UNIT II

OVERVIEW
Lathe Principle of working, specification of lathe types of lathe
Lathe operations & Important Accessories Taper turning & thread
turning-Problems-machining time calculations.
Turret and Capstan lathes Differences tool holding devices - tool
layout, examples.
Shaping and Planing machines Differences- Principles of working
Quick return mechanisms- Principal parts specification, classification,
operations performed, machining time calculations.

The Lathe Machine Tool

Invented by the English Inventor

Henry Maudsley in 1757

Live center

Principle of working of Lathe

A Machine tool which removes the metal from a piece of round
(cylindrical) work to the required shape & size by holding the work
between two rigid and strong supports called centers or in a chuck or
face plate while the work revolves. The cutting tool is rigidly held and
supported in a tool post and is fed against the revolving work.

Driving Plate and Lathe Carriers Or Dogs

Dead

Live

CARRIAGE

MAIN PARTS
HEAD STOCK - This end of the lathe contains the driving motor and
gears. Power to rotate the part is delivered from here. This typically has
levers that let the speeds and feeds be set.
TAIL STOCK - This can be used to hold the other end of the part or perform
drilling, reaming, boring etc., operations on work.
LATHE BED WAYS - These are hardened rails that the carriage and tailstock
rides on.
LATHE BED Base on which different fixed and operating parts of the lathe
are mounted.
CARRIAGE - This part of the lathe carries the cutting tool and moves
based on the rotation of the lead screw or feed rod.
FEED ROD - A long shaft used for driving carriage for various cutting feeds.
LEAD SCREW - A large screw with a few threads per inch used for
cutting threads

Engine Lathe The most common form of lathe, motor

driven and comes in large variety of sizes

and shapes General purpose

Types
of
Lathe

Bench Lathe

For small & precision work- mounted

on bench

Speed Lathe

Employed for wood turning, metal

spinning etc.,-tool fed & actuated by
hand-no carriage, no gear box

Tool Room
Lathe

Size same as engine lathe-for more

accurate & precision work- has all
attachments

Capstan & Turret

Lathes
Automatic Lathe
Special purpose
Lathes

For high production rates-semiautomatic type-less operator skill

For mass production-no operator
intervention
Crankshaft lathe, screw cutting
lathe, tracer lathe, facing lathe

ENGINE LATHE
HEAD STOCK
TAIL STOCK

LATHE BED
LEAD SCREW

CARRIAGE

FEED ROD

ENGINE LATHE

Bench Lathe

Speed Lathe

Tool Room Lathe

Capstan & Turret Lathes

BLOCK DIAGRAM OF CAPSTAN / TURRET LATHE

Rear Tool Post

Chuck

Lathe Bed

11
12

10

1
2

Hexagonal turret
Front Tool Post

Cross slide

Automatic Lathe

automatic lathes are mechanically automated ones

Automatic Lathe

Although all electronically controlled (CNC) lathes are automatic, they are
usually not called by that name
CNC has not yet entirely displaced mechanically automated machines.
An automatic lathe may have a single spindle or multiple spindles.

Special purpose lathes

Precision Lathe-0.002 mm accuracy

Facing lathe-Carriage driven by separate motor
Frontal lathe- 2 carriages
Vertical lathe-For turninng & boring very large
rotating parts
Crankshaft lathe
Duplicating lathe-Tracer attachment
Screw cutting lathe

LATHE SPECIFICATIONS
Live
center

Dead
center

Tail
stock

Head
stock

Slide
ways

Carriage

(1) A: Maximum length that can be accommodated between the centers

(2) B: Swing in Gap
(3) C: Height of centers
(4) D: Swing over carriage
(5) E: Swing over Bed

6. Length of Bed
7. Width of Bed
8. Number of spindle speeds
9. Range of spindle speeds
10. Metric threads: Pitch range
11. Inch Threads: Pitch range
12. Lead Screw diameter
13. Motor HP

Lathe Operations
Turning: To produce Straight, Tapered, curved, or grooved workpieces
Facing: To produce a flat surface at the end of the part or for making face
grooves.
Threading: To produce external or internal threads
Knurling:
surfaces

To produce a regularly shaped roughness on cylindrical

Drilling: To produce a hole by fixing a drill in the tailstock

Boring: To enlarge a hole or cylindrical cavity made by a previous
process or to produce circular internal grooves.

Lathe Operations

LATHE BED
The Bed forms the base of a Lathe machine.
It provides a heavy rigid frame on which all the other basic
components are mounted. It must be rigid enough to resist deflection in
any direction under load.
The bed is made as single piece casting using cast iron, in a box
shape incorporating cross ribs, and is supported on legs, a cabinet, or
a bench.
Cast iron- Easy sliding action, wear resistance and absorbs vibrations.
To avoid distortions during solidification of castings, it is allowed for
ageing with rough machining and left in open for couple of years and
then machined to the required size for final assembly.
The headstock and the tailstock are located at either end of the bed
and the carriage rests over the Lathe bed and slides over it.
Fine grained with 200 BHN

Bed ways

The ways of the lathe are the flat or V-shaped surfaces on which
the carriage and the tailstock are moved left and right.

