Lathe

PowerPoint to accompany
Technology of Machine Tools

6th Edition
Krar Gill Smid
The Lathe
Section 11
Copyright The McGraw-Hill Companies, Inc. Permission required for reproduction or display.
History
Lathe forerunner of all machine tools First application was potter's wheel
Rotated clay and enabled it to be formed into cylindrical shape
Very versatile (many attachments)

Used for turning, tapering, form turning, screw cutting, facing, drilling, boring, spinning, grinding and polishing operations
Cutting tool fed either parallel or right angles
Special Types of Lathes

Engine lathe
Not production lathe, found in school shops, toolrooms, and jobbing shops Basic to all lathes
Turret lathe
Used when many duplicate parts required Equipped with multisided toolpost (turret) to which several different cutting tools mounted
Employed in given sequence

6th Edition
Krar Gill Smid
Engine Lathe Parts

Unit 45
Engine Lathe
Accurate and versatile machine Operations
Turning, tapering, form turning, threading, facing, drilling, boring, grinding, and polishing
Three common
Toolroom Heavy-duty Gap-bed
Lathe Size and Capacity

Designated by largest work diameter that can be swung over lathe ways and generally the maximum distance between centers Manufactured in wide range of sizes
Most common: 9- to 30- in. swing with capacity of 16 in. to 12 feet between centers Typical lathe: 13 in. swing, 6 ft long bed, 36 in. Average metric lathe: 230-330 mm swing and bed length of 500 3000 mm
Lathe Size
Indicated by the swing and the length of the bed
Parts of the Lathe

Headstock
Tailstock
Quick Change Gearbox
Bed
Carriage
Setting Speeds on a Lathe

Speeds measured in revolutions per minute
Changed by stepped pulleys or gear levers
Belt-driven lathe Safety Note!! NEVER change speeds

Various speeds obtained by changing flat belt when and back gear drive lathe is running. Speeds changed by moving speed levers into proper positions according to r/min chart fastened to headstock
Geared-head lathe
Shear Pins and Slip Clutches

Prevents damage to feed mechanism from overload or sudden torque Shear pins
Made of brass Found on feed rod, lead screw, and end gear train
Spring-loaded slip clutches

Found only on feed rods When feed mechanism overloaded, shear pin will break or slip clutch will slip causing feed to stop
Shear pin in end gear train prevents damage to the gears in case of an overload
Spring-ball clutch will slip when too much strain is applied to feed rod

6th Edition
Krar Gill Smid
Lathe Accessories
Unit 46
46-15
Lathe Accessories
Divided into two categories
Work-holding, -supporting, and driving devices
Lathe centers, chucks, faceplates Mandrels, steady and follower rests Lathe dogs, drive plates
Cutting-tool-holding devices
Straight and offset toolholders Threading toolholders, boring bars Turret-type toolposts
46-16
Lathe Centers
Work to be turned between centers must have center hole drilled in each end
Provides bearing surface
Support during cutting Most common have solid Morse taper shank 60 centers, steel with carbide tips Care to adjust and lubricate occasionally
46-17
Chucks
Used extensively for holding work for machining operations
Work large or unusual shape
Most commonly used lathe chucks

Three-jaw universal Four-jaw independent Collet chuck
46-18
Three-jaw Universal Chuck

Holds round and hexagonal work Grasps work quickly and accurate within few thousandths/inch Three jaws move simultaneously when adjusted by chuck wrench
Caused by scroll plate into which all three jaws fit
Two sets of jaw: outside chucking and inside chucking

46-19
Four-Jaw Independent Chuck

Used to hold round, square, hexagonal, and irregularly shaped workpieces Has four jaws
Each can be adjusted independently by chuck wrench
Jaws can be reversed to hold work by inside diameter
46-20
Headstock Spindles
Universal and independent chuck fitted to three types of headstock spindles 1. Threaded spindle nose
Screws on in a clockwise direction Held by lock nut that tightens on chuck
2. Tapered spindle nose
46-21
Headstock Spindles
3. Cam-lock spindle nose
Held by tightening cam-locks using T-wrench Chuck aligned by taper on spindle nose
Registration lines on spindle nose Registration lines on cam-lock Cam-locks Cam-lock mating stud on chuck or faceplate
46-22
Collet Chuck
Most accurate chuck Used for high-precision work Spring collets available to hold round, square, or hexagon-shaped workpieces Each collet has range of only few thousandths of an inch over or under size stamped on collet
46-23
Collet Chuck
Special adapter fitted into taper of headstock spindle, and hollow draw bar having internal thread inserted in opposite end of headstock spindle. It draws collet into tapered adapter causing collet to tighten on workpiece.
46-24
Types of Lathe Dogs

