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MFG - Week10 Turning 2025 1 Watermark

The document provides an overview of turning processes in manufacturing engineering, detailing various operations such as turning, facing, boring, and threading, typically performed on a lathe. It discusses the mechanics of turning, including tool geometry, material removal rates, and the forces involved during the process. Additionally, it outlines design and operation guidelines for effective machining practices.

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7 views17 pages

MFG - Week10 Turning 2025 1 Watermark

The document provides an overview of turning processes in manufacturing engineering, detailing various operations such as turning, facing, boring, and threading, typically performed on a lathe. It discusses the mechanics of turning, including tool geometry, material removal rates, and the forces involved during the process. Additionally, it outlines design and operation guidelines for effective machining practices.

Uploaded by

lovelivemaki905
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Introduction to Manufacturing Engineering

( )
Week 10

Turning Processes

Prof. Sang Won Lee

SKKUME
Machining Material Removal Processes
Turning process ( )
Introduction
Turning ( )
The part is rotated while it is being machined.
The starting material is generally a workpiece that has been made by other
processes, such as casting, forging, extrusion, drawing, or powder metallurgy.
Turning processes, which typically are carried out on a lathe.
Turning operations
Turning: to produce straight, conical, curved, or grooved workpieces
workpieces, such as shafts, spindles,
and pins
Facing: to produce a flat surface at the end of the part and perpendicular to its axis
Cutting with form tools: to produce various axisymmetric shapes for functional or for aesthetic
purposes
Boring: to enlarge a hole or cylindrical cavity made by a previous process or to produce
circular internal grooves
Drilling: to produce a hole, which then may be followed by boring it to improve its dimensional
accuracy and surface finish
Parting: also called cutting off, to remove a piece from the end of a part, as is done in the
production of slugs or blanks for additional processing into discrete products Threading: to
produce external or internal threads
Knurling: to produce a regularly shaped roughness on cylindrical surfaces, as in making
knobs and handles
Introduction

FIGURE 23.1 Miscellaneous operations that can be performed on a lathe; note that all parts are circular. The tools used,
their shape, and the processing parameters are described throughout this chapter.
Introduction
Introduction
Lathe ( )

FIGURE 23.2 General view of a typical lathe, showing various components.


Source: Courtesy of South Bend Lathe Co.
Turning Process
Turning operation and schematic illustration
Performed at various (a) rotational speeds, N, of the workpiece clamped in a
spindle, (b) depths of cut, d, and (c) feeds, f

FIGURE 23.3 (a) A turning operation, showing insert and chip removal; the machine tool is traveling from right
to left in this photograph. (b) Schematic illustration of the basic turning operation, showing depth of cut, d; feed,
f; and spindle rotational speed, N, in rev/min. The cutting speed is the surface speed of the workpiece at the tool
tip. Source: (a) Courtesy of Kennametal Inc.
Turning Process
Single-point cutting tool for turning
Tool angles can be varied according to the workpiece materials.

FIGURE 23.4 Designations for a right


right-hand cutting tool, meaning that the tool travels from right to left, as
shown in Fig. 23.3b.
Turning Process
Single-point cutting tool for turning
Tool geometry
Rake angle: controlling both the direction of chip flow and the strength of the tool tip
Positive rake angle - reducing forces and temperatures, but premature tool chipping and
failure
Side rake angle: more important than the back rake angle
Usually controls the direction of chip flow ((-5
5 deg. ~ +5 deg.)
Cutting-edge angle chip formation, tool strength, and cutting forces to various degrees
Relief angle: controls interference and rubbing at the tool workpiece interface (~ 5 deg.)
Too large: the tool tip may chip off; Too small: flank wear may be excessive
Nose radius surface finish and tool-tip
tool strength
Smaller: rougher surface finish and lower tool strength
Larger: lead to tool chatter
Turning Process
Material-removal Rate (MRR) ( )
The volume of material removed per unit time [mm3/min]

MRR avg dfN dfV


Davg D0 D f /2
d : depth of cut (mm)
f : feed (mm/rev)
N : rotational speed
ed (rev/min)
V : cutting speed

t l/(fN)
l/( N)
t : cut
cutting time
ime for a workpiece of length l
Turning Process
Material-removal Rate (MRR)
( )
The volume of material removed per
unit time [mm3/min]
Turning Process
Forces in Turning
Fc: cutting force
downward on the tool tip, energy required for cutting
Ft: thrust force (also called feed force)
push the tool toward the right and
away from the chuck
Fr: radial force
push the tool away from
the workpiece

FIGURE 23.5 Forces acting on a cutting tool in


turning. Fc is the cutting force, Ft is the thrust or
feed force (in the direction of feed), and Fr is the
radial force that tends to push the tool away from
the workpiece being machined.
Turning Process
Roughing and Finishing Cuts
Roughing cuts
Typically at high feed rates and large depths of cut
MRRs , Dimensional tolerance & Surface roughness
Finishing cuts
Typically at a lower feed and smaller depth of cut
Good surface finish
Tool materials, Feeds and Cutting speeds

FIGURE 23.6 The range of applicable


cutting speeds and feeds for a variety of
tool materials.
Lathe and Lathe Operations
Lathe the oldest machine tool (metal working late 1700s)
Components
Bed( ) supports all major components (gray or nodular cast iron) and
has two ways
Carriage( ) -slides
slides along the ways and consists of the cross
cross-slide, tool
post, and apron
Headstock( )
Fixed to the bed
Equipped with motors, pulleys and V V-belts
V- belts that supply power to a spindle
Hollow spindle on which work
work-holding
holding devices (such as chucks and collets)
are mounted
Tailstock( )
Slides along the ways and can be clamped at any position
supports the other end of the workpiece
Drills and reamers can be mounted on the tailstock quill to drill axial holes in
the workpiece.
Lead screw( )
Specifications swing (max. diameter of the workspiece), max. distance
between the headstock and tailstock centers, length of the bed
Lathe and Lathe Operations
Work-holding Devices and Accessories

FIGURE 23.8 (a) and (b) Schematic illustrations of a draw-in type of collet. The workpiece is placed in the collet hole, and
the conical surfaces of the collet are forced inward by pulling it with a draw bar into the sleeve. (c) A push-out type of collet.
(d) Work holding of a workpiece on a face plate.
Lathe and Lathe Operations
Computer-numerical-control (CNC) Lathe ( )

FIGURE 23.11 (a) A computer-numerical-control lathe; note the two turrets. These machines have higher power and
spindle speed than other lathes in order to take advantage of new cutting tools with enhanced properties. (b) A typical
turret equipped with 10 tools, some of which are powered.
Design Considerations and Guidelines
Design guidelines
Parts should be designed so that they can be fixtured and clamped easily into work
work-holding
devices.
The dimensional accuracy and surface finish specified should be as wide as permissible, but
the part must still function properly.
Sharp corners, tapers, steps, and major dimensional variations in the part should be avoided.
Blanks to be machined should be as close to final dimensions as possible, such as by near
near-
net-shape
shape forming, so as to reduce production cycle time.
Parts should be designed so that cutting tools can travel across the workpiece without any
obstruction.
Design features should be such that commercially available standard cutting tools, inserts,
and toolholders can be used.
Workpiece materials should preferably be selected for their machinability.
Operation guidelines
Minimize tool overhang
Support the workpiece rigidly
Use machine tools with high stiffness and high damping capacity
When tools begin to vibrate and chatter (Section 25.4), modify one or more of the process
parameters, such as tool geometry, cutting speed, feed rate, depth of cut, and cutting fluid

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