Each has its separate pair of ways, often one flat surface, for
stability and supports by taking maximum portion of load and
stresses, and one V-way for guidance(guideways) in a perfectly
straight line & disallows the entry of chips and durt between the
saddle and bed and preventing the contact surfaces from being
spoiled due to scratching
These ways are hardened and scraped or ground to close
tolerances.
The basic accuracy of movement of the carriage depends on the
ways.
To improve wear resistance of beds:
1.Chilling of casting
2.Flame hardening to improve hardness
3.Superimposing separately hardened steel slide ways and
prismatic(inverted V) ways over the top of the bed casting

LATHE BED AND BED WAYS

LATHE BED

LATHE BED WAYS

HEAD STOCK

The headstock is the powered end and is always at the

operators left.

This contains the speed changing gears and the revolving,

driving spindle, to which any one of several types of work
holders is attached.

The center of the spindle is hollow so that long bars may be put
through it for machining.

A live centre, a face plate, collet or a chuck can be fitted to the

spindle nose to hold and drive the work.

Headstock spindle can be driven by a stepped pulley and a belt

or by transmission gears in the headstock.

Head Stock
Serves as a housing for the driving pulleys and back gears, provides bearing
For the machine spindle and keeps the spindle in alignment with the bed.
1.Cone pulley
2.Back gears and back gear engaging lever
3.Main spindle or head stock spindle
4.Live Centre
5.Feed reverse lever(Tumbler reversing Mechanism)
1.Stepped cone pulley
Mounted on the main spindle, which carries a spur gear at its one end
and a pinion at the other.
Spur gear is firmly keyed to the spindle so that it can never revolve free.
A spring knob engages the gear with the cone pulley.
The cone pulley is driven by means of a belt, through a counter shaft, by
an electric motor. This arrangement enables 4 different speeds of spindle

2.Back gears
These are used for reduction in spindle speeds, there by facilitating a wider
range of speeds.
Back gears are mounted on an eccentric shaft which is operated by means
of a hand lever known as backgear engaging lever.
Back gears consists of a spur gear and a pinion. When speed reduction is
desired, the spring knob is pulled out to make the cone pully free of gear on
spindle and hence free from spindle.
The back gears are put into mesh with the spindle gears by pulling the
eccentric shaft.
Now the sequence of transmission of motion and power is through the
upper eccentric shaft and reduction in speed is possible

Without Backgears

With Backgears

HEAD STOCK GEAR BOX

HEAD STOCK GEAR BOX

Sectional Top-View

GT Translating Gear (127 teeth)

A simple nine speed all geared head stock. Power transmitted to spindle
shaft S1 from driving motor. Power is transmitted from S1 to S2 and to S3.
G4,G5,G6 rotate freely on shaft S2 in their own positions, but they cant
be shifted axially.

HEAD STOCK GEAR BOX

All geared head stock is the common mechanism used in all modern
lathes
The mechanism of gear operation is sliding gear mechanism
The spindle speeds are arranged in a geometric progression
The different spindle speed possible are:
(1) G1/ G4 G4/ G7 (2) G1/ G4 G5/ G8 (3) G1/ G4 G6/ G9
(4) G2/ G5 G4/ G7 (5) G2/ G5 G5/ G8 (6) G2/ G5 G6/ G9
(7) G3/ G6 G4/ G7 (8) G3/ G6 G5/ G8 (9) G3/ G6 G6/ G9
Advantages of gear drive:
1) More compact design
2) Power available at the tool is constant for all speeds
3) Changing of speeds is easy thru levers safe & quick to change
4) Less vibrations

3. LATHE SPINDLE (Main Spindle or Head stock spindle)

Main spindle is hollow and tapered at front end to

accommodate centers.
A tapered sleeve (bush) fits into the tapered hole and a live
center which supports the work fits into the sleeve
At font end, the outside surface is threaded to accommodate
job holding devices like chucks, face plate, driving plate.
The spindle revolves on two large thrust bearings housed on
the head stock casting.

LATHE SPINDLE Contd..

Hollow shaft- Threaded front end to receive the job holding devices such
as chuck, face plate or driving plate.
Trueness of the spindle has a considerable effect on the accuracy of the
job, and hence it should always be in perfect alignment

HEAD STOCK SPINDLE

4.Live Centre
It is the centre support which is fitted into the tapered inside portion of
the spindle nose while using a drive plate or face plate
No such centre is required when the work is held in chuck.
It acts as a bearing support for the work during the operation
It is usually softer than the dead centre fitted in the tail stock, as
there is no wear occurring on live centre surface as it is always
revolving along with the work

5.Feed Reverse lever(Feed Direction lever) using Tumbler mechanism

For providing power feeds to the carriage. Lever is at head stock and all
gears are in Apron of carriage
3 positions of lever
1.Central position: Disengaged carriage is moved by hand wheel
2.Position1 To give feed to the carriage from right to left(Left hand threads)
3.Position2 To give feed to the carriage from left to right(Right hand threads)
This lever should not be operated while the spindle is running. The
machine should be stopped before operating this lever.
This lever effects the above change, by changing the direction of
rotation of the lead screw through a set of gears, while the spindle
continuous to revolve in the same direction always.
To change the direction of rotation of spindle, a reversible switch is used,
to make the driving motor to revolve in reverse direction and hence the
spindle.

