Self-instruction manual for working on a metal lathe. Lathe and turning. Processing parts on lathes

Turner has been and remains one of the most in demand. Wood and metal processing is the area of application of turning craft. To optimize labor, accuracy and speed of manufacturing parts, there are many machines and other equipment that are constantly being improved, allowing the master to perform the most complex and precise operations.

Specifics of the term

Turning has come a long way of development before it acquired the forms of production that we know now. At the present stage, this includes cutting metal and non-metallic materials and alloys, threading different types on parts, turning individual elements of equipment and applying various notches, grooves, etc. to them, turning wooden blanks to give them the desired shape. The final products of production are the familiar bolts and nuts, valves and adapters, plugs and many other fittings, as well as various housings and other parts.

Turning is closely related to turning production. This concept fits, in principle, any enterprise where appropriate machines and other tools are installed for working with different materials, from single orders to an entire series or line. In order to be able to perform the necessary actions and understand each stage of the operation, you need to have a good knowledge of the properties of heat treatments of materials, navigate the drawings and have many other knowledge. Therefore, turning is considered a complex science, interacting most closely with related ones.

History and traditions

If we go back to the distant past, we can remember that our ancestors used dishes that were hollowed out, carved and turned from wood, as well as household items, furniture and even toys. This was done first in a crude way and with improvised means, and then on devices that resembled lathes and became their prototypes. This is how the turned brothers, bowls, and cups appeared. Consequently, it is from there that modern turning takes its origins. To this day, turned parts and entire products are found in folk crafts. wide application. For example, various kitchen accessories: stands for hot kettles, pots and pans, etc.; interior design accessories: wooden “curtains” made of polished round pieces of wood or sticks, souvenir sculptures and figurines. Lathes process almost any type of wood quickly and accurately, with all the necessary precision. In this case, the size of the product does not play a special role. You can sharpen both a miniature netsuke, indicating even the smallest details, and a large product. Such objects give special beauty and expressiveness

there is artistic painting.

With the development of industry and the active use of iron in production, metal turning, technically close to woodworking, arose. Now no one can do without him manufacturing process. The most complex mechanisms are basically made from parts created on lathes. Therefore, a turner, especially a milling machine operator, is always in demand at enterprises. And training in turning is carried out in all specialized vocational schools and in many large plants and factories.

Summary

The profession of a turner, interesting and difficult, requires great self-discipline, accuracy and constant self-improvement. This is one of those specialties that support the most complex high-tech processes.

Questions about turning

TO category:

Turning

Questions about turning

1. What are the characteristics of parts obtained by processing on a lathe?
2. Name the main components of a screw-cutting lathe and indicate their purpose.
3. What is the essence of the metal cutting process?
4. What surfaces are distinguished on the workpiece being processed?
5. Name the main parts, elements and angles of a turning tool.
6. What is depth of cut, cutting speed?
7. How does the spindle speed depend on the permissible cutting speed and workpiece diameter?
8. What are cutting fluids used for?

1. What are the requirements for cylindrical surfaces?
2. Name the main parts of a three-jaw self-centering chuck.
3. What are rigid and rotating centers used for and how are they designed?
4. What cutters are used for processing external cylindrical surfaces?
5. Name the types and measures to prevent defects when turning external cylindrical surfaces.
6. What is the purpose of the floating center and how is it designed?
7. How and with what are external surfaces controlled?

1. What is a technological process and what elements does it consist of?
2. What is an allowance, for what reasons is the processing allowance assigned?
3. What is an installation base, in what cases
4. Name the rules for choosing rough and pure bases.

1. Name the main parts and elements of a twist drill.
2. Name the main causes of drill failures, types of defects during drilling and measures to prevent them.
3. How do you control the length and diameter of the boring hole?
4. How are internal grooves bored?
5. Name the main reasons and measures to prevent defects during countersinking and reaming.
6. How is the concentricity of the outer surface and hole ensured when processing simple bushings from bar stock?

1. What elements characterize the thread?
2. What is the difference between metric thread and inch thread?
3. How does the threading head work and work?
4. Name the parts, elements and indicate the features of the geometry of the ball.
5. What are the advantages of thread rolling?
6. How and with what are external and internal threads controlled?