Standard bent-tail lathe dog
Most commonly used for round workpieces Available with square-head setscrews of headless setscrews
Straight-tail lathe dog

Driven by stud in driveplate Used in precision turning
46-25
Types of Lathe Dogs

Safety clamp lathe dog
Used to hold variety of work Wide range of adjustment
Clamp lathe dog

Wider range than others Used on all shapes
46-26
Left-Hand Offset Toolholder

Offset to the right Designed for machining work close to chuck or faceplate and cutting right to left Designated by letter L
46-27
Right-Hand Offset Toolholder

Offset to the left Designed for machining work close to the tailstock and cutting left to right
Also for facing operations
Designated by letter R
46-28
Straight Toolholder
General-purpose type Used for taking cuts in either direction and for general machining operations Designated by letter S
46-29
Toolholders for Indexable Carbide Inserts

Held in holder by cam action or clamps Types available
Conventional
Turret-type Heavy-duty toolposts
46-30
Cutting-Off (Parting) Tools

Used when work must be grooved or parted off Long, thin cutting-off blade locked securely in toolholder by either cam lock or locking nut Three types of parting toolholders
Left-hand Right-hand Straight
46-31
Threading Toolholder
Designed to hold special form-relieved thread-cutting tool
Has accurately ground 60 angle
Maintained throughout life of tool
Only top of cutting surface sharpened when becomes dull
46-32
Super Quick-Change Toolpost

6th Edition
Krar Gill Smid
Cutting Speed, Feed, and Depth of Cut

Unit 47
47-34
Cutting Speed
Rate at which point on work circumference travels past cutting tool Always expressed in feet per minute (ft/min) or meters per minute (m/min) Important to use correct speed for material
Too high: cutting-tool breaks down rapidly Too low: time lost, low production rates
47-35
Lathe Cutting Speeds in Feet and Meters per Minute Using High-Speed Steel Toolbit
Turning and Boring Rough Cut Finish Cut Material Tool steel Cast iron Bronze Machine steel 70 60 90 21 18 90 27 90 80 27 100 27 24 100 Threading 30 30 25 30 35 9 8 25 8 11 ft/min m/min ft/min m/min ft/min m/min
Aluminum
200
61
300
93
60
18
47-36
Calculating Lathe Spindle Speed

Given in revolutions per minute Cutting speed of metal and diameter of work must be known Proper spindle speed set by dividing CS (in/min) by circumference of work (in)
CS x 12 CS x 4 r/min D D
47-37
Example:
Calculate r/min required to rough-turn 2 in. diameter piece of machine steel (CS 90):
CS x 4 r/min D 90 x 4 r/min 180 2 CS x 320 r/min Metric Formula D
47-38
Lathe Feed
Distance cutting tool advances along length of work for every revolution of the spindle Feed of engine lathe dependent on speed of lead screw for feed rod
Speed controlled by change gears in quick-change gearbox
47-39
Two Cuts Used to Bring Diameter to Size

Roughing cut
Purpose to remove excess material quickly Coarse feed: surface finish not too important
.010- to .015-in. (0.25- to 0.4-mm)
Finishing cut
Used to bring diameter to size Fine feed: Produce good finish
.003- to .005-in (0.07- to 0.012-mm)
47-40
Feeds for Various Materials (using high-speed steel cutting tool)

Rough Cuts Material Machine steel in. mm in. Finish Cuts mm
.010.020 0.250.5
.003.010 0.
Tool steel
Cast iron Bronze
.010.020 0.250.5
.015.025 0.40.65
.003.010 0.070.2
.005.012 0.130.3
.015.025 0.40.65
.003.010 0.
Aluminum
.015.030 0.40.75
.005.010 0.130.2
47-41
Depth of Cut
Depth of chip taken by cutting tool and onehalf total amount removed from workpiece in one cut Only one roughing and one finishing cut
Roughing cut should be deep as possible to reduce diameter to within .030 to .040 in. (0.76 to 1 mm) of size required Finishing cut should not be less than .005 in.
47-42
Example: Depth of cut on a lathe
47-43
Factors Determining Depth of Rough-Turning Cut

Condition of machine Type and shape of cutting tool used
Rigidity of workpiece, machine, and cutting tool

Rate of feed
47-44
Inch System
Circumference of crossfeed and compound rest screw collars divided into 100-125 equal divisions
Each has value of .001 in.
Turn crossfeed screw clockwise 10 graduations, cutting tool moved .010 in. toward work Lathe revolves, so .010 depth of cut taken from entire work circumference reducing diameter .020 in.
Check machine for its' graduations
47-45
On machines where the workpiece revolves, the cutting tool should be set in for only half the amount to be removed from the diameter.
47-46
On machines where the workpiece does not revolve, the cutting tool should be set in for the amount of material to be removed.
47-47
Hints on Graduated Collar Use