Feed Direction Lever(Tumbler Gear)- Head stock

Power Feed Lever-Apron

Tumbler reversing Mechanism

The gear mechanism operated by means of the feed reverse lever is called
the Tumbler reversing mechanism.
Used for providing power feeds to the carriage.
Motion from the spindle to the lead screw or feed rod is transmitted through
this mechanism.
A desired speed of lead screw or feed rod can be obtained by selecting the
suitable change gears having proper no. of teeth.
Stud gears and quadrant are used to enable proper meshing of change
gears.

Carriage
The carriage can be moved left or right either by hand
wheel or power feed.
Carriage consists of the following parts:
(1) Saddle,
(2) Cross-slide,
(3) Compound-slide or compound rest,
(4) Tool post, and
(5) Apron.

CARRIAGE

Feed

Motions of a Carriage

1.Saddle
The saddle is an H-shaped casting that fits over the bed
and slides along the bed ways.
It carries the cross-slide and tool post.
2.Cross Slide
The cross slide is mounted on the carriage and can be
moved in and out perpendicular to the carriage motion.
This is the part that moves when facing cuts are made with
power feed.
This, or the compound, is also used to set the depth of cut
when turning.
The cross slide can be moved by its hand wheel or by
power feed.

3.Compound Rest:

The compound rest is fitted on the top of the cross-slide, is used

to support the cutting tool.

It can be swiveled to any angle for taper turning operations and

is moved manually.

It can be moved in and out by its hand wheel for facing or for
setting the depth of cut.

It can also be rotated 360 degrees and fed by its hand wheel at
any angle.

4.TOOL POSTS

The tool post is mounted on the compound rest.

This can be any of several varieties but in its simplest form is

merely a slotted cylinder, which can be moved, left or right in
the T-slot in the compound and clamped in place.

It can also be rotated so as to present the cutter to the work

at whatever angle is best for the job.

The various types of tool posts are:

1) Single screw tool posts
2) Four bolt tool post
3) Open side tool post
4) Four way tool post

(a) A tool post for single-point tools and (b) a quick change indexing square
turret, which can hold up to four tools.

SINGLE SCREW TOOL POSTS

OPEN SIDE TOOL POST

FOUR WAY TOOL POST

5.APRON-Hanging part infront of the carriage

Holds most of the control levers through which power feeds can
be given to carriage and the cross-slide.

The apron is fastened to the saddle, houses the gears and

mechanisms required to move the carriage and cross-slide
automatically.

The apron hand wheel can be turned manually to move the

carriage along the Lathe bed. This hand wheel is connected to
a gear that meshes in a rack fastened to the Lathe bed.

It also carries the clutch mechanism and split half nut.

Clutch mechanism is used to transmit motion from the feed rod

to carriage

Split half nut in conjunction with the lead screw, moves the
whole carriage in thread cutting.

APRON MECHANISM

Apron mechanism is used for transferring rotary motion of the

feed rod and the lead screw into feed motion of the carriage.

Both automatic longitudinal and cross-feed can be provided to

the carriage by changing the position of feed change lever
(power feed lever or feed selection lever)

The mechanism is so designed that when the half-nut is

engaged with the lead screw, the automatic feed motion from the
feed rod is disconnected.

There is an interlocking device which prevents simultaneous

engagement of the carriage with the feed rod and lead screw
and saves the machine from any probable damage.
Apron mechanism is not capable of providing power feeds both to
carriage as well as the cross-slide simultaneously.

For hand feed : Feed Selection Lever is put in position 2(center)

When power feed is to be given to the carriage, lever is put in position 3,
(above) and star wheel is tightened.
To give power feed to the cross-slide, lever is put in position1.(below)
Apron mechanism is not capable of providing power feeds both to carriage as
well as the cross-slide simultaneously.

(Power feed lever or Feed selection lever)

For thread cutting, feed change lever(power feed lever or feed selection
lever) on the apron is placed in neutral position and the carriage in desired
position can be clamped to the bed by tightening the carriage lock-screw.

The motion is transmitted from lead screw to the carriage by engaging

the half-nuts with lead screw. A thread dial is fastened to the right side of
the apron to indicate the exact point to engage the half nuts while cutting
the threads.
A feed reverse lever(in head stock) is used to control the direction of
rotation of the lead screw to cut left-hand or right-hand threads.

CARRIAGE

FEEDROD

The feedrod is a long shaft that has a keyway.

