How to use a metal lathe

Metal turning - all about turning technology

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.

Metal turning process

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. Turning 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.

Main types of metal turning work

 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 on lathes, 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.

Measuring tools often used in turning

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 workpieces made of mild steel, copper, tin, lead and their alloys, and polymer materials are processed at high speeds.

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.

Types of chips during turning

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.

Main types of turning tools

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 processing performed on a lathe depend not only on the correct choice of 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 to the geometry of the cutting tool.

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 rigid 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.
• A parting cutter is chosen for making grooves and trimming the workpiece.
• 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.

Screw-cutting lathe 1V625MP

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.

Machine tools that are controlled using special computer programs—CNC machines—are becoming increasingly widespread. The design of such machines differs from the usual one only in that it contains a special control unit.

The following types of turning machines are classified into separate categories:

• turning-turret equipment used for processing parts of complex configurations;
• rotary lathes, among which there are one- and two-column ones;
• multi-cutting semi-automatic equipment, which can be found at enterprises that produce their products in large batches;
• processing complexes that can perform both turning and milling operations.

Today it is extremely difficult to imagine many manufacturing industries without turning. Therefore, this type of metal work continues to develop, despite the already high level, which allows us to ensure the highest quality and speed of processing.

Source: http://met-all.org/obrabotka/tokarnaya/tokarnaya-obrabotka-metalla.html

Advantages, features and video examples of metal turning on a machine

A widely known and popular method for producing metal parts and products for various purposes is metal turning. During this process on a lathe, the excess layer is removed from the products, and the output is a part of the desired shape with a rough surface and the required dimensions. Modern equipment controlled by computer-integrated devices can significantly improve the quality of the resulting products.

General information about metal turning

The metal processing procedure is carried out on special lathes using various cutting tools. The workpiece is installed in the spindle of the device , the operation of which begins after the electric motor is turned on.

The workpiece begins to rotate at high speed and a small layer of metal is removed from it over its entire surface with a cutter, drill or other cutting tool.

With the help of constant movement of the tool, the part is continuously cut to the required sizes and shapes. A more detailed process of turning a part can be seen in the video clip.

The machines allow efficient processing of various workpieces, resulting in a conical, threaded, cylindrical, shaped or other surface. With the help of turning work the following can be performed:

• rings;
• shafts;
• pulleys;
• couplings;
• gear rings;
• bushings;
• nuts

In addition, on a lathe you can:

1. Make grooves.
2. Cut off various parts of products.
3. Process various holes using countersinking, reaming, drilling, boring.
4. Cut the thread.

In the process of performing work, it is imperative to use various measuring instruments, which determine the sizes, shapes and layout options of the workpieces. In single and small-scale production, bore gauges, calipers, and micrometers are used for this purpose. Large enterprises use extreme calibers.

Advantages of metal turning

This process is considered a universal technology and is used for the manufacture of various products from alloys and metals. On a machine equipped with special-purpose cutters, even particularly hard materials can be processed.

Main advantages of the technology:

1. High surface cleanliness of the resulting products.
2. Processing precision.
3. Possibility of producing a product with a complex configuration in one working cycle.
4. The chips obtained after processing the part are melted and can be reused.
5. When using special equipment, it is possible to produce large-sized parts.

In addition, with the help of turning equipment it is possible to organize mass production of products for various purposes.

Features of turning. examples

The essence of the metal processing process is as follows:

• machine movements are carried out in clear directions;
• the spindle of the device, together with the workpiece, rotates along the Z axis, which is the starting point in operation;
• the straight X axis must be strictly perpendicular to the Z axis;
• the cutters should be located in the XZ plane;
• The distance to the cutter must be adjusted when applying equipment.

In modern lathes there is a third coordinate, which is equal to the angle of the main spindle. This indicator can be set and adjusted using software.

Types of lathes

The most popular device for metal processing is the screw-cutting lathe, which is highly versatile. It is used in large enterprises, as well as in single and small-scale production.

In addition , there are other types of lathes:

1. Screw-cutting lathes.
2. Semi-automatic multi-cutting devices for serial and large-scale production.
3. Turning-rotary two- or single-column.
4. Turret lathes designed to work with complex products.
5. Modern turning and milling complexes.

To produce parts with particularly precise diametrical and linear geometric parameters, programmable machines are used. In their design they are almost no different from universal ones.

Cutting tools for lathes

The efficiency of the equipment depends on the cutting speed, the amount of longitudinal feed of the workpiece, and the cutting depth. Using these indicators you can achieve:

• maximum permissible chip volume;
• stability of the tool and the required level of its impact on the workpiece;
• necessary processing of the part;
• increased spindle rotation.

