck(3 or 4 jaws) Jaw chuck and center Between centers Steady/Follow rest Mandrel Elastic collet VIDEO by Endika Gandarias
  • 40.
    40 Jaw chuck  Partclamped 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 WORKHOLDING DEVICES by Endika Gandarias
  • 41.
    41 Chucks: Manual Chucks: Powerdriven Pneumatic or Hydraulic WORKHOLDING DEVICES Magnetic operated  Centering is more complex.  Working with small workpieces is more difficult because they lack sufficient surface area. Independent jawsSelf-centering jaws by Endika Gandarias VIDEO VIDEO VIDEO
  • 42.
    42 Chucks: Number ofjaws Six jaw chuck WORKHOLDING DEVICES Four 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. by Endika Gandarias VIDEO
  • 43.
    43 Jaw Chuck andCenter  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. For cantilevers between 1.5Ø and 10Ø Live Center: Center contact point is mounted on bearings and allowed to spin with workpiece. It is mounted in the tailstock quill (60º vertex). WORKHOLDING DEVICES by Endika Gandarias VIDEO
  • 44.
    44 Between Centers  Parthold 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). WORKHOLDING DEVICES Dead Center: Solid steel tip that workpiece spins against. It is mounted in the spindle hole (60º vertex). by Endika Gandarias
  • 45.
    45 Face Plates WORKHOLDING DEVICES byEndika Gandarias  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.
  • 46.
    46 Steady and Followrests Steady rest  Used in external or internal machining operations.  It stands stationary from a rigid mounting on the bed, and it supports the workpiece at the rest's center, typically with three contact points 120° apart. 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. WORKHOLDING DEVICES VIDEO by Endika Gandarias Cantilever L > 1.5Ø Cantilever L > 10Ø VIDEO VIDEOVIDEO
  • 47.
    47 Mandrel  For external/internalconcentric 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. WORKHOLDING DEVICES by Endika Gandarias Gang mandrel
  • 48.
    48 Cone mandrel  Theworkpice 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. WORKHOLDING DEVICES by Endika Gandarias 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
  • 49.
    49 Elastic collets  Commonlyused 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). One of the characteristics of this clamping system is the possiblity to clamp and unclamp the workpiece with no need to stop spinning. WORKHOLDING DEVICES by Endika Gandarias VIDEO
  • 50.
  • 51.
    51 TOOLHOLDINGDEVICES TOOL HOLDING SYSTEM Tool post Turret Shank VDI CBI CDI Mini-turret TOOLINSERT HOLDING SYSTEM Rigid clamping Lever clamping Screw clamping Wedge clamping TOOLHOLDING DEVICES by Endika Gandarias
  • 52.
    52 TOOLHOLDING DEVICES Tool holdingsystem BORING BAR SHANK SPRING CLAMP by Endika Gandarias Tool post
  • 53.
    53 TOOLHOLDING DEVICES Shank turret VDIturret (DIN 69880)  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 (longer gauge line). by Endika Gandarias Tool holding system Turret
  • 54.
    54 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. by Endika Gandarias Tool holding system Turret
  • 55.
    55 TOOLHOLDING DEVICES Four turningtools in one Two turning tools in one by Endika Gandarias Tool holding system Mini-turret
  • 56.
    56 Type P  Negativeinserts.  Chip flow with no obstacle.  Easy exchange. Type C & D  Negative inserts  Excellent fixation.  Easy exchange. Type S  Positive inserts.  Chip flow with no obstacle  Secure insert clamping. Type W  Negative inserts.  Excellent fixation. TOOLHOLDING DEVICES Rigid clamping Lever clamping Screw clamping Wedge clamping Tool insert holding system
  • 57.
  • 58.
    58 TURNING. Machining operations MACHININGOPERATIONS INTERNAL TURNINGEXTERNAL TURNING by Endika Gandarias VIDEO
  • 59.
    59 Turning Facing VIDEO MACHINING OPERATIONS Fr ↑= higher tool vibration. Tool entry smoother. External turning by Endika Gandarias Fr = radial Ff = axial 95° Fr = radial Ff = axial 45° VIDEO
  • 60.
    60 1. The compoundrest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). 2. By offsetting the tailstock (Long and slim tapers, up to 10-15%). VIDEO 3. CNC lathes – 2 axes Interpolation MACHINING OPERATIONS Taper turning External turning by Endika Gandarias VIDEO VIDEO
  • 61.
    61 MACHINING OPERATIONS Grooving External turning Twotypes of grooving: Outer Diameter (OD) grooving Face grooving by Endika Gandarias VIDEOVIDEO
  • 62.