The power is transmitted from the lathe spindle to the apron
gears through a feedrod via a large number of gears.
The feedrod is used to move the carriage or crossslide for
turning, facing and all other operations except thread cutting.

LEADSCREW

The leadscrew is powered by gears from the head stock and is

used for providing specific accurate mechanized movement to the
carriage for cutting threads on the workpiece.
The leadscrew has a definite pitch.
A split nut is used to engage the leadscrew with the carriage.
In some lathes, the leadscrew performs the functions of feed rod
and there is no separate feed rod.

The Half Nut or Split Nut mechanism

The half nut makes the carriage to engage or disengage
with the leadscrew.

It comprises of a pair of half nuts capable of moving in or

out of mesh with the lead screw.

The half nut can be engaged with the lead screw by

means of a lever provided on the apron.
This mechanism is called half nut mechanism.
The half nut or split nut is used only for thread cutting.

SPLIT NUT
MECHANISM

Thread Chasing Dial

TAIL STOCK

Or sleeve

Also called loose head stock or puppet head

LATHE ACCESSORIES
The devices employed for Work holding and Tool holding in lathe
are called its Accessories

LATHE ATTACHMENTS
Attachments are additional equipments used for specific
purposes
Examples: Taper turning attachment, Grinding wheel attachment,
Bar Stops, Thread chasing dial, Milling attachment.

Lathe
Accessorie
s

Chucks For short length, large diameter w/ps

Face Plate For holding w/ps like pipe elbows
which cannot be held in chuck or
centers

Work
Holding
devices

Angle
Plate

Used in conjunction with face plate

Driving Used to drive w/p when held between

centers
Plate
Lathe Carriers Used in conjunction with face plate
Or Dogs
Lathe Centers For holding the work between centers
Lathe Mandrels For holding hollow work pieces
Rests

To support long slender w/ps when turned

between centers

CHUCKS

Four Jaw
Independent
chuck

Three jaw
universal
chuck

Combination Magnetic Collet

chuck
chuck
chuck

Air
operated
chuck

Three jaw universal chuck

A three jaw chuck is used for gripping cylindrical workpieces
The jaws have a series of teeth that mesh with spiral grooves on a circular
plate within the chuck.
This plate can be rotated by the key inserted in the square socket,
resulting in simultaneous radial motion of the jaws.
Since the jaws maintain an equal distance from the chuck axis, cylindrical
workpieces are automatically centered when gripped.
Also called as self centering chuck or universal chuck. All the jaws move
together in equal amounts to clamp the work educe
Job is automatically centred and reudce the time of set-up. Jaws are not
reversible and separate internal and external jaws have to be used.
It has less gripping capacity and centering accuracy is lost due to wear.
This chuck is not suitable for irregular shaped workpieces which demands
the use of four jaws chuck

Three jaw universal chuck

Three jaw universal chuck

Four Jaw Independent chuck

With the four jaw chuck, each jaw can be adjusted independently by
rotation of the radially mounted threaded screws.
Although accurate mounting of a workpiece can be time consuming,
a four-jaw chuck is often necessary for non-cylindrical workpieces.

Magnetic chuck
The workpieces are held in this chuck by means of powerful
electro- magnets.
Used for very thin w/ps which cannot be held in chuck

Collet Chuck

Collet Chuck

Collets are used when smooth bar stock, or workpieces that have
been machined to a given diameter, must be held more accurately
than normally can be achieved in a regular three or four jaw chuck.

Collets are relatively thin tubular steel bushings that are split into three
longitudinal segments over about two thirds of their length.

The smooth internal surface of the split end is shaped to fit the piece
of stock that is to be held.

The external surface at the split end is a taper that fits within an
internal taper of a collet sleeve placed in the spindle hole.

When the collet is pulled inward into the spindle, by means of the
draw bar that engages threads on the inner end of the collet, the
action of the two mating tapers squeezes the collet segments
together, causing them to grip the workpiece.

Air or Hydraulic operated chuck

The workpieces are held in this chuck by means of fluid pressure
used in mass production work for fast and effective gripping

Face Plate and Angle plate

Face Plate
A face plate consists of a circular disc bored out and thread
to fit the nose of the spindle.
This has radial, plain and T slots for holding work by bolts
and clamps.
Face plates are used for holding workpieces which cannot
be held conveniently held between centers or chucks.

Angle plate
This is a cast iron plate having two faces machined to make
them absolutely at right angles to each other.
Holes and slots are provided on both faces so that it may be
clamped on the face plate and can hold the workpiece on the
other face by clamps and bolts.
Angle plates are used in conjunction with a face plate when
the holding surface of the workpiece should be kept horizontal,
as for example, in machining a flange of a pipe elbow.
When eccentric jobs are bolted on the face plate, a balance
weight or counter weight must be added.