1. Make sure collar is secure before setting a depth of cut 2. All depths of cut must be made by feeding cutting tool toward workpiece 3. If graduated collar turned past desired setting, must be turned backward half-turn and fed into proper setting to remove backlash 4. Never hold graduated collar when setting depth of cut
47-48
5. Graduated collar on compound rest can be used for accurately setting depth of cut
Shoulder turning
Compound rest set at 90 to cross-slide Lock carriage in place Spacing of shoulders to within .001 in. accuracy Compound rest swung to 30, amount removed from length of work = amount of feed on collar
Facing
Machining accurate diameters

Set compound rest to 8416' to the cross-slide .001 in movement = .0001-in. infeed movement
47-49
The compound rest is set at 8416' for making fine settings.

6th Edition
Krar Gill Smid
Lathe Safety
Unit 48
48-51
Safety
Be aware of safety requirements in any area of shop Always attempt to observe safety rules Failure results in:
Serious injury Resultant loss of time and pay Loss of production to company
48-52
Safety Precautions
Lathe hazardous if not operated properly Important to keep machine and surrounding area clean and tidy Accidents usually caused by carelessness
48-53
Safety Precautions
Always wear approved safety glasses Rollup sleeves, remove tie and tuck in loose clothing Never wear ring or watch
48-54
Safety Precautions
Do not operate lathe until understand controls Never operate machine if safety guards removed Stop lathe before measure work or clean, oil or adjust machine Do not use rag to clean work or machine when in operation
Rag can get caught and drag in hand
48-55
Safety Precautions
Never attempt to stop a lathe chuck or driveplate by hand Be sure chuck or faceplate mounted securely before starting
If loose, becomes dangerous missile
Always remove chuck wrench after use

Fly out and injure someone Become jammed, damaging wrench or lathe
48-56
Safety Precautions
Move carriage to farthest position of cut and revolve lathe spindle one turn by hand
Ensure all parts clear without jamming Prevent accident and damage to lathe
Keep floor around machine free from grease, oil, metal cuttings, tools and workpieces
Oil and grease can cause falls Objects on floor become tripping hazards
48-57
Safety Precautions
Avoid horseplay at all times Always remove chips with brush
Chips can cause cuts if use hands Chips become embedded if use cloths
Always remove sharp toolbit from toolholder when polishing, filing, cleaning, or making adjustments

6th Edition
Krar Gill Smid
Mounting, Removing, and Aligning Lathe Centers

Unit 49
49-59
Objectives
Mount and/or remove lathe centers properly
Align lathe centers by visual, trial-cut, and dial-indicator methods
49-60
Lathe Centers
Work machined between centers turned for some portion of length, then reversed, and other end finished Critical when machining work between centers that live center be absolutely true
Concentric work
49-61
To Mount Lathe Centers

Remove any burrs from lathe spindle, centers, or spindle sleeves Clean tapers on lathe centers and in headstock and tailstock spindles Partially insert cleaned center in lathe spindle Force center into spindle Follow same procedure when mounting tailstock center Check trueness of center
49-62
To Remove Lathe Centers

Live center
Use knockout bar pushed through headstock spindle (slight tap) Use cloth over center and hold to prevent damage
Dead center
Turn tailstock handwheel to draw spindle back into tailstock
End of screw contacts end of dead center, forcing it out of spindle
49-63
Alignment of Lathe Centers
Parallel diameter produced when lathe center aligned Three common methods used to align
1. Aligning centerlines on back of tailstock with each other
Only a visual check and not too accurate
49-64
Alignment of Lathe Centers

2. Using the trial-cut method where small cut taken from each end of work and diameters measured with a micrometer 3. Using parallel test bar and dial indicator
Fastest and most accurate method
49-65
To Align Centers by Adjusting the Tailstock

1. Loosen tailstock clamp nut or level 2. Loosen on of the adjusting screws, depending on direction tailstock must be moved and tighten other until line on top aligns with line on bottom half 3. Tighten screw to lock both halves in place 4. Make sure tailstock lines still aligned 5. Lock tailstock clamp nut or lever
49-66
To Align Centers by Trial-Cut Method

1. Take a light cut (~.005 in.) to true diameter from section A at tailstock end for .250 in. long 2. Stop feed and note reading on graduated collar of crossfeed handle 3. Move cutting tool away from work with crossfeed handle 4. Bring cutting tool close to headstock end
49-67

5. Return cutting tool to same graduated collar setting as at section A
6. Cut a .500-in (13 mm) length at section B and stop lathe

7. Measure both diameters with micrometer
49-68

8. If both diameters not same size, adjust tailstock either toward or away from cutting tool difference of two readings 9. Take another light cut at A and B at same crossfeed graduated collar setting. Measure diameters and adjust tailstock.
49-69
To Align Centers Using Dial Indicator and Test Bar