    62 Positioning of the tool Typeof tool: 1.Insert type (shallow groove) 2.Screw-clamp (medium groove) 3.Spring-clamp (deep groove) 1 2 3 OD GROOVING: VIDEO 1 MACHINING OPERATIONS Grooving External turning by Endika Gandarias
  • 63.
    63 MACHINING OPERATIONS Grooving External turning Thecorrect curve on the tool is dependent on the radius of the workpiece. FACE GROOVING: by Endika Gandarias 2 VIDEO Left hand (L) tool Right hand (R) tool
  • 64.
    64  Similar togrooving, but the cutter moves radially until the center or inner diameter of the workpiece.  Reduce feed by 75% when approaching the centre, around 2 mm before the part comes off  vibration ↓ and tool life ↑. Stop the feed 0.5mm before the centre and the part will drop down.  Chip evacuation is a critical factor in parting operations. MACHINING OPERATIONS Parting or Cut-off External turning 1 2 3 by Endika Gandarias Type of tool: 1. Insert type (shallow groove) 2. Screw-clamp (medium groove) 3. Spring-clamp (deep groove) VIDEO VIDEO VIDEO
  • 65.
    65  Cutting toolhas 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. MACHINING OPERATIONS  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. Form turning Profiling or Contour turning External turning by Endika Gandarias VIDEOVIDEO
  • 66.
    66 Profiling or Contourturning MACHINING OPERATIONS External turning by Endika Gandarias VIDEO Insert radius = component radius Insert radius < component radius  Typically used on Heat resistant super alloys (HRSA).  Machinng strategy:  Roll into cut with reduced feed  Increase feed to max fn for linear cuts  Roll out of cut with reduced feed reduced fn max reduced fn maxfn max THROCHOIDAL TURNING
  • 67.
    67  Machining ofan angle on the corner of the cylinder with not much precision, forming a "chamfer“.  OBJECTIVE: Eliminate the sharp edge for part handling, ease assemblying, thread inlets, etc.  Machining of a groove that facilitates the tool outlet for further operations: threading, grinding, etc.  Round cutting edges are required. MACHINING OPERATIONS Chamfering Notch machining or undercutting External turning by Endika Gandarias
  • 68.
    68  This isnot 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. Knurling tool Knurling wheels or Knurls Knurled part VIDEO MACHINING OPERATIONS Knurling External turning by Endika Gandarias
  • 69.
    69  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. MACHINING OPERATIONS Insert types Infeed strategies Threading External turning Each insert can only cut one pitch. Can result in burr formation that needs to be taken away. Reduced number of infeeds  Productivity ↑ by Endika Gandarias VIDEOVIDEOVIDEO VIDEOVIDEO
  • 70.
    70 MACHINING OPERATIONS Threading External turning byEndika Gandarias RIGHT SIDE LEFT SIDE CNC thread generator: http://vargen.vargus.com/VargusGenWeb/Pages/ThreadSelection.aspx
  • 71.
    71 MACHINING OPERATIONS Threading External turning byEndika Gandarias BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales NUT SCREW
  • 72.
    72 Internal threads --6H External threads – 6g MACHINING OPERATIONS Threading External turning by Endika Gandarias Tolerances: BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales The absence of tolerance class designation means: The absence of the designation for the group of length of thread engagement means the group "normal" N is specified.  M-10x1 – 5H 6H – L Pitch value Pitch diameter (D2) tolerance Minor diameter (D1) tolerance Length of thread engagement (S, N or L)  M-10 – 6H Pitch & minor (D2, D1) diameter tolerance  M-10x1 – 5g 6g – N Pitch diameter (d2) tolerance Major diameter (d) tolerance Length of thread engagement (S, N or L)  M-10 – 6g Pitch & minor (d2, d) diameter tolerance INTERNALTHREADEXTERNALTHREAD
  • 73.
    73 MACHINING OPERATIONS Threading External turning byEndika Gandarias BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales
  • 74.
    74 MACHINING OPERATIONS Threading External turning byEndika Gandarias Example: Internal thread (nut) M-10 Pitch value: default value 1.5mm Pitch diameter (D2) tolerance: default value 6H  Tolerance [0, +180] µm  Theoretical D2 value = d -0.649p = 10 – 0.649*1.5 = 9.026 mm D2 = [ 9.026, 9.206] mm Minor diameter (D1) tolerance: default value 6H  Tolerance [0, +300] µm  Theoretical D1 value = d -1.082p = 10 – 1.082*1.5 = 8.377 mm D1 = [ 8.377, 8.677] mm External thread (screw) M-10 Pitch value: default value 1.5mm Pitch diameter (d2) tolerance: default value 6g  Tolerance [-32, -164] µm  Theoretical d2 value = d -0.649p = 10 – 0.649*1.5 = 9.026 mm d2 = [ 8.862, 8.994] mm Major diameter (d) tolerance: default value 6g  Tolerance [-32, -268] µm  Theoretical d value = 10 mm d = [ 9.732, 9.968] mm BS 3643-1:2007 ISO metric screw threads UNE 17701 Rosca métrica ISO para usos generales
  • 75.