1. Name the basic data technical specifications flock 1K62.
2. Show on the kinematic diagram of the 1K62 machine the devices for regulating the speed of rotation of the Schandel.
3. How many speed levels during forward and reverse rotation of the spindle does the gearbox of the 1K62 machine provide?
4. How many electric motors are 1K62?
5. Show on the kinematic chain of longitudinal and feeds.
6. What is the purpose of the apron safety coupling and how does it work?
7. How is the tailstock of the 1K62 machine designed?

1. How is the 16K20 machine configured for cutting metric, inch, modular and pitch threads?
2. Name the main design features of the 16K20 machine components.

1. How do you check a lathe for radial runout of the spindle, alignment of the axes of the headstock spindle and tailstock quill? 2 Name the main directions of modernization of old lathes.
2. Changing the lubricant in the gearbox, feed box and caliper apron.
3. During work, do not place workpieces, parts, cutting and measuring tools on the guides of the frame; use wooden or foam tablets for this purpose.
4. To securely fasten the tool holder, do not tap the handle with a hammer or metal rod. Periodically, the tool holder is removed, the supporting surface is cleaned of dirt, washed with kerosene and the sockets of the clamps are wiped.
5. Do not leave the machine engine turned on for a long time, stop the machine when measuring workpieces (parts) being processed, during interruptions in the power supply, during adjustment or repair work at the machine. When performing manual work (reaming, cutting threads with a tap, drilling with manual quill feed, polishing), when automatic feed of the caliper is not required, turn off the feed mechanism by placing the bit handle in the neutral position.
6. Carefully clean the machine after work, make sure that no chips, dirt, or moisture remain on the guides of the bed and supports. Wiping materials used to clean shavings should not leave marks or lint on the surfaces being wiped.

1. How are shaped surfaces processed using a combination of two feeds?
2. What copying devices are used for processing shaped surfaces?
3. How are shaped surfaces controlled?
4. What is the method of processing spherical (spherical) surfaces using a measuring tool?
5. List the main types of defects when processing shaped surfaces and indicate measures to prevent them.

1. What are the methods for lapping and polishing on a lathe?
2. What is the essence of surface plastic deformation and what tools are used to perform it?
3. How are corrugations rolled?
4. Name the main types, causes and measures to prevent defects when rolling corrugations.

1. What geometry should a thread cutter have?
2. For what types of work are thread dies used?
3. Derive a formula for calculating the gear ratio of the replacement gears of a guitar for setting up the machine “directly” when cutting threads.
4. Select replacement guitar gears for cutting 3mm pitch threads.
5. How are trapezoidal and rectangular threads cut?
6. Explain the principle of high-speed (“vortex”) thread cutting.
7. List the main types of defects when cutting threads with a cutter, their causes and preventive measures.

1. How is the workpiece secured to a conical or shaped surface?
2. Under what conditions is it possible to combine the processing of complex surfaces with the processing of cylindrical surfaces in one operation?
3. How the workpieces are secured complex shape on the faceplate?
4. Why and how is the workpiece balanced on the faceplate?
5. What kind of SPs are used on lathes?
6. How are shafts classified by stiffness?
7. How are eccentric and crankshafts processed?

1. Explain the essence of the process of chip formation.
2. Why does cutting heat arise and how is it distributed?
3. What is cold hardening?
4. Why does build-up form and how does it affect the quality of the surface?
5. Why do vibrations occur during the cutting process and in what ways are their harmful effects overcome?

1. What are the requirements for tool materials?
2. List the main grades and properties of high-speed tool steels.
3. Name the main brands of hard alloys for processing cast iron and steel.
4. What parts and elements does a turning tool have?
5. Name the angles of the cutter in plan and in the main cutting plane.
6. On what factors does the choice of the clearance angle depend?
7. In what cases is a cutter with a negative rake angle used?
8. How does the installation of the cutter relative to the center affect the angles of the cutter?
9. What is the angle of inclination of the cutting edge and in what cases is it taken as a positive value?
10. What are the advantages of diamond sharpening and finishing of cutters?
11. How is the cutter geometry controlled?
12. What are the advantages of cutters with mechanical fastening of multi-edge non-grinding carbide inserts?

1. How does cutter wear occur and what explains it?
2. How does tool life depend on cutting speed?
3. How does the leading angle affect cutting speed?
4. Why does increasing the depth of cut have less effect on the decline in tool life than increasing the feed?
5. How do the mechanical properties of the material being processed, the cross-sectional dimensions of the holder and the cutting fluid affect the cutting speed?
6. What components is the cutting resistance force divided into, what is their ratio?
7. Write the formula for cutting force, explain the influence of depth of cut and feed on cutting force.