1. Clean lathe and work center, mount test bar 2. Adjust test bar snugly between centers and tighten tailstock spindle clamp 3. Mount dial indicator on toolpost or lathe carriage
Indicator plunger should be parallel to lathe bed and contact point set on center
49-70

4. Adjust cross-slide
Indicator registers approximately .025 in at tailstock, indicator bezel to 0
5. Move carriage by hand so indicator registers on diameter at headstock end and not indicator reading 6. If both indicator readings not same, adjust tailstock with adjusting screws until indicator registers same at both ends
49-71

7. Tighten adjusting screw that was loosened 8. Tighten tailstock clamp nut 9. Adjust tailstock spindle until test bar snug between lathe centers 10. Recheck indicator readings at both ends and adjust tailstock, if necessary

6th Edition
Krar Gill Smid
Grinding Lathe Cutting Tools

Unit 50
50-73
Grinding Lathe Cutting Tool

Wide variety of cutting tools for lathe
All have certain angles and clearances regardless of shape
Shape and Dimensions of General-purpose Lathe Toolbit
50-74
To Grind a General-Purpose Toolbit

1. Dress face of grinding wheel 2. Grip toolbit firmly, supporting hands on grinder toolrest 3. Hold toolbit at proper angel to grind cutting edge angle
Tilt bottom of toolbit toward wheel and grind 10 side relief or clearance angle
50-75
Cutting edge ~ In long and extend over width of toolbit 10 side relief or clearance angle
50-76
4. While grinding, move toolbit back and forth across face of wheel
Prevents grooving wheel
5. Toolbit must be cooled frequently during grinding

Never overheat toolbit! Never quench stellite or cemented-carbide tools Never grind carbides with aluminum oxide wheel
50-77
6. Grind end cutting edge so it forms angle of a little less than 90 with side cutting edge
Hold tool so that end cutting edge angle and end relief angle of 15 ground at same time
70 to 80 Point Angle
50-78
7. Using toolbit grinding gage, check amount of end relief when toolbit is in toolholder
50-79
8. Hold top of toolbit approximately 45 to axis of wheel and grind side rake to approximately 14
Do not grind below top of toolbit
Creates a chip trap
Side rake ground the length of the cutting edge
50-80
9. Grind slight radius on point of cutting tool, being sure to maintain same front and side clearance angle 10. With oilstone, hone cutting edge of toolbit slightly
Lengthen life of toolbit Enable it to produce better surface finish on workpiece

6th Edition
Krar Gill Smid
Machining Between Centers

Unit 52
52-82
Machining Between Centers

Training programs (schools)
Remove and replace work in lathe many times before completed Need assurance that machined diameter will run true with other diameters
Machining between centers saves time in setting up
Common operations
Facing, rough and finish-turning, shoulder turning, filing and polishing
52-83
Setting Up a Cutting Tool

1. Move toolpost to the left-hand side of the T-slot in the compound rest 2. Mount toolholder in toolpost so setscrew in toolholder 1 in. beyond toolpost
52-84
Heavy Cuts: Set toolholder at right angles to work
52-85
Setting Up a Cutting Tool: cont.

3. Insert proper cutting tool into toolholder, having tool extend .500 in. beyond toolholder and never more than twice its thickness 4. Set cutting-tool point to center height
Check it against lathe center point
5. Tighten toolpost securely to prevent it from moving during a cut
52-86
Purposes of a Trial Cut
Produce accurate turned diameter

Measured with micrometer
Set cutting-tool point to the diameter Set crossfeed micrometer collar to the diameter
52-87
Procedure to Take a Trial Cut

1. Set up workpiece and cutting tool as for turning 2. Set proper speeds and feed to suit material 3. Start lathe and position toolbit over work approximately .125 in. from end 4. Turn compound rest handle clockwise of a turn to remove any backlash
52-88
5. feed toolbit into work by turning crossfeed handle clockwise until light ring appears around entire circumference of work 6. Do NOT move crossfeed handle setting 7. Turn carriage handwheel until toolbit clears end of workpiece by about .060 in. 8. Turn crossfeed handle clockwise about .010 in. and take trial cut .250 in. along length of work 9. Disengage automatic feed and clear toolbit past end of work with carriage handwheel
52-89
10. Stop the lathe 11. Test accuracy of micrometer by cleaning and closing measuring faces and then measure trial-cut diameter 12. Calculate how much material must still be removed from diameter of work 13. Turn crossfeed handle clockwise amount of material to be removed
52-90
14. Take another trial cut .250 in. long and stop the lathe
15. Clear toolbit over end of work with carriage handwheel