Driving Plate and Lathe Carriers Or Dogs

Driving Plate(Catch plate) and Lathe Carriers(Dogs)

Carriers or lathe dogs and catch plates are used to hold workpiece
when it is held between centers.
Carriers or lathe dogs are attached to the end of the workpiece by
setscrews; catch plates are either screwed or bolted to the nose of
head stock spindle.
A projecting pin from the carriers fits into the slots provided in the
catch plate

A catch plate with live centre

Driving Plate and Lathe Carriers Or Dogs

Lathe Centers

A - Ordinary Center

E - Tipped Center

B - Ball Center
F - Insert type center

C - Revolving center
(Frictionless center)

G - Pipe center

Lathe Centers
D - Half center
H - Use of Half Center

Lathe Mandrels
A mandrel is a device for holding and rotating hollow
workpiece that has been previous drilled or bored.
The work revolves with the mandrel which is mounted
between two centers.
It is generally made of high carbon steel.
The ends are slightly smaller in diameter and flattened to
provide effective gripping surface of the lathe dog
screws.

Lathe Mandrels

Lathe Mandrels

Rests
Steady rest

Follower rest

Steady rest

Follower rest

Steady rest

Follower rest

Rests
Steady rest
A steady rest consists of cast iron base, which may be made
to slide on the lathe bed ways and clamped at any desired
position where support is necessary.
This is so designed that the upper position is hinged at one
end which facilitates setting and removal of the workpiece
without disturbing the position of the steady rest.
There are three jaws on the steady rest, two on the lower
base and one on the upper frame, the jaws may be adjusted
radially by rotating individual screws to accommodate work
of different diameters.
The main function of the steady rest is to provide support to
a long slender work.
For a very long work more than one steady rest may be
used.
However the carriage cannot be fed to the full length of the
work when steady rest is used.

Follower rest:

A follower rest consists of a C like casting having two

adjustable jaws which support the work.
The rest is bolted to the back end of the carriage and moves
with it.
Before setting the follower rest, the end of the workpiece is
machined slightly wider than the jaws to provide the true
bearing surface.
The tool is slightly in advance position than the jaws, and the
tool is fed longitudinally be the carriage, the jaws always
follow the tool giving continuous support to the workpiece.
The follower rest prevents the job from springing away when
the cut is made and is used in finish turning operation.
The follow rest is normally used with small diameter stock to
prevent the workpiece from springing under pressure from
the turning tool

Taper Geometry
D

d
B
A

Where,

D = Large diameter of taper in mm.

d = small diameter of taper in mm.
l = length of taper part in mm
2 = full taper angle
= angle of taper angle or half taper angle.

The Amount Of Taper in a workpiece is specified by ratio of the difference in

diameters of the taper to its length. This is termed as CONICITY(or taper K) and
designated by letter K.

Dd
K
l

From figure
Dd
2
BC l
Dd
tan
2l
K
tan
2
K 2 tan
AB

Example:
If D = 90mm; d = 80mm and l = 100mm. Find the value of K

Dd
Solution: Using the relation: K
l
K = 90 80 = 1/10
100

This means the amount of taper is 1:10 (or 1/10)

or in a length of 10 mm the diameter of the taper is reduced by 1mm
Problem:
A shaft of 1200mm long has a taper of 1:200 for a length of
600mm. The maximum diameter of the shaft is 75mm. Determine
the minimum diameter of the shaft.
Solution: d = 72mm

TAPER TURNING METHODS

1)By a broad nose form tool
2) By swivelling the compound rest
3) By setting over the tailstock center
4) By a taper turning attachment

1.Taper Turning By Form Tool

This method uses a tool which is a broad nose tool having straight cutting edge.
The tool is set on the work piece at half taper angle, and is fed straight into the
work to generate a tapered angle.
Method is limited to turn limited length taper only.
This is due to the reason that the metal is removed by entire cutting edge, and
any increase in length of the taper will necessitate the use of a wider cutting edge.
This will require excessive cutting pressure, which may distort the work due to
vibration and spoil the work due to vibration and spoil the work surface.

Work piece

Tool

feed

2.Taper Turning By Swiveling the Compound Rest

This method employs the principle of taper turning by feeding the tool
at an angle to the axis of rotation of the workpiece.
The tool post is on the compound rest and compound rest is attached
to a circular base, graduated in degrees, which may be swiveled and
clamped at any desired angle (angle limitation - 45 on either side of
lathe axis.
Once the compound rest is set at the desired half taper angle, rotation
of the compound slide screw by hand will cause the tool to be fed at an
angle and generate the corresponding taper.
This method is limited to turn a short but steep taper owing to limited
movement of the cross slide.
The movement of the tool in this method is controlled by hand, thus
this gives low production rate and poor surface capacity.

Taper Turning By Swivelling the Compound Rest Contd

Compound rest screw

Taper = (D-d)/l
l = length of taper, L= Total length between centers

Problem: 1
A job of 80mm long has to be taper turned for its full length. The two
resulting diameters will be 40mm and 30mm. Find the angle though which
the compound rest should be swiveled to produce the desired taper.
Solution: = 335

Problem2. Calculate the compound rest angle for turning short taper of 1:15
Taper= (D-d)/l = 1/15

Dd
1
1

2l
15 x 2 30

= 1.910

Problem3. Calculate the compound rest angle to turn a short taper of 1mm per 12 mm

= 2.3860

3.Taper turning by setting over the tailstock

The principle of turning taper by this method is to shift the axis of

rotation of the workpiece, at an angle to the lathe axis, and feeding
the tool parallel to the lathe axis.

