Power requirement in turning: Machining time calculation:
required power depends on speed, feed, d.o.c, tool Calculate N (spindle rpm)= 1000V/Πd
material, work material –its hardness and
Time for single pass= L+overtravel/F.N( overtravel
machiniability and nature of machining. may be 2 -4 mm. either side depend on operator choice)
However, for a rough estimation of power in turning is
done by = cutting forcex cutting speed; Number of roughing pass: = (total allowance-
Cutting force= Kxdxf ( d=d.o.c in mm, f is feed in roughing allow.)/d.o.c
mm/rev, K=constant based on work material N/mm2) Number of finish pass= finish allow./ finish
d.o.c
problem1. estimate the actual machining time required for the component of length 120mm
to turn to 42mm. Available speed70,110,176,280,440,700,1100,1760, 2800. roughing speed
30mm/min and feed .24mm/rev. finish speed 60mm/min and feed .1mm/rev. finish allow.
0.75mm and blank dia 50mm. Find power required.
Sol: stock to be removed (50-42)/2= 4mm
for roughing-available stock=4-.75=3.25mm. Considering max d.o.c =2mm no.of pass=2
avg. dia = (50+42)/2=46mm.
N= 207rpm. Take N= 176,
Machinig time for roughing=2x (120+4)/(.24x176)
=5.82min
finishing rpm= 60x1000/πx42=440rpm
machining time for finishing=124/(.1x440)=2.77 min.
Problem1. A taper pin of length 80mm has taper
length 48mm.The larger dia 83mm and smaller dia
73mm.
(i)Calculate the angle for compound rest set up.
(ii) tail stock set over.
Problem2.calculate tail stock offset for a taper of 8
degree on a job of 120mm long and larger dia 80mm.
Problem3. calculate change gears to cut a single start
thread of 0.5 mm pitch on a centre lathe having a
lead screw of 12mm pitch.
Problem4. calculate the change gears to cut a single
start thread of 4 tpi on a centre lathe with lead
screw of 3mm pitch.
Reciprocating machine tools
Machining of flat surfaces (horizontal/vertical/inclined ) by means of straight line reciprocating
single point cutting tool is performed eiyher in shaper or planing machine or slotting machines.
▪In case of shaping work-piece is stationaery and cutting motion is provided in the cutting tool.
feed motion is provided in a plane perpendicular to cutting motion. Shaping is limited to small to
medium size of work-piece as stroke length is limited to 800-1000mm.
▪For planing prime cutting motion is given to the work-piece on table. Tool is moved slowly for
imparting feed motion. Planing are performed for heavy and large job of heavy duty. Having a box
type of configuration it is more rigid and able to take heavier cuts.
▪Slotter works on same principle as shaper but tool travels in vertical plane. Slotter is provided
with indexable rotary table about vertical axis. Table moves on saddle. Rotary alongwith two
straight line motion of table enhances its capability on working range. It is widely used for
machining blind holes, spilnes, keyways etc. machining of straight and curved die can also be
machined.
SHAPER
▪ Base: provide support, carry dead weight and dynamic load. Generally grey cast iron,
▪Housing: hollow casting, mounted on base. Houses drive mechanism for ram movement and
table. Top of housing are arranged with guideways for smooth motion of ram.
▪ Table: fastened at the front of housing, table is moved across the housing on cross rail for
feeding. It can also be moved up and down on housing to accommodate different size of work-
piece by elevating screw.
▪Ram: it carries the tool head at front and travels in guide to provide straight motion to the tool.
Based on the nature of drive- mechanical/hydraulic , shaper is classified.
Tool head:
it is connected to front of ram and hold the
cutting tool via tool holder on other side.
The tool post and tool block have snug fit in
the clapper box and hinged at upper edge.
During forward stroke, the tool block is
solidly supported against clapper box due to
cutting force. During return stroke, tool
block is free to swing forward from pivot.
This lift up the tool to avoid rubbing against
machined surface.
Tool head has a feed screw rotated by
handle for raising or lowering the tool to
adjust d.o.c. the slide is rotated on swivel
plate which enable tool head to be rotated
to take angular cuts. While machining
inclined surface, clapper box must be swung
along an arc away the work-piece surface.
Flat surface generation
• Nature of tool geometry
develops triangular hill valley
profile on machined surface
based on tool geometry and
operating parameters. The
height from valley to hill can be
reduced by decreasing
feed/stroke which reduces MRR.
Another option is to use broad
nose tool with high feed/stroke
but causes unavoidable
vibrational problem.