16. Measure diameter and readjust crossfeed handle until diameter is correct 17. Machine diameter to length
52-91
Rough Turning
Removes as much metal as possible in shortest length of time Accuracy and surface finish are not important in this operation
.020- to .030-in. feed recommended
Work rough-turned to
Within .030 in. of finished size when removing up to .500 in. diameter Within .060 in. when removing > .500 in.
52-92
Procedure for Rough Turning

1. Set lathe to correct speed for type and size of material being cut 2. Adjust quick-change gearbox for a .010to .030-in. feed
Depends on depth of cut and condition of machine
3. Move toolholder to left-hand side of compound rest and set toolbit height to center
52-93
4. Tighten toolpost securely to prevent toolholder from moving during machining 5. Take light trial cut at right-hand end of work for a .250 in. length 6. Measure work and adjust toolbit for proper depth of cut 7. Cut along for .250 in., stop lathe, and check diameter for size
1. Diameter .030 in. over finish size
8. Readjust depth of cut, if necessary
52-94
Finish Turning
Follows rough turning Produces smooth surface finish and cuts work to an accurate size Factors affecting type of surface finish
Condition of cutting tool Rigidity of machine and work Lathe speeds and feeds
52-95
Procedure For Finish Turning

1. Make sure cutting edge of toolbit free from nicks, burrs, etc.
2. Set toolbit on center; check it against lathe center point 3. Set lathe to recommended speed and feed
52-96
4. Take light trial cut .250 in. long at righthand end of work
Produce true diameter Set cutting tool to diameter Set graduated collar to diameter
5. Stop lathe and measure diameter 6. Set depth of cut for half amount of material to be removed 7. Cut along for .250 in., stop lathe, check 8. Readjust depth of cut and finish-turn
52-97
Filing in a Lathe
Only to remove small amount of stock, remove burrs, or round off sharp corners Work should be turned to within .002 to .003 in. of size For safety, file with left hand so arms and hands kept clear of revolving chuck Remove toolbit from toolholder before filing Cover lathe bed with paper before filing
52-98
Procedure to File in a Lathe

1. Set spindle speed to twice that for turning 2. Mount work between centers, lubricate, and carefully adjust dead center in work 3. Move carriage as far to right as possible and remove toolpost 4. Disengage lead screw and feed rod 5. Select 10- or 12-in. mill file or long-angle lathe file
52-99
6. Start lathe 7. Grasp file handle in left hand and support file point with fingers of right hand
52-100
8. Apply light pressure and push file forward to its full length; release pressure on return stroke 9. Move file about half width of file for each stroke and continue filing until finished
Use 30-40 strokes per minute Roll sleeves above elbow Remove watches and rings Never use file without properly fitted handle Never apply too much pressure Clean file frequently with file brush
10. Safety precautions
52-101
Procedure for Polishing in a Lathe

1. Select correct type and grade of abrasive cloth for finish desired
Piece about 6 8 in. long and 1 in. wide Use aluminum oxide abrasive cloth for ferrous metals Use silicon carbide abrasive cloth should be used for nonferrous metals
2. Set lathe to run at high speed 3. Disengage feed rod and lead screw
52-102
4. Remove toolpost and toolholder 5. Lubricate and adjust dead center 6. Roll sleeves up above elbows and tuck in any loose clothing 7. Start lathe 8. Hold abrasive cloth on work 9. With right hand, press cloth firmly on work while tightly holding other end of abrasive cloth with left hand 10. Move cloth slowly back and forth
52-103
Shoulder
Shoulder: the change in diameters, or step, when turning more than one diameter on a piece of work Three common types of shoulders
Square Filleted Angular or Tapered
52-104
Three Types of Shoulders

6th Edition
Krar Gill Smid
Knurling, Grooving, and Form Turning

Unit 53
53-106
Knurling
Process if impressing a diamond-shaped or straight-line patter into the surface of the workpiece
Improve its appearance Provide better gripping surface Increase workpiece diameter when press fit required
53-107
Knurling
Diamond- and straight-pattern rolls available in three styles
Fine
Medium
Course
53-108
Knurling Tool
Toolpost-type toolholder on which pair of hardened-steel rolls mounted
Knurling tool with one set of rolls in self-centering head
Knurling tool with three sets of rolls in revolving head
53-109
Universal Knurling Tool System

Dovetailed shank and as many as seven interchangeable knurling heads that can produce wide range of knurling patterns Combines in one tool
Versatility Rigidity Ease of handling Simplicity
53-110
Procedure to Knurl in a Lathe

1. Mount work between centers and mark required length to be knurled
If work held in chuck for knurling, right end of work should be supported with revolving tailstock center
2. Set lathe to run at one-quarter speed required for turning 3. Set carriage feed to .015 to .030 in.
53-111
4. Set center of floating head of knurling tool even with dead-center point
5. Set knurling tool at right angles to workpiece and tighten it securely