The angle at which axis of rotation of the workpiece is shifted is

equal to half angle of taper.

The amount of setover is limited.

This method is suitable for turning small taper on long jobs.

Disadvantags of this method:

1) The live and dead centers are not equally stressed and the wear is
not uniform.
2) The lathe dog being set at an angle, the angular velocity is not
constant.

Taper Turning By Setting Over The Tailstock Center Contd

TOPVIEW

D - Large diameter; d - Small diameter; L - length of work;

l - length of taper; -Half taper angle; S-Setover

From geometry:
BC setover
BC AB sin
setover L sin
If the angle , the anle of taper, is very small, for all practical purposes,
sin tan
setover L tan
Dd
setover L
2l
entire length of the work X conicity
setover
2
if the taper is turned on the entire length of the workpiece, then l L
Dd
setover
2

Problems:
1.A job of 250mm long has to carry a taper for only 125mm length from
its one end. The smaller diameter of the tapered part is 32mm and the
initial diameter of the job, before turning the taper was 40mm.Calculate
the amount of tail stock setover.
Solution: Setover = 8mm
2. Find the tailstock setover to turn a taper of 10mm per 250mm, if the
work is 250 mm long
Tail stock setover S=

Dd

2l

= 5 mm

L=250, l=250, Taper=(D-d)/l =10/250

3. The length of work is 300 mm, the amount of taper is 1:25. Find the
tailstock setover required.
(D-d)/l =1/25

Answer: 6 mm

4.A shaft 800 mm long is to be turned taper for a length of 300 mm. The
amount of taper is 1:90. Find the tail stock setover required.
Answer: 4.45 mm
5.A spindle of 500 mm length is to be taper turned over the length of 350mm.
The large diameter is 50 mm and small diameter is 45 mm. Find the amount
of tailstock setover.
L=500, l=350, D=50, d= 45
S= 3.57 mm

4.Taper turning by taper turning attachment

The principle of taper turning by taper turning attachment is to

guide the tool in a straight path set at an angle to the axis of
rotation of the workpiece, while the work is being held by a
chuck or between centres aligned to the lathe axis.

A taper turning attachment consists of a frame or bracket which

is attached to the rear end of the lathe bed and supports a guide
bar pivoted at the centre.

The Guide bar having graduations in degrees may be swiveled

on either side of the zero graduation and is set at any desired
angle with the lathe axis.

When taper turning attachment is used, the cross slide is first

made free from the lead screw by removing the binder screw.

1) Bracket or
Frame

Attachment

2) Guide
block
3) Guide bar
4) Crossslide
5) Binder
screw

Cross slide
Feed
direction

GUIDE BAR

attachment

Taper turning attachment

Thread Nomenclature

Thread Nomenclature
1) Pitch: distance from one point on the thread to the
corresponding point on the adjacent thread measured
parallel to thread axis
2) Major diameter: Largest diameter of a screwed part
measured normal to thread axis
3) Minor diameter: Smallest diameter
4) Depth: distance between crest and root
5) Pitch diameter; Virtual diameter
6) Flank: Sloping line connecting crest and root
7) Thread angle: Included angle between the flanks
8) Lead: Axial distance moved for one rotation of the thread

Right Hand and Left Hand Threads

Thread sloping left to right from top->Right hand thread(commonly used thread)
Thread sloping right to left->Left hand thread
3 positions of lever for Tumbler gear
1.Central position: Disengaged carriage is moved by hand wheel
2.Position1 To give feed to the carriage from right to left(Left hand threads)
3.Position2 To give feed to the carriage from left to right(Right hand threads)

START OF THREADS
Pitch = Lead / No. of Starts

Start of threads: This denoted the no. of separate thread grooves running
parallel to each other along the surface of the screwed part.
Single or multistart
Advantage of multistart: To obtain more axial advancement for the same
amount of rotation f the screwed part as compared to single start thread.
Single start thread->lead=pitch
Double start thread->lead= 2x pitch
Triple start thread-> lead= 3x pitch

lead
Pitch
no. of starts

For cutting of threads, it is necessary that for every revolution of the

spindle(or work), the tool should move parallel to the axis of the job by a
distance equal to the lead of the screw to be cut.
There should be a definite ratio between the longitudinal feed of the tool
and the speed of the spindle.