1. Give a general classification of parts whose blanks are processed on lathes.
2. How are blanks of parts such as cups and thin-walled bushings processed?
3. How are parts such as disks and rings made on a lathe?
4. What is the essence of processing using a standard technological process?

1. Name the main steps to increase labor productivity in turning.
2. What are the advantages of power and rotary turning?
3. How does a pneumatic chuck work?
4. Tell us about the methods of multi-cutting adjustment of a jukar machine.
5. Give examples of rational use of the rear tool holder.
6. How do I quickly replace cutting tools mounted in the tool holder and in the tailstock quill?
7. In what sequence is the lathe set up to work on the drum stop?

1. What features do frontal and rotary machines have?
2. Tell us about the structure and operation of turret machines.
3. What is the difference between the semi-automatic hydrocopier 1722 and the semi-automatic 1A730? 4 How is the feed movement carried out on a Yu-car machine?

1. What is production mechanization?
2. How does automation differ from mechanization?
3. Describe the means of intra-shop transport.

1. What devices does the automatic control system consist of?
2. What is the difference between CNC and other program control systems?
3. How does a stepper motor work and work?

1. What safety rules must be followed on site and in machine shops?
2. List the basic safety rules when working on a lathe.
3. What safety precautions should be followed when sharpening a tool?

ABOUTlearning turning - this is a section of the site that contains information not only for professional turners, but also for turning students. Turning is very promising, because in our time, try to find a real turner.

Pprofession of a turnerhighly paid, so if you are not lazy and want to earn good money for your work, start learning the basics of turning on our website.

The lathe is designed for processing by cutting a body by rotation, including rotating end planes and helical surfaces. In addition, work not related to cutting can be performed on lathes.

List of all lathe capabilities very big and consideration lathe functions will take a lot of time. AND Learn all the functions of a lathe in one lesson it’s practically impossible, but gradually we will get to know everyone intricacies of turning. Turning training we will start using the following list turning lessons.

Turning lessons :

Lesson #1. Lathe device

Lesson #2. Working on a lathe or operating a lathe

Content:

1. Tocar cutters

Tocar cutters- These are special cutting tools that are used for turning parts.

TOkar cutters are used as the main tool for turning, planing, and other work on machine tools.

DFor high-quality and precise processing of the part and achieving the required shapes and sizes of the product, a turning cutter is used, with which layers of material are sequentially cut off.

INIn the process of cutting a layer of material, the cutter cuts into it, removing chips from its surface.

ABOUTThe sharp edge of the cutter is its main working element.

WITHOver time, the cutter is subject to wear, as evidenced by chipping of the cutting part (edge). To use a turning cutter in the future, it must be re-sharpened.

1.1 The device of a turning cutter

1.2 Feed of turning tool

1.3 Cutting metal with a turning tool

1.4 Cutting surface

1.5 Cutter design

1.6 Turning tool angles

1.7 Wear and durability of cutter

1.8 Cutters for lathes

1.9 Materials for turning tools

1.10 Designs of turning tools

1.11 Manufacturing of carbide cutters

1.12 Manufacturing of cutters with blades

1.13 Manufacturing of high-speed and carbon cutters

2. Tokar machine

Tokar machine -This is a machine for processing parts by cutting and turning.

ABOUTThe main works performed on lathes are: turning, boring and turning of various types of surfaces, threading, processing the ends of parts, drilling, countersinking and cutting holes.

Zthe workpiece is installed in the center and rotates using a spindle, then the feed mechanism moves the cutting tool, the cutter, together with the support of the running shaft.

DTo perform additional types of operations on the machine, such as grinding, drilling, milling holes, additional equipment is installed on the machines.

TThe window-screw-cutting machine is designed for lathe work with non-ferrous and ferrous metals.

TThe window-screw-cutting machine consists of:

WITHtannin is the main part of the machine, which is the framework for mounting all the mechanisms of the machine.
Pheadstock – it is also called the spindle headstock, due to the placement of the spindle, gearbox and other elements in it.
TOThe feed box provides movement from the spindle to the support.
WITHSupport – designed to secure the cutting tool and feed it.
Fartuh - necessary to convert the rotation of the roller into the movement of the caliper.
Ccenter - an installation for supporting a workpiece or tool.

