IENG 475 - Lecture 05

Lathe Operations

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Manufacturing Systems
Bonus Quiz 1
 Name the three primary parameters that
must be specified for a machining operation.

 These three parameters allow us to decide if

we have the power to physically perform the
operation. What (three letters) calculation
can we get from the primary parameters to
begin to address the necessary power
requirements?

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Manufacturing Systems
Manufacturing Operations
 Four classes of Processing Operations:
• Solidification Processes
• Particulate Processes
• Deformation Processes
• Material Removal Processes
 Two classes of Assembly Operations:
• Mechanical Assembly
• Joining
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Manufacturing Systems
Machining
 Variety of work materials  Wasteful of material
can be machined • Chips generated in
• Most frequently applied to machining are wasted
metals material, at least in the
unit operation
 Variety of part shapes and
special geometry features  Time consuming
possible, such as: • A machining operation
• Screw threads
generally takes more time
to shape a given part than
• Accurate round holes alternative shaping
• Very straight edges and processes, such as
flat surfaces casting, powder
 Good dimensional metallurgy, or forming
accuracy and surface finish
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Manufacturing Systems
Machining Operations
 Generally performed after other manufacturing
processes (casting, forging, …)
• Other processes create the general shape of the workpart
• Machining provides the final shape, dimensions, finish, and
special geometric details that other processes cannot create
 Most important machining operations:
• Turning
• Drilling
• Milling
 Other machining operations:
• Shaping and planing
• Broaching
• Sawing
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Manufacturing Systems
Primary Machining Parameters

 Cutting Speed – (v)

• Primary motion
• Peripheral speed m/s ft/min
 Feed – (f)
• Secondary motion
• Turning: mm/rev in/rev
• Milling: mm/tooth in/tooth
 Depth of Cut – (d)
• Penetration of tool below original work surface
• Single parameter mm in
 Resulting in Material Removal Rate – (MRR)
MRR = v f d mm3/s in3/min
where v = cutting speed; f = feed; d = depth of cut
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Manufacturing Systems
Turning Parameters Illustrated

Figure 22.5 - Turning operation [Groover (2004), p.503]

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Manufacturing Systems
Drilling
 Creates a round hole in
a workpart
 Contrasts with boring
which can only enlarge
an existing hole
 Cutting tool called a drill
or drill bit
 Customarily performed
on a drill press
Figure 21.3 (b) drilling
[Groover (2004), p.501]

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Manufacturing Systems
Milling Parameters Illustrated

Figure 21.3 - Two forms of milling:

[Groover (2004), p.516]
(a) peripheral milling, and (b) face milling

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Manufacturing Systems
 Machining Operations &
Parameters
Operation Type Speed Feed Depth of Cut
Turning: Surface speed Parallel to the Tool penetration
(periphery) of workpiece axis* below original
workpiece rotates
workpiece (*except parting/grooving) work surface
single point cutting

Drilling: Surface speed Parallel to the Tool penetration

(periphery) of tool axis below original
tool rotates
tool work surface
single pass cutting (depth of hole)

Milling: Surface speed Perpendicular to Tool penetration

(periphery) of the tool axis below original
tool rotates
tool work surface
multi-point cutting

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Manufacturing Systems
Cut Types: Roughing &
Finishing
Number
Cut Type of Speed Feed Depth of Cut
Passes
Roughing: 1+ Low High High
removes large 0.4 - 1.25 mm/ 2.5 - 20 mm
amounts to get .015 - .050 in/ .100 - .750 in
close to shape
Finishing: 1-2 High Low Low
achieves final 0.125 - 0.4 mm/ 0.75 - 2.0 mm
dimensions, .005 - .015 in/ .030 - .075 in
tolerances, and
finish

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Manufacturing Systems
Turning
 A single point cutting tool removes material
from a rotating workpiece to generate a
rotationally symmetric shape
 Machine tool is called a lathe
 Types of cuts:
• Facing
• Contour turning
• Chamfering
• Parting (Cut-off) / Grooving
• Threading

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Manufacturing Systems
Turning Parameters Illustrated

Figure 22.5 - Turning operation [Groover (2004), p.503]

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Manufacturing Systems
Facing

Tool is fed
radially inward

Figure 22.6 (a) facing

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Manufacturing Systems
Contour Turning
Instead of feeding the
tool parallel to the axis
of rotation, tool follows a
contour that is not
necessarily straight
(thus creating a
contoured form).

Figure 22.6 (c) contour turning

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Manufacturing Systems
Right & Left Hand Tools
 Right Hand Tool:
• Cuts from right to left

 Left Hand Tool:

• Cuts from left to right

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Manufacturing Systems
Chamfering

Cutting edge
cuts an angle on
the corner of the
cylinder, forming
a "chamfer"

Figure 22.6 (e) chamfering

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Manufacturing Systems
Parting (Cutoff) / Grooving

Tool is fed
radially into
rotating work at
some location to
cut off end of
part, or provide
a groove
Figure 22.6 (f) cutoff

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Manufacturing Systems
Threading
Pointed form tool
is fed linearly
across surface of
rotating workpart
parallel to axis of
rotation at a large
feed rate, thus
creating threads

Figure 22.6 (g) threading

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Manufacturing Systems
Engine Lathe

Figure 22.7
Diagram of
an engine
lathe,
showing its
principal
components

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Manufacturing Systems
Chuck

Figure 22.8 (b) three-jaw chuck

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Manufacturing Systems
Turret Lathe
 Manual operation is replaced by a
“turret” that holds multiple tools
• Tools are rapidly brought into action by
indexing the turret
• Tool post is replaced by multi-sided turret
to index multiple tools
• Applications: high production work that
requires a sequence of cuts on the part

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Manufacturing Systems
 CNC Turret Lathe
Spindle Speed

Tool Turret
+ X-axis
Ways

+ Z-axis

Cross Slide
Spindle

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Manufacturing Systems
CNC Lathe: Air-Operated Chuck

Right Hand
Profile Tool

Chuck

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Manufacturing Systems
CNC Lathe: Tool Turret
Left Hand
Profile Tool

Tool Turret

Grooving /
Parting Tool

Tool Holder
Right Hand
Profile Tool

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Manufacturing Systems
Machining Calculations:
Turning
 Spindle Speed - N v (rpm)
• v = cutting speed N
• Do = outer diameter π Do
 Feed Rate - fr (mm/min -or- in/min)
• f = feed per rev fr  N f
 Depth of Cut - d Do  Df (mm/rev -or- in/rev)
• Do = outer diameter d 
• Df = final diameter 2
 Machining Time - Tm L (min)
• L = length of cut Tm 
fr
 Mat’l Removal Rate - MRR (mm3/min -or- in3/min)
MRR  v f d
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Manufacturing Systems
Questions & Issues
 Finish Machining (Drilling & Milling) Next Week:
• Next Topic: Process Planning
• Following Week: Group Technology
 Lab this week:
• Fixturing (manual tools & drill press)
 Lab next week:
• Manual Lathe & Mill Operations:
• Rough & Finish Profiling Cuts
• Facing Cuts
• Parting Cuts
• Tool Changes
• Touch-Off

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Manufacturing Systems