    75  It consistson increasing a previously drilled workpiece diameter. This operation is accomplished moving the tool using the longitudinal carriage. VIDEO MACHINING OPERATIONS VIDEO Turning or boring Internal turning by Endika Gandarias
  • 76.
    76  It consistson 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,… MACHINING OPERATIONS Facing Internal turning Grooving by Endika Gandarias
  • 77.
    77  It consistson machining internal surfaces perpendicular to the part rotational axis.  It is accomplished moving the tool along the transverse axis. MACHINING OPERATIONS Profiling Internal turning by Endika Gandarias • The compound rest may be swiveled on the cross-slide to any angle in the horizontal plane (short tapers). • CNC lathes – 2 axes Interpolation Taper turning VIDEO
  • 78.
    78  It consistson creating a blind hole or a through hole using a drill.  Two ways to obatain a hole: 1. The part spins and the drill has no rotation, only an axial displacement thanks to the tailstock. 2. Using a live tool. VIDEO MACHINING OPERATIONS Drilling Internal turning by Endika Gandarias WC HSS Solid carbide drills Indexable insert drills Exchangeable tip drills  It needs to be minimized for best performance. TIR (Total Indicator Runout) 0,02 mm 0,03 mm 0,02 mm VIDEO
  • 79.
    79  It isa special drilling and countersank (60º) operation done with a center drill to fit later a live or dead center. MACHINING OPERATIONS Center hole machining Internal turning by Endika Gandarias  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).  The tool is called “reamer”. VIDEO Reaming
  • 80.
    80 MACHINING OPERATIONS Threading Internal turning byEndika Gandarias RIGHT SIDE LEFT SIDE VIDEO 1 SINGLE POINT THREADING TOOL
  • 81.
    81 MACHINING OPERATIONS WHIRLING RING2 byEndika Gandarias Threading Internal turning VIDEO
  • 82.
    82 MACHINING OPERATIONS 1 –Jaws 2 - Chuck 3 - Stock 1 - External facing 2 - External turning (Rough/Finish) 3 - External Grooving 4 - External threading 5 - Pecking 6 - Drilling 7 - Boring or internal turning 8 - Cut-off EXERCISE EXAMPLE: by Endika Gandarias
  • 83.
    83 SAFETY GUIDELINES by EndikaGandarias SAFETY GUIDELINES
  • 84.
    84by Endika Gandarias Goggles Earmuff or Ear plug Gloves Clothing Shoes safety guards or machine encapsulation SAFETY GUIDELINES
  • 85.
  • 86.
    86 AEROSPACE APPLICATIONS by EndikaGandarias 4 – FAN CASTING – Titanium 7 – COMBUSTION CASING – Heat Resistant Super Alloy 6 – TURBINE DISC – Heat Resistant Super Alloy VIDEO
  • 87.
    87 AUTOMOTIVE APPLICATIONS GEAR WHEEL–Hardened Steel SHAFT – Cast iron or steel by Endika Gandarias
  • 88.
    88 BIOMEDICAL APPLICATIONS by EndikaGandarias TULIP HEAD – Titanium BONE SCREW – Titanium or Stainless Steel DENTAL SCREW – Titanium VIDEO VIDEO
  • 89.
    89 BIOMEDICAL APPLICATIONS VIDEO VIDEO byEndika Gandarias FEMORAL HEAD & ACETABULAR CUP – Titanium or Stainless Steel
  • 90.
    90 OIL & GASAPPLICATIONS by Endika Gandarias SPOOL BODY – Steel or inconel TUBING HANGER – Steel or inconel MANDREL – Steel
  • 91.
    91by Endika Gandarias POWERGENERATION APPLICATIONS STEAM TURBINE DIAPHRAGM Stainless steel
  • 92.
    92by Endika Gandarias 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)
  • 93.
    93 WIND POWER APPLICATIONS byEndika Gandarias 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
  • 94.
  • 95.