2.1 Screw-cutting lathe model 1A62

2.2 Friction clutch of lathe model IA62

2.3 Tailstock design

2.4 Design of a screw-cutting lathe

2.5 Care of the lathe

2.6 Adjusting the lathe

2.7 Lathe safety

2.8 Devices for securing parts processed in centers

2.9 Lathe accuracy

Zhere you will find out how to determine and adjust the accuracy of a lathe, master concepts such as rigidity during turning, machining on mandrels, working with a mandrel.

Pravila work With spindle mandrels. In the turning section we consider screw cutting lathes, such as screw-cutting lathe 1A62. More details about turning tools, their types, turning tool materials their design. Wear and durability of the cutter also have a significant impact on turning.

The most common methods for manufacturing parts with given geometric parameters include metal turning. The essence of this technique, which also makes it possible to obtain a surface with the required roughness, is that the excess layer of metal is removed from the workpiece.

Principles of turning

The technology of metal turning involves the use of special machines and cutting tools (cutters, drills, reamers, etc.), through which a layer of metal of the required size is removed from the part. is performed through a combination of two movements: the main one (rotation of the workpiece fixed in a chuck or faceplate) and the feed movement performed by the tool when processing parts to the specified parameters of their size, shape and surface quality.

Due to the fact that there are many techniques for combining these movements, turning equipment is used to work with parts of various configurations, and also carry out a whole list of other technological operations, which include:

cutting threads of various types;
drilling holes, boring them, reaming them, countersinking;
cutting off part of the workpiece;
turning grooves of various configurations on the surface of the product.

Thanks to such a wide functionality of turning equipment, you can do a lot with it. For example, it is used to process products such as:

nuts;
shafts of various configurations;
bushings;
pulleys;
rings;
couplings;
gear wheels.

Naturally, turning involves obtaining a finished product that meets certain quality standards. In this case, quality means compliance with the requirements for the geometric dimensions and shape of parts, as well as the degree of surface roughness and the accuracy of their relative position.

To ensure control over the quality of processing, measuring instruments are used: at enterprises that produce their products in large series, – maximum calibers; for conditions of single and small-scale production - calipers, micrometers, internal gauges and other measuring devices.

The first thing that is considered when learning turning is the technology of metal processing and the principle by which it is carried out. This principle lies in the fact that the tool, cutting its cutting edge into the surface of the product, clamps it. To remove a layer of metal corresponding to the size of such an incision, the tool must overcome the adhesion forces in the metal of the workpiece. As a result of this interaction, the removed layer of metal is formed into chips. The following types of metal shavings are distinguished.

Merged

Such chips are formed when high speeds workpieces made of mild steel, copper, tin, lead and their alloys, polymer materials are processed.

Elemental

The formation of such chips occurs when workpieces made of low-viscosity and hard materials are processed at low speed.

Broken shavings

Chips of this type are obtained when processing workpieces made of material characterized by low ductility.

Stepped

The formation of such chips is typical for medium-speed processing of workpieces made of medium-hard steel and parts made of aluminum alloys.

Lathe cutting tool

The efficiency that distinguishes work on a lathe is determined by a number of parameters: cutting depth and speed, the amount of longitudinal feed. In order for the processing of a part to be of high quality, it is necessary to organize the following conditions:

high rotation speed of the workpiece fixed in a chuck or faceplate;
stability of the tool and a sufficient degree of its impact on the part;
the maximum possible layer of metal removed during the passage of the tool;
high stability of all machine components and maintaining them in working condition.

The cutting speed is selected based on the characteristics of the material from which the workpiece is made, the type and quality of the cutter used. In accordance with the selected cutting speed, the rotation speed of the machine spindle equipped with a lathe chuck or faceplate is selected.

Using various types of cutters, roughing or finishing types of turning work can be performed, and the choice of tool is mainly influenced by the nature of the processing. By changing the geometric parameters of the cutting part of the tool, you can adjust the size of the removed metal layer. There are right cutters, which move from the tailstock to the headstock during the processing of the part, and left cutters, which move, respectively, in the opposite direction.

According to the shape and location of the blade, cutters are classified as follows:

tools with an extended working part, the width of which is less than the width of their fastening part;
straight;
bent.

Cutters also differ according to their purpose of use:

scoring (processing surfaces perpendicular to the axis of rotation);
pass-through (turning flat end surfaces);
groove (formation of grooves);
shaped (receiving a part with a certain profile);
boring (boring holes in the workpiece);
threaded (thread cutting of all types);
cutting (cutting off a part of a given length).