The specific cutting speed depends on the type of material being processed, as well as the type and quality of cutters used.

Cutting tools for lathes can be rough or finishing. Their selection and application depends on the nature of the processing. Based on the direction of movement, they are divided into right and left. Various geometric sizes of cutters allow you to work with any area of ​​the layer that needs to be cut.

According to their purpose, cutting tools can be:

• cut-off;
• threaded;
• boring;
• shaped;
• grooved;
• walk-through;
• trimmed.

To process the cylindrical surface and end plane, through-thrust cutting tools are used. Parting cutters are used to cut off parts of a product and make grooves. Conventional straight and bent ones are optimal for processing the outer surfaces of metal parts. Using boring cutters, previously drilled holes are bored out.

Based on the shape of the incisor and the location of the blade, the incisors are divided into bent, straight and retracted . The width of the drawn cutters is lower than the width of the fastening part.

The geometry of the cutter used has a great influence on the quality of cutting parts. With properly selected angles between the cutter edges and the feed direction, processing productivity increases. The first angle depends on the installation of the tool, the second on its sharpening.

For large cross-section products, an angle of 30-45 degrees , and for thin non-rigid parts - 60-90 degrees. The auxiliary angle should be 10-30 degrees.

It is worth noting that regardless of what type of machine is used, the main role in turning belongs to the cutting tool. But no matter what equipment and tools the turner works with, his workplace must be clearly organized and fully equipped.

Source: https://stanok.guru/stanki/tokarnye-stanki/tokarnye-raboty-po-metallu-osobennosti-processa-i-video.html

How to operate a lathe

One of the methods that today allows us to produce metal products is turning. Using turning techniques, it is possible to produce parts of various shapes and sizes, with geometrically correct parameters. This method allows you to completely remove the unnecessary layer of material.

If you decide to start turning, you need to familiarize yourself with the rules, understand how to use a lathe, and follow safety precautions.

How to turn on a lathe

1. Turn on the electric motor of the device using the start buttons.

2. Using the “Start” button, start the spindle rotation, and turn the handle to the left all the way.

3. Move the handles on the feed box to the required position.

4. Move the handle located on the apron to a vertical position.

How to use a metal lathe

It’s not difficult to learn how to work with a small-sized device, and if you use the machine for home needs, you won’t have to spend a lot of time on training. The main thing is to remember certain rules that will help you make parts correctly and accurately. In addition, do not forget about the safety rules.

If you decide to use a lathe, the first thing you should learn is how to machine workpieces. This will allow you to work with parts of various shapes and lengths that are installed between the centers of the headstock and tailstock. During operation, the workpiece constantly rotates around its axis, and the cutting element also moves continuously.

Processing of workpieces comes down to the fact that when the cutting element and the part come together, the teeth remove the top layer of the workpiece, which becomes chips. It can be stepped, continuous, broken, elemental (it all depends on the type of metal being processed). If you want to learn how to operate and drill on a lathe, regular practice is essential to help you hone your skills.

How to center a lathe

Today craftsmen use various centering methods. One option is centering with a center punch. Using a hammer, you can make a recess that serves as the center. However, this method is considered not very correct.

Another option is to make a hole using a hand or electric drill. The method is very popular when working with large parts. But this option is imperfect and is most often used if preliminary alignment needs to be done.

The most perfect option is centering on horizontal drilling machines.

How to check a lathe

If you need to ensure the geometric and technological accuracy of the device, you should check the following parameters:

• no backlash - for more precise movement of moving parts of the machine;
• how correctly the parts of the apparatus on which the workpiece will be placed are located.

Various tools are used to carry out the check:

• level;
• control line;
• square;
• slot nut;
• holder with indicator.

Safety precautions

If you decide to sharpen parts on a lathe, do not forget about these rules:

• the device must be firmly fixed on the work surface (if you are using a desktop model);
• do not place foreign objects on the bed (the base of the unit being used) - this rule also applies to any tools used during the work;
• protect the belt drive parts;
• leaning on any part of the device is strictly prohibited;
• You must wear special glasses that will protect your eyes when chips form.

If you decide to drill on a lathe, these tips will help you begin your acquaintance with such a unit.

Source: https://pr-stroy.com/articles/kak-rabotat-na-tokarnom-stanke/

Working on a lathe or operating a lathe

This article is devoted to the rules and techniques of operating a lathe . Your safety depends on following the rules for working on a lathe. Confident lathe control technology affects the quality of the product and the productivity of the work being controlled. If your goal is to learn more about turning, follow the guide.