53-112
6. Start machine and lightly touch rolls against work to check tracking
7. Move knurling tool to end of work so only half the roll face bears against work
8. Force knurling tool into work approximately .025 in. and start lathe
OR
Start lathe and then force knurling tool into work until diamond pattern come to point
53-113
9. Stop lathe and examine pattern 10. Once pattern correct, engage automatic carriage feed and apply cutting fluid to knurling rolls 11. Knurl to proper length and depth
Do not disengage feed until full length has been knurled; otherwise, rings will be formed on knurled pattern
12. If knurling pattern not to point after length has been knurled, reverse lathe feed and take another pass across work
53-114
Grooving
Done at end of thread to permit full travel of nut up to a shoulder or at edge of Square shoulder for proper fit Also called recessing, undercutting, or necking Rounded grooves used Round where there is strain on part V-shaped
53-115
Procedure to Cut a Groove

1. Grind toolbit to desired size and shape of groove required
2. Lay out location of groove 3. Set lathe to half the speed for turning 4. Mount workpiece in lathe
5. Set toolbit to center height
53-116
6. Locate toolbit on work at position where groove is to be cut 7. Start lathe and feed cutting tool toward work using crossfeed handle until toolbit marks work lightly 8. Hold crossfeed handle in position and set graduated collar to zero 9. Calculate how far crossfeed screw must be turned to cut groove to proper depth 10. Feed toolbit into work slowly using crossfeed handle
53-117
11. Apply cutting fluid to point of cutting tool

To ensure cutting tool will not bind in groove, move carriage slightly to left and to right while grooving Should chatter develop, reduce spindle speed
12. Stop lathe and check depth of groove with outside calipers or knife-edge verniers
Safety note: Always wear safety goggles when grooving on a lathe

6th Edition
Krar Gill Smid
Threads and Thread Cutting

Unit 55
55-119
Threads
Used for hundreds of years for holding parts together, making adjustments, and transmitting power and motion Art of producing threads continually improved Massed-produced by taps, dies, thread rolling, thread milling, and grinding
55-120
Threads
Thread
Helical ridge of uniform section formed on inside or outside of cylinder or cone
Used for several purposes:

Fasten devices such as screws, bolts, studs, and nuts Provide accurate measurement, as in micrometer Transmit motion Increase force
55-121
Thread Terminology
55-122
Thread Terminology
Screw thread
Helical ridge of uniform section formed on inside or outside of cylinder or cone
External thread
Cut on external surface or cone
Internal thread
Produced on inside of cylinder or cone
55-123
Major diameter
Largest diameter of external or internal thread
Minor diameter
Smallest diameter of external or internal thread
Pitch diameter
Diameter of imaginary cylinder that passes through thread at point where groove and thread widths are equal Equal to major diameter minus single depth of thread Tolerance and allowances given at pitch diameter line
55-124
Number of threads per inch

Number of crests or roots per inch of threaded section (Does not apply to metric threads)
Pitch
Distance from point on one thread to corresponding point on next thread, measured parallel to axis Expressed in millimeters for metric threads
Lead
Distance screw thread advances axially in one revolution (single-start thread, lead = pitch)
55-125
Root
Bottom surface joining sides of two adjacent threads External thread on minor diameter Internal thread on major diameter
Crest
Top surface joining two sides of thread External thread on major diameter Internal thread on minor diameter
Flank
Thread surface that connects crest with root
55-126
Depth of thread
Distance between crest and root measured perpendicular to axis
Angle of thread
Included angle between sides of thread measured in axial plane
Helix angle
Angle that thread makes with plane perpendicular to thread axis
55-127
Right-hand thread
Helical ridge of uniform cross section onto which nut is threaded in clockwise direction When cut on lathe, toolbit advanced from right to left
Left-hand thread
Helical ridge of uniform cross section onto which nut is threaded in counterclockwise direction When cut on lathe, toolbit advanced from left to right
55-128
Thread Forms
April, 1975 ISO came to an agreement covering standard metric thread profile
Specifies sizes and pitches for various threads in new ISO Metric Thread Standard Has 25 thread sizes, range in diameter from 1.6 to 100 mm Identified by letter M, nominal diameter, and pitch M 5 X 0.8
55-129
American National Standard Thread

Divided into four main series, all having same shape and proportions
National Coarse (NC) National Fine (NF) National Special (NS) National Pipe (NPT)
Has 60 angle with root and crest truncated to 1/8th the pitch Used in fabrication, machine construction
55-130
American National Standard Thread
.6134 D .6134 x P or N .125 F .125 x P or N
55-131
Unified Thread
Developed by U.S., Britain, and Canada for standardized thread system Combination of British Standard Whitworth and American National Standard Thread
55-132
.6134 N .5413 D (internal thread) .5413 x P or N .125 F (external thread) .125 x P or N .250 F (internal thread) .250 x P or N D (external thread) .6134 x P or
55-133
American National Acme Thread