The quality, accuracy and productivity of machining performed on a lathe depend not only on the right choice tool, but also on its geometric parameters. That is why in lessons in special educational institutions, where future turning specialists are trained, a lot of attention is paid specifically to the issues of cutting tool geometry.

The main geometric parameters of any cutter are the angles between its cutting edges and the direction in which the feed is carried out. These angles of the cutting tool are called leading angles. Among them are:

main angle – φ, measured between the main cutting edge of the tool and the feed direction;
auxiliary – φ1, located, respectively, between the auxiliary edge and the feed direction;
the angle at the tip of the cutter is ε.

The angle at the tip depends only on how the tool is sharpened, and the auxiliary angles can also be adjusted by installing it. As the main angle increases, the apex angle decreases, and the part of the cutting edge involved in processing decreases; accordingly, the tool life also becomes shorter. The smaller the value of this angle, the larger part of the cutting edge is involved both in processing and in removing heat from the cutting zone. Such cutters are more durable.

Practice shows that for turning not too hard workpieces of small diameter, the optimal main angle is the value of which is in the range of 60–90 degrees. If you need to process a workpiece of large diameter, then the main angle must be selected in the range of 30–45 degrees. The strength of the tip of the cutter depends on the size of the auxiliary angle, so it is not made large (as a rule, it is selected from the range of 10–30 degrees).

Particular attention in turning lessons is paid to how to choose the right type of cutter depending on the type of processing. Thus, there are certain rules according to which the processing of surfaces of one type or another is carried out using a cutter of a certain category.

Conventional straight and bent cutters are necessary for processing the outer surfaces of the part.
A thrust tool will be required for end and cylindrical surfaces.
chosen for turning grooves and trimming workpieces.
Boring cutters are used to machine previously drilled holes.

A separate category of turning tools consists of cutters, with which you can process shaped surfaces with a generatrix line length of up to 40 mm. Such cutters are divided into several main types:

By design features: rod, round and prismatic;
in the direction in which the product is processed: radial and tangential.

Types of turning equipment

Of all types of equipment for turning, the most widespread in both large and small enterprises is the screw-cutting lathe. The reason for such popularity is the versatility of this device, thanks to which it can rightfully be called universal.

Let us list the main design elements of such a machine:

two headstocks - front and rear (the machine's gearbox is placed in the front headstock; a spindle with a lathe chuck (or faceplate); the longitudinal slide and equipment quill are located on the tailstock);
a caliper, the design of which distinguishes between upper and lower slides, a rotary plate and a tool holder;
The supporting element of the equipment is a frame mounted on two pedestals in which electric motors are placed.
gearbox.

CNC lathe

The book discusses the technology of processing parts on lathes; provides information about equipment, tools, devices and the selection of the most rational cutting modes; issues of mechanization and automation of parts processing on lathes, as well as safety issues when working on these machines are covered; examples of the work of innovative turners are given.
The book is intended as a textbook for training turners in urban vocational schools and can be used in the network of individual and team training at industrial enterprises.

BASIC CONCEPTS ABOUT THE DEVICE OF A LATHE - SCREW-CUTTING MACHINE. PURPOSE OF LATHE MACHINES.
The most common method of processing materials by cutting is processing on lathes. Lathes process parts that primarily have the shape of rotating bodies (rollers, mandrels, bushings, blanks for gears, etc.). In the manufacture of such parts, it is necessary to process cylindrical, conical, shaped surfaces, cut threads, grind grooves, process end surfaces, drill, countersink and ream holes, etc. When performing these works, the turner has to use a wide variety of cutting tools: cutters, drills, countersinks, reamers, taps, dies, etc.

TYPES OF LATHES. Lathes constitute the largest group of metal-cutting machines in machine-building plants and are very diverse in size and type. The main dimensions of lathes are: the largest permissible diameter of the workpiece being processed above the bed, or the height of the centers above the bed; distance between centers, i.e. a distance equal to the longest length of the part that can be installed on a given machine.

All lathes according to the height of the centers above the bed can be divided into:
small machines - with center heights up to 150 mm; medium machines - with a center height of 150-300 mm; large machines - with a center height of more than 300 mm. The distance between centers for small machines is no more than 750 mm, for medium ones 750, 1000 and 1500 mm, for large ones from 1500 mm.

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