Step 1. Check the lathe before starting

Before starting the lathe , tolerance control must be carried out, namely:

1. During shift work in production, the shift worker handing over the lathe to you is obliged to report any problems noticed in it (orally, in writing, by telephone). The absence of comments implies that the lathe is in good condition.

In production, the repair service is responsible for troubleshooting the lathe. The machine operator only has to inform them about the occurrence of a malfunction.

Before turning on the lathe, make sure:

1. That there is no warning on the machine, such as ( do not turn on the lathe for repairs );
2. Covers, doors, hatches that cover the main parts, and mechanisms of the lathe must be closed.
3. The control handles for the spindle, feeds, and uterine nut must be in a neutral position.
4. The cooling supply is turned off, the liquid supply nozzles are directed downward.
5. The speeds and feed steps are set to what you want to see after the spindle starts.
6. The part you installed that needs to be processed must be securely fastened.
7. The floor near the lathe should be clean, and there should be no unnecessary objects under your feet.
8. The turner's clothes should be neat (without hanging flaps).
9. Do not forget the key in the holder (always ensure that the key is removed from the holder).

Having completed the tolerance control: we turn on the main switch of the lathe, additional switches, if any. Next, the lathe .

Step 2. Spindle control.

Before starting the spindle or main motor, be sure to make sure that the rotating elements on it, in particular the chuck, will not have any obstacles to rotation from the stationary parts of the machine. A particular danger when starting the spindle at high speeds is represented by thin rod workpieces protruding beyond its limits.

This also applies to parts of large diameters with a significant protrusion from the chuck and the center of the tailstock not pressed at the other end.

As already mentioned in , “Design of a lathe,” the spindle speed settings are made by setting the switches and levers on its components to a certain position according to the table located on the machine.

The rules for switching can be summarized as follows: “You cannot switch or complete switching if they cause the characteristic sound of gear teeth not engaging. In this case, the necessary shifts should be made at a complete stop.

On all lathes, forward revolutions are turned on by pushing the switch handle towards you, and reverse revolutions - away from you. The handle has vertical movement (pull upward), and the handle has horizontal movement (pull this to the right).

Straight turns on all lathes correspond to the spindle turning clockwise when viewed from the back of the spindle. Braking the spindle at high speeds due to reversal of the clutches or reverse thrust of the main engine is unacceptable, as it leads to overload and overheating of the mechanism. Braking must be done with a brake. And if the brake efficiency is not enough, then it should be restored by adjustment or repair.

To fasten parts in a three-jaw chuck, one “0” socket is usually used to insert a key into it, which requires installing this socket in the upper clamping and releasing position. In machines with a mechanical clutch, this action (with some skills) can be performed using the clutch control handle.

When machining with a cutter, you cannot stop the spindle with the feed on and the cutter not moved away from the part (this leads to breakage of the cutter).

Step 3: Lathe Feed Control

Manual control of the feed of the machine involves feeding the tool over short lengths (during processing, settings, liners).

Manual feed allows you to quickly feed, interrupt and resume feed, as well as instantly change its speed (depending on changing conditions and processing situations). Manual feed in the longitudinal direction is driven by a handwheel with or without a horizontal handle. Rotating the flywheel counterclockwise causes the caliper to move to the left, and clockwise to the right.

The longitudinal movement of the caliper on a lathe is carried out by a rack and pinion gear. Such gears have backlash or gaps in the contacts of the parts and its mechanisms.

Manual control of cross feed (performed by a T-shaped handle with a horizontal handle). Rotating the handle clockwise moves the tool forward, that is, away from you, while turning the handle counterclockwise moves the tool toward you. Our machine has an accelerated activation of the slide movement. There are different techniques for turning the handwheel with one and two hands, which are used depending on the work being performed on the lathe.

Top feed

On the top slide, turning the handle clockwise moves the slide forward, and turning it counterclockwise moves the handle backward. Quick idle movement of such handles can be done using one of the handles. In this case, the slide should be adjusted for easy movement. We will look in more detail about adjusting mechanisms, slides, and a lathe in the next lesson on turning .

Step 4. Mechanical feed control

Mechanical feeds operate from a drive through the running shaft, and they are controlled by the handle of a 4-position switch. The direction of movement of the switch handle corresponds to the direction of movement of the tool on the support.

Before turning on the mechanical feed in any direction, you need to visually make sure that all points of the support are free of obstacles from other machine components, especially rotating ones. A common mistake of novice turners is to try to bring the caliper closer to the chuck with the slide moved to the right, which leads to a collision. Therefore, the smooth movement of the caliper should be checked in advance.

It is necessary to practice manual feeding techniques so that the cutter does not stop or the stop is minimal.