Replacing square thread in many cases Used for feed screws, jacks, and vises
D = minimum .500P = maximum .500P + 0.010 F = .3707P C = .3707P - .0052 (for maximum depth)
55-134
Brown & Sharpe Worm Thread

Used to mesh worm gears and transmit motion between two shafts at right angles to each other but not in same plane
D = .6866P
F = .335P C = .310P
55-135
Square Thread
Being replaced by Acme thread because of difficulty in cutting it D = .500P Often found on vises F = .500P and jack screws C = .500P + .002
55-136
International Metric thread

Standardized thread used in Europe
D = 0.7035P (maximum) = 0.6855P (minimum) F = 0.125P R = 0.0633P (maximum) = 0.054P (minimum)
55-137
Thread Fits and Classifications

Fit
Relationship between two mating parts Determined by amount of clearance or interference when they are assembled
Nominal size
Designation used to identify size of part
Actual size
Measured size of thread or part Basic size: size from which tolerances are set
55-138
Allowance
Permissible difference between largest external thread and smallest internal thread Difference produces tightest fit acceptable for any given classification
The allowance for a 1 in.8 UNC Class 2A and 2B fit is: Minimum pitch diameter of the internal thread (2B) = .9188 in. Maximum pitch diameter of the external thread (2A) = .9168 in. Allowance = .002 in.
55-139
Tolerance
Variation permitted in part size May be expressed as plus, minus, or both Total tolerance is sum of plus and minus tolerances In Unified and National systems, tolerance is plus on external threads and minus on internal threads
The tolerance for a 1 in.8 UNC Class 2A thread is: Maximum pitch diameter of the external thread (2A) = .9168 in. Minimum pitch diameter of the external thread (2A) = .9100 in. Tolerance = .0068 in.
55-140
Limits
Maximum and minimum dimensions of part
The limits for a 1 in.8 UNC Class 2A thread are:
Maximum pitch diameter of the external thread (2A) = .9168 in.. Minimum pitch diameter of the external thread (2A) = .9100 in.
55-141
Three Categories of Unified Thread Fits

External threads classified as 1A, 2A, and 3A and internal threads as 1B, 2B, 3B Classes 1A and 1B
Threads for work that must be assembled Loosest fit
Classes 2A and 2B
Used for most commercial fasteners Medium or free fit
Classes 3A and 3B
Used where more accurate fit and lead required No allowance provided
55-142
Thread Calculations: Example 1

To cut a correct thread on a lathe, it is necessary first to make calculations so thread will have the proper dimensions. Calculate pitch, depth, minor diameter, and width of flat for a 10 UNC thread. D = single depth of thread P = pitch
Minor dia Major dia - ( D D) .75 - (.061 .061) .628 in.
1 1 P .100 in. tpi 10 P 1 1 Width of flat x D .61343 x P 8 8 10 .61343 x .100 .061in. .0125 in.
55-143
Thread Calculations: Example 2

What are the pitch, depth, minor diameter, width of crest and width of root for an M 6.3 X 1 thread?
P = pitch = 1 mm D = 0.54127 x 1 = 0.54 mm
Width of root 0.25 x P 0.25 x 1 0.25 mm
Minor dia Major dia - ( D D) 6.3 - (.54 .54) 5.22 mm Width of crest 0.125 x P 0.125 x 1 0.125 mm
55-144
Procedure to Set the QuickChange Gearbox for Threading

1. Check drawing for thread pitch required 2. From chart on quick-change gearbox, find whole number that represents pitch in threads per inch or in millimeters 3. With lathe stopped, engage tumbler lever in hole, which is in line with the pitch 4. Set top lever in proper position as indicated on chart
55-145
5. Engage sliding gear in or out as required 6. Turn lathe spindle by hand to ensure that lead screw revolves 7. Recheck lever settings to avoid errors
55-146
Thread-Chasing dial
Lathe spindle and lead screw must be in same relative position for each cut
Thread-chasing dial attached to carriage for this purpose
Dial has eight divisions

Even threads use any division Odd threads either numbered or unnumbered: not both
55-147
Thread Cutting
Produces a helical ridge of uniform section on workpiece Performed by taking successive cuts with threading toolbit of same shape as thread form required Work may be held between centers or in chuck
55-148
Procedure to Set Up a Lathe for Threading (60 Thread)