    95 GLOSSARY by Endika Gandarias ENGLISHSPANISH BASQUE Bar Barra Baraila Bench / Center / Engine lathe Torno paralelo Tornu paraleloa Between centers Entre puntos Puntuen artean Bone Hueso Hazur Boring Mandrinado Mandrinaketa Boring bar Barra de mandrinado Mandrinatzeko barra Bow Arco Arkua Cam Leva Espeka Cantilever Voladizo Hegalkin Carriage Carro Orga Center Punto Puntua Center hole machining Punteado Punteaketa Chamfering Achaflanado Alakaketa Clamp Amarrar Lotu Collet Pinza Pintza Compound rest Carro orientable Orga birakorra Countersank Avellanado Abeilanatu Cross slide Carro transversal Zeharkako orga Cutting depth Profundidad de pasada axial Sakontze sakonera Cutting speed Velocidad de corte Ebaketa abiadura Dead center Punto Puntu finkoa Dog Perro de arrastre Arraste txakurra Dog plate Plato de arrastre Arrastratze platerra Drilling Taladrado Zulaketa Ear muff / Ear plug Orejera de casco Entzumen kaskoak Face lathe Torno al aire Tornu airean Face plate Plato plano Plater laua Facing Refrentado Aurpegiketa
  • 96.
    96 GLOSSARY by Endika Gandarias ENGLISHSPANISH BASQUE Fan Ventilador Haizegailu Feed Avance por minuto Aitzinamendu abiadura Feeder Alimentador Elikatzaile Form turning Torneado de forma Forma torneaketa Follow rest Luneta móvil Luneta mugikorra Gear wheel Rueda de engranaje Engranai gurpila Gearbox Caja de cambios Abiadura kaxa Gloves Guantes Eskularruak Goggles Gafas de seguridad Segurtasun betaurrekoak Grasp Amarrar Lotu / Heldu Groove Ranura Arteka Headstock Cabezal Buru High Speed Steel Acero rápido Altzairu lasterra Idle time Tiempos no productivos Denbora ez produktiboa Insert Plaquita Plakatxo Jaw chuck Plato de garras Atzapardun platera Knurling Moleteado Moletaketa Lathe Torno Tornua Lever clamping Amarre por palanca Palanka bidezko lotze sistema Live center Punto rotatorio Puntu birakorra Live tool = Driven tool Herramienta motorizada Erraminta motorizatua Loading Carga Karga Mandrel Mandrino Mandrino Multitasking machine Máquina multitarea Ataza anitzeko makina Notch machining Entallado Hozkadura Nut Tuerca Azkoina Off-centre Descentrado Deszentratu Offset Descentrar Deszentratu
  • 97.
    97 GLOSSARY by Endika Gandarias ENGLISHSPANISH BASQUE Part feeding Alimentación de piezas Piezen elikatze Parting / Cutting-off Tronzado Trontzaketa Pecking Punteado Punteaketa Pitch Paso Neurri Pole Poste Zutoin Profiling Perfilado Perfilaketa Ram Carnero Ahari Reamer Escariador Otxabu Reaming Escariado Otxabuketa Remnant Resto / Remanente Hondar / Soberakin Runout Excentricidad Eszentrikotasun Safety guidelines Normas de seguridad Segurtasun arauak Screw Tornillo Torloju Self-centering jaws Garras auto-centrante Atzapar autozentranteak Set-up time Tiempo de puesta a punto Prestaketa denbora Shaft Eje Ardatza Shallow Superficial Azaleko Shank Mango Kirten Single spindle / Multi spindle Monohusillo / Multihusillo Ardatz bakarra / Ardatz aniztun Slender Esbelto Lerden Sliding head machine Máquina de cabezal móvil Buru mugikorreko makina Soft jaw Garra blanda Atzapar biguna Solid mandrel Mandril fijo Mandril finkoa Spindle speed Velocidad de giro Biraketa abiadura Spool body Cuerpo de carrete Txirrika gorputza Spring clamp Amarre por deformación Deformazio bidezko lotzea Stainless steel Acero inoxidable Altzairu erdoilgaitza Steady rest Luneta fija Luneta finkoa
  • 98.
    98 GLOSSARY by Endika Gandarias ENGLISHSPANISH BASQUE Steam turbine diaphragm Turbina de vapor Lurrun turbina Tailstock Contrapunto Kontrapuntu Taper turning Torneado cónico Torneaketa konikoa Template Plantilla Txantiloi Threading Roscado Hariztaketa Tip Punta Punta Tool post Torreta portaherramienta Erreminta-etxe dorretxo Tool turret Torreta portaherramientas Erreminta-etxe dorretxoa Toolhonding device Sistema de amarrar herramientas Erramintak lotzeko sistemak Tubing hanger Soporte de tubería Tutu euskarria Tulip Tulipa Tulipa Turning Torneado Torneaketa Turning centre Centro de torneado Torneaketa zentrua Turning operation Operación de cilindrado Zilindraketa operazioa Turret lathe Torno revolver Tornu errebolberra Twin / Double / Sub spindle Doble cabezal Buru bikoitza Unloading Descarga Deskarga / Huste Washer Arandela Zirrindola WC (Hard metal) Metal duro Metal gogorra Whirling ring Cabezal giratorio Buru birakorra