PRINCIPLE OF THREAD TURNING

All the threads are formed on the principle of Helix
There are two pre-requisites for thread turning on lathe:
A specified relationship between longitudinal movement of the
cutting tool and work rotation must established
The cutting tool should have an included angle corresponding to
the thread angle
Both Internal & External threads may be cut.
For both of these a proper system of gearing between the lathe
spindle and the lead screw is required so as to establish the required
ratio of speeds between the two.
For lathes equipped with quick change gear box obtaining specified
pitch of thread is easy - just by operating the gear change levers - as
the requisite gears are already mounted speed and feed charts for
particular pitch are available on the machine tool

PRINCIPLE OF THREAD TURNING

1 Head stock spindle

2 Carriage
3 Lead Screw
4 Change gears

The process of thread cutting is to produce a helical groove on a

cylindrical surface by feeding the tool longitudinally.
1. The job is revolved between centre or by a chuck. The longitudinal feed
should be equal to the pitch of the thread to be cut per revolution of the work
piece.
2. The carriage should be moved longitudinally obtaining feed through the
lead-screw of the lathe.
3. A definite ratio between the longitudinal feed and rotation of the headstock
spindle should be found out. Suitable gears with required number of teeth
should be mounted on the spindle and the leadscrew.
4. A proper thread cutting tool is selected according to the shape of the thread.
It is mounted on the tool post with its cutting edge at the lathe axis and
perpendicular to the axis of the work.
5. The position of the tumbler gears are adjusted according to the type of the
thread (Right hand & Left hand thread)
6. Suitable spindle speed is selected and it is obtained through back gears.
7. After the process of thread cutting is over, the thread is checked by suitable
gauges.

 For lathe machine tools not having gear boxes a suitable set of gears
has to be found out and mounted for cutting threads of different pitches.
The principle of thread cutting is to produce a helical groove on a
cylindrical surface by feeding the tool longitudinally
The longitudinal feed should be equal to the pitch of the thread to be cut
per revolution of workpiece
Obviously there will be definite ratio between the longitudinal feed of
tool and speed of spindle
The desired ratio is obtained with the help of lead screw by connecting it
to the spindle through a train of gears
Now the motion from the spindle is transmitted to the lead screw
through these gears
By engaging the split nut the movement of the carriage and hence the
tool is guided by the lead screw
If the spindle speed and the lead screw rotate at the same speed, the
pitch of the thread cut on the work will be the same as that of the lead
screw

Spindle speed->reversing gears->change gears->lead screw->split half

nut engaged-> carriage moves-> hence the tool
Calculating change gears: To establish a definite ratio between spindle
speed and longitudinal tool feed.
If the spindle and lead screw rotate at the same speed, the pitch of the
thread cut on the work will be the same as that of the lead screw.
If the pitch of lead screw=3, the tool will advance parallel to the axis of the
work by a distance equal to 3 mm for each revolution of the lead screw,
giving 3 mm pitch helical groove on the surface of the job.
If 6 mm pitch is required to be cut on same lathe, tool should move a
distance equal to 6 mm for every revolution of the spindle.
But, since the lead screw pitch is only 3 mm, for 6 mm displacement of the
tool, the lead screw should make 2 revolutions. That is the lead screw should
rotate at a speed double that of the spindle.

The speed of the lead screw will be as many times higher than that of the
spindle as its(spindle) pitch is smaller than that of the screw to be cut.

The speed of the lead screw will be as many times lower than that of
the spindle as its(spindle) pitch is greater than that of the screw to be
cut.
To effect this variations in speeds, change gears are employed and
the amount by which the speed of the lead screw should be higher or
lower than that of the work determines what is known as gearing ratio.

Calculation of Change Gears

To calculate the gears required for cutting a thread of certain pitch can
calculated from the following formula:
The gear of the spindle shaft is the driver and the gear on the leadscrew
is the driven gear.
speed of lead screw
Gear ratio

speed of the work

pitch of screw to be cut

pitch of lead screw
TPI on lead screw

TPI on job
lead of the screw to be cut

lead of lead screw threads

No. of teeth on driver(stud gear)

No. of teeth on driven(lead screw)

Note: Engine lathes are equipped with a set of gears ranging from
20 to 120 teeth in steps of 5 teeth, and one gear with 127 teeth
(Translating gear) for cutting metric threads.

Selection of Gear Train

Lead screw=Driven
Spindle=Driver

Intermediate gears or idle gears has no effect on speed ration.

Used only to fill the gap between driver and driven and to obtain a
desired direction of the lead screw.

To cut Metric thread on Metric leadscrew:

The cutting of metric thread (mm) on a lathe with an Metric (mm)
leadscrew

Driver teeth Pitch of the screw to be cut in mm

Driven teeth
Pitch of the lead screw in mm

To cut English threads(inch) on Metric leadscrew(mm)

Driver teeth Pitch of the screw to be cut in inches

Driven teeth
Pitch of the lead screw in mm
Pitch of the screw to be cut in inches 25.4mm

Pitch of the lead screw in mm

Pitch of the screw to be cut in inches (127 / 5)
=
Pitch of the lead screw in imm
127 Pitch of the screw to be cut in inches

5
Pitch of the lead screw in mm

1 inch = 2.54 cm = 25.4 mm and 5 x 25.4 = 127

Pitch

lead
no. of starts

Gear ratio

pitch to be cut
5 x pitch to be cut in mm

pitch of lead screw 5 x 25.4 x pitch of lead screw in inches

5 x Pc
5 Pc

nx
127 x PL
127PL

Where
Pc = Pitch to be cut in mm
PL= Pitch of lead screw in inches
n = No. of starts

127 Pc
Gear ratio= n x
5 PL
Where
Pc = Pitch to be cut in inches
PL=Pitch of lead screw in mm

Pitch

lead
no. of starts

1
Pitch
No.of TPI

To cut Metric thread on English leadscrews:

The cutting of metric thread (mm) on a lathe with an English (inch)
leadscrew may be carried out by introducing a translating gear of 127
teeth.