1. Set lathe speed to speed used for turning 2. Set quick-change gearbox for required pitch in threads per inch or in millimeters 3. Engage lead screw 4. Secure 60 threading toolbit and check angle using thread center gage 5. Set compound rest at 29 to right; set to left for left-hand thread
55-149
6. Set cutting tool to height of lathe center point 7. Mount work between centers
Make sure lathe dog is tight on work If work mounted in chuck, it must be held tightly
8. Set toolbit at right angles to work, using thread center gage 9. Arrange apron controls to allow split-nut lever to be engaged
55-150
Thread-Cutting Operation
Procedure to cut a 60 thread 1. Check major diameter of work for size 2. Start lathe and chamfer end of workpiece with side of threading tool to just below minor diameter of thread 3. Mark length to be threaded by cutting light groove at this point with threading tool while lathe revolving
55-151
4. Move carriage until point of threading tool near right-hand end of work
5. Turn crossfeed handle until threading tool close to diameter, but stop when handle is at 3 o'clock position
6. Hold crossfeed handle in this position and set graduated collar to zero
7. Turn compound rest handle until threading tool lightly marks work
55-152
8. Move carriage to right until toolbit clears end of work
9. Feed compound rest clockwise about .003 in.

10. Engage split-nut lever on correct line of thread-chasing dial and take trial cut along length to be threaded 11. At end of cut, turn crossfeed handle counterclockwise to move toolbit away from work and disengage split-nut lever
55-153
12. Stop lathe and check number of tpi with thread pitch gage, rule, or center gage
13. After each cut, turn carriage handwheel to bring toolbit to start of thread and return crossfeed handle to zero
14. Set depth of all threading cuts with compound rest handle
See Table 55.2 and Table 55.3
55-154
When tool is fed in at 29, most of the cutting is done by the leading edge of toolbit.
55-155
Table 55.2 Depth settings for cutting 60 national form threads*

Compound Rest Setting
tpi 24 20 18 16 14 0 .027 .036 30 .031 29 .0308
.0325 .0375 .037 .0417 .041 .0405 .0468 .046 .0465 .0537 .0525
13 Portion of.0577 taken .050 table .057 from .068 .0674 11 .059 textbook
55-156
15. Apply cutting fluid and take successive cuts until top (crest) and bottom (root) of thread are same width 16. Remove burrs from top of thread with file 17. Check thread with master nut and take further cuts
55-157
Six Ways to Check Threads

Depends on accuracy required:
1. Master nut or screw 2. Thread micrometer 3. Three wires 4. Thread roll or snap gage 5. Thread ring or plug gage 6. Optical comparator

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Technology of Machine Tools

Krar Gill Smid

Very versatile (many attachments)

Special Types of Lathes

Technology of Machine Tools

Krar Gill Smid

Engine Lathe Parts

Lathe Size and Capacity

Indicated by the swing and the length of the bed

Parts of the Lathe

Quick Change Gearbox

Setting Speeds on a Lathe

Belt-driven lathe Safety Note!! NEVER change speeds

Shear Pins and Slip Clutches

Spring-loaded slip clutches

Technology of Machine Tools

Krar Gill Smid

Most commonly used lathe chucks

Three-jaw Universal Chuck

Two sets of jaw: outside chucking and inside chucking

Four-Jaw Independent Chuck

Jaws can be reversed to hold work by inside diameter

2. Tapered spindle nose

Types of Lathe Dogs

Straight-tail lathe dog

Types of Lathe Dogs

Clamp lathe dog

Left-Hand Offset Toolholder

Right-Hand Offset Toolholder

Toolholders for Indexable Carbide Inserts

Cutting-Off (Parting) Tools

Super Quick-Change Toolpost

Technology of Machine Tools

Krar Gill Smid

Cutting Speed, Feed, and Depth of Cut

Calculating Lathe Spindle Speed

CS x 4 r/min D 90 x 4 r/min 180 2 CS x 320 r/min Metric Formula D

Two Cuts Used to Bring Diameter to Size

Feeds for Various Materials (using high-speed steel cutting tool)

Example: Depth of cut on a lathe

Factors Determining Depth of Rough-Turning Cut

Rigidity of workpiece, machine, and cutting tool

Check machine for its' graduations

Hints on Graduated Collar Use

Machining accurate diameters

The compound rest is set at 8416' for making fine settings.

Technology of Machine Tools

Krar Gill Smid

Always remove chuck wrench after use

Technology of Machine Tools

Krar Gill Smid

Mounting, Removing, and Aligning Lathe Centers

To Mount Lathe Centers

To Remove Lathe Centers

Alignment of Lathe Centers

Alignment of Lathe Centers

To Align Centers by Adjusting the Tailstock

To Align Centers by Trial-Cut Method

To Align Centers by Trial-Cut Method

6. Cut a .500-in (13 mm) length at section B and stop lathe

To Align Centers by Trial-Cut Method

To Align Centers Using Dial Indicator and Test Bar

To Align Centers Using Dial Indicator and Test Bar