4.

Lathe, Shaper, and Milling

1. Turning.
Turning is A single point cutting tool removes material from a rotating work piece to
generate a cylindrical shape and it is Performed on a machine tool called a lathe
2. Taper turning
Taper turning:
● A conical surface produced on a lathe is called taper turning.
● The tool moves at an angle to the axis of rotation.

3. Boring.

Boring: Boring is the operation of enlarging the previously drilled hole with the aid of
single point cutting tool called boring tool.

[Link].

Reaming: A reamer is a type of rotary cutting tool used in metalworking. Precision reamers
are designed to enlarge the size of a previously formed hole by a small amount but with
a high degree of accuracy to leave smooth sides. The process of enlarging the hole is
called reaming.

5. Shaper.

The Shaper:

 Machine tool used for shaping operation is called shaper.

 Designed for machining flat surfaces on small sized jobs.

If the size of the job is large, then planning is used.

 In a shaper, the work piece is held stationary during cutting, while the tool
reciprocates horizontally. The feed and depth of cut are normally provided by
moving the work. Such shaper is called a horizontal shaper.
6. Functions of Shaper.

Shaper is a machine tool used primarily for:

[Link] a flat or plane surface which may be in horizontal, a vertical or
an angular plane.
[Link] Making slots, slots, grooves and keyways
[Link] contour of concave/convex or a combination of these.

7. “Milling” operation.

Milling is the process of machining flat, curved, or irregular surfaces by feeding the
workpiece against a rotating cutter containing a number of cutting edges. The milling
machine consists basically of a motor driven spindle, which mounts and revolves the
milling cutter, and a reciprocating adjustable worktable, which mounts and feeds the
workpiece.
8. Different Type of Milling Operations

 Plain Milling
 End Milling
 Gang Milling
 Straddle Milling

9. Plain Milling.

Plain milling is the milling of a flat surface with the axis of the cutter parallel to the
machining surface. It can be carried out either on a horizontal machine or a vertical
machine as shown in figure.
10. End Milling.

End Milling is the milling of a flat surface with the axis of the cutter perpendicular to the
machining surface as shown in figure

11. Gang Milling.

Gang milling is a horizontal milling operation that utilises three or more milling cutters
grouped together for the milling of a complex surface in one pass. As illustrated in
figure, different type and size of cutters should be selected for achieving the desire
profile on the workpiece.

12. Straddle Milling.

Straddle Milling: In straddle milling, a group of spacers is mounted in between two side
and face milling cutters on the spindle arbor as shown in figure . for the milling of two
surfaces parallel to each other at a given distance.
13. Explain about thread cutting process.

 Thread cutting is the process of producing a helical groove on a cylindrical

component.
 The saddle receives motion from lead screw.
 In one revolution of the spindle, the tool traverse a distance equal to the pitch of
the thread to be cut.
 This is achieved by a gear train.

14. Working principle of lathe.

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

 Center or Engine Lathe

 Speed Lathe
 Capstan and Turret Lathe
 Tool Room Lathe
 Bench Lathe
 Automatic Lathe
 Special Purpose and
 CNC Lathe Machine
[Link] Operation.

Knurling: The operation is performed for producing indentations on a part of a workpiece.

Knurling allows hands or fingers to get a better grip on the knurled object than would be
provided by the originally smooth metal surface. Occasionally, the knurled pattern is a
series of straight ridges or a helix of "straight" ridges rather than the more-usual criss-
cross pattern.

17. Different types of shapers.

Shapers can be classified into many types based on several criteria:

1. Based on the type of driving mechanism used

 Crank and slotted lever driving mechanism type

 Whitworth quick return driving mechanism type
 Hydraulic driving mechanism type
 2. Based on the table design

 Plain Shaper
 Universal Shaper

3. Based on the position of the reciprocating ram used

 Horizontal shaping machine (Most common type of shaper used)

 Vertical shaping machine
 Travelling head shaping machine

4. Based on the type of cutting stroke of the tool

 Push out type

 Draw cut type

18. Explain Milling Processes.

Milling is a metal removal process by means of using a rotating cutter having one or more
cutting teeth as illustrated in figure . Cutting action is carried out by feeding the workpiece
against the rotating cutter. Thus, the spindle speed, the table feed, the depth of cut, and
the rotating direction of the cutter become the main parameters of the process. Good
results can only be achieved with a well balanced settings of these parameters.
19. Explain about Up-cut Milling.
20. Explain about down-cut milling.
21. Difference between “Shaping” and “Planing”?