1. Calculate change gears for cutting RH threads of 2 mm pitch on a

lathe having a lead screw of 6 mm pitch

Gear ratio

pitch to be cut
2 1 20 20 1 25 25 1 30 30
x
x
x
pitch of lead screw 6 3 20 60 3 25 75 3 30 90

Problem:2
Calculate change gears for cutting Right Hand threads of 7mm pitch on a lathe
having a leadscrew of 4 threads per inch. The lathe is equipped with gears from
20 teeth to 120 teeth in steps of 5.
Solution:
Pitch of thread to be cut in mm ; Lead screw threads per inches
Change gears is calculated by the formula

Driver teeth
5
140

7 4
Driven teeth 127
127
Generally 140 teeth gear is not available so we have to compound the ratio
140 70 2 70 40
=

127
127 127 20
Driver gear will have 70 and 40 teeth and Driven gear will have 127 and 20 teeth

Compound gear train

70

127
40

20

To lead screw

3.Find the change gears for cutting screw of 6 mm pitch on a lathe with a
lead screw of 4 TPI. Change gears available are 20 to 120 teeth with a
progression of 5 and 127 teeth.

Pitch to be cut Pc = 6 mm
No. of threads on lead screw=4 TPI
Therefore, pitch = =0.25 inch
Gear ratio=

5 pc
5 x6
30
60 50 Drivinggear

127 pl 127 x0.25 127 x0.25 127 25 Drivengear

4. Calculate change wheels to cut threads of 1 mm pitch on a lathe having

a lead screw of 8 mm pitch. Gears 20,30,60,80 are available.

1 20

8 160

As, 160 gear is not available, simple gear train is not possible. So go for
compound gear train
1 1 1 1 20 1 30 20 30
x x
x x

x
8 4 2 4 20 2 30 80 60

5.Find the change gears to cut 16 TPI thread on a lathe with 6 TPI lead screw

Pitch to be cut =Pc= 1/16

Pitch of lead screw=PL=1/6
1
driver Pc 16
6
6 x5 30 No. of teeth on gear of lathe spindle

1 16 16 x 5 80
driven PL
No. of teeth on gear of lead screw
6

6.Find a suitable gear train to cut a 1.5 mm pitch , 2 start thread on a

lathe with a lead screw of 12.5 mm pitch. Gears from 20 to 100 are
available
Gear ratio n x

Pc
1.5
3
2x

PL
12.5 12.5

3 10 30 2 x15 2 15 2 10 15 4 20 60
x

x x x x x
12.5 10 125 5 x 25 5 25 5 10 25 4 50 100

LATHE ATTACHMENTS
Attachments are additional equipments used for specific purposes
Examples: Stops, Thread chasing dial, Taper turning attachment,
Milling attachment, Grinding attachment.
Bar Stop

Thread chasing dial

I.

II.

When the length of the threaded part is short, after each cut, the
carriage is brought back to its starting position by reversing the
direction of rotation of lead screw. Therefore in this case the half
nut is not disengaged from the leadscrew so the relative position
is maintained.
When threading long jobs, the above mentioned method is not
suitable, as it requires lot of time. So after each cut the machine is
stopped, the carriage is disengaged from the leadscrew, by
disengaging the half nut. It is then brought back to the starting
position by rotating the hand wheel in suitable direction. If the
leadscrew pitch is an exact multiple of the pitch to be cut than the
half nut can engaged anywhere and the tool will follow the
previously cut groove. But if not, a reference dial present on the
right hand side of the apron called thread chasing dial has to be
used. A fixed zero mark is provided on the saddle surface adjacent
to the periphery of the dial. When the first cut is to be taken, the
half nut is engaged when zero mark and in subsequent cuts the
half nut should be engaged when the zero mark coincides with the
same mark on the dial.

Taper turning attachment

1) Bracket or
Frame

Attachment

2) Guide
block
3) Guide bar
4) Crossslide
5) Binder
screw

Cross slide
Feed
direction

Tool Post Grinder attachment

Milling attachment

 This is a milling head, comprising a motor, a small gear box and a

spindle to hold the milling cutter, mounted on the saddle after
removing the cross slide etc.
Milling attachments are generally used for making flat surfaces,
straight and helical grooves, splines, long and deep screw threads,
worms etc. in centre lathes by using suitable milling cutters.