22. Explain the Shaper with line diagram.

The Shaper Construction: The main parts of the Shaper machine is

 Base
 Body (Pillar, Frame, Column )
 Cross rail, Ram
 Tool head (Tool Post, Tool Slide, Clamper Box Block )
23. Specifications of Lathe.

Specifications of Lathe
1) a) Height of centers
b) type of bed(straight , semi gap, or gap)
c) center distance
2) a)swing over bed
b) swing over cross slide
 c) swing in gap
d) gap in front of face place
3) a) spindle speeds range
b) spindle nose
c) spindle bore
d) taper nose
4) a)Metric thread piches
b)lead screw pitch
c)longitudinal feeds
d)cross feeds
5) a) cross slide travel
b) top slide travel
c) tool section
6) a)tailstock sleeve travel
b)taper in sleeve bore
7) Motor horsepower and RPM
8) shipping dimensions ---(length*width*height*weight)

24. Draw the line diagram of Lathe and write the main parts names.
25. Lathe operations, explain about turning and Reaming.

Lathe Operations:
 Turning,
 Facing,
 Taper Turning,
 Step Turning,
 Eccemtric Turning ,
 Parting-Off,
 Drilling,
 Boring,
 Reaming,
 Knurling,
 Thread Cutting….
Turning:

Turning is the machining operation in which excess material is removed by rotating the
work piece against a cutting tool.

Reaming.

 Reaming is the process of making hole smoothly and accurately to size.

 The work with drilled hole is held in a chuck and reamers are inserted in tailstock
spindle and rotated
26. Explain taper turning setup with a neat sketch

Taper turning:

 A conical surface produced on a lathe is called taper turning.

 The tool moves at an angle to the axis of rotation.

The simplest way to produce a taper is to use a form tool.

 It is limited to very short tapers.

 The angle is dictated to angle of the tool.
 Care is needed to avoid poor finishing.

The second easiest way to produce a taper will be to offset the compound slide.

 It is limited to short tapers.

 The angle set on the compound slide is half the included angle of the
taper required.
 Care is needed to avoid poor finishing.
 For tapers on longer shafts, you can offset the tailstock from the centre line.

 The limitations are on the size of taper, it will only be a shallow taper.
 Calculations on the offset will be needed.
 The tailstock must be reset after taper turning, the offset will not be
obvious to another user.

27. Explain the Working Principle of Shaping machine.

Working Principle of Shaping machine The main functions of shaping machines are to
produce flat surfaces in different planes.

Above fig. shows the basic principle of generation of flat surface by shaping machine.
The cutting motion provided by the linear forward motion of the reciprocating tool and the
intermittent feed motion provided by the slow transverse motion of the job along with the
bed result in producing a flat surface by gradual removal of excess material layer by layer
in the form of chips. The vertical infeed is given either by descending the tool holder or
raising the bed or both. Straight grooves of various curved sections are also made in
shaping machines by using specific form tools. The single point straight or form tool is
clamped in the vertical slide which is mounted at the front face of the reciprocating ram
whereas the workpiece is directly or indirectly through a vice is mounted on the bed.
28. Write the applications of Shaping machine.

Various applications of Shaping machine

It is already mentioned that shaping machines are neither productive nor versatile.
However, its limited applications include:

Machining flat surfaces in different planes. Fig. shows how flat surfaces are produced
in shaping machines by single point cutting tools in

(a) horizontal,

(b) vertical and

(c) inclined planes.

29. What are the different types of Milling machines? Explain briefly
30. Explain the working principle of Milling.