Step #5. Rapid feed of lathe

On machines with rapid feed, the following requirements must be met:

• To prevent accidental pressing of the rapid feed button, the feed switch lever must be controlled by applying your hand from the side, but not from above.
• Before starting rapid feed, you need to reliably make sure that there are no obstacles to movement at any points on the support, including the tool, in the direction where you want to feed.
• Rapid feed cannot for short movements, especially when approaching rotating elements.
• Heavy supports of medium-sized machines have inertia, which increases with accelerated feed by its drive mechanism.

There are combined feeds of lathes (by type of drive, by direction). Such lathes are used for processing non-critical cones (irresponsible chamfers) and shaped surfaces.

Threaded feeds

To cut threads, the caliper is fed by closing the master nut with the lead screw. Turning the uterine nut on and off is done with a separate lever. The spindle and lead screw rotate synchronously, regardless of the set thread pitch.

Changing the direction of rotation of the spindle leads to a change in the direction of movement of the caliper. Also, changing the spindle speed leads to a change in the speed of movement of the caliper.

The entry of the cutter into a previously cut groove is ensured by synchronizing the rotation of the spindle and lead screw and, accordingly, the travel of the caliper.

You can cut both right-handed and left-handed threads using a switch on the headstock, which changes the direction of movement of the screw relative to the spindle. When cutting threads, it is not recommended to get carried away with high spindle speeds, since its rotation is directly related to the movement of the caliper.

Tailstock control of a lathe

Fixing the tailstock of a lathe is done with a lever, and as the working stroke progresses, the clamping force increases. When processing heavy loads that require better fixation by the tailstock, the action on the lever must be vigorous.

It is important not to confuse the resistance of the lever when clamping with its rigid stop at the end of the stroke. When the tailstock is used with minimal loads, its maximum fixation with the bed is not necessary. It is rational to measure the tailstock clamp with the upcoming load.

The tailstock quill is driven by manual feed by rotating the flywheel. The tools and accessories are secured in the quill cone in the following order:

• Checking the quill cones and tools for contamination;
• Inserting the outer cone into the quill cone and finding the position where the lock connector in the quill matches the tab on the tool cone (not required for tools that do not have a tab).

Toolholder control

The tool holder is a fairly precise mechanism that ensures rigidity of the tool attachment in specified positions. The correct position of the tool holder handle when clamped should correspond to the clockwise position at 3-4 o'clock. This position is ensured by the position of the spacer washer under the nut of the tool holder handle.

The lever is clamped with an average elbow force. And pressing the handle cannot be done using your own weight to avoid weight loss. Squeezing the handle is done with one or more short pushes with the heel of the palm in a counterclockwise direction. Before rotating the tool holder, make sure there are no obstructions to the tool holder or the tool attached to it.

Obstacles from the rotating elements of the machine pose a great danger.

Lathe malfunctions

In the process of work, any turner will sooner or later have to face unforeseen situations when working on a lathe.

Possible situations when working on a lathe:

• Spontaneous stopping of the lathe during operation, during a power outage or mechanical failure;
• Collisions of rotating elements with caliper elements;
• Rotating the part in the chuck;
• Tearing of a part from the clamping devices of a lathe;

Malfunctions of the lathe can be expressed in extraneous noise, the smell of burning electrical wiring, etc.

It is prohibited to leave the lathe (you cannot leave the lathe unattended).

To urgently stop processing a part, quickly move the cutter away from the part, turn off the feed, stop the spindle and turn off the main engine. When stopping the spindle, the main thing is not to turn on the reverse speed, but to turn on the neutral position. Malfunctions of the lathe should be reported to management immediately.

Source: https://www.autoezda.com/tokarnoedelo/1062-%D1%80%D0%B0%D0%B1%D0%BE%D1%82%D0%B0-%D0%BD%D0%B0- %D1%82%D0%BE%D0%BA%D0%B0%D1%80%D0%BD%D0%BE%D0%BC-%D1%81%D1%82%D0%B0%D0%BD% D0%BA%D0%B5-%D0%B8%D0%BB%D0%B8-%D1%83%D0%BF%D1%80%D0%B0%D0%B2%D0%BB%D0%B5% D0%BD%D0%B8%D0%B5-%D1%82%D0%BE%D0%BA%D0%B0%D1%80%D0%BD%D1%8B%D0%BC-%D1%81% D1%82%D0%B0%D0%BD%D0%BA%D0%BE%D0%BC.html

Working on a lathe: what can be done, types of machines, methods

Lathes are designed for processing bodies of revolution. When working on a lathe, cylindrical, conical and shaped surfaces are turned, both internal and external, as well as thread cutting and knurling. In addition, they can be used for drilling, but this is only possible if the hole is located in the axis of the part or with some offset from it.

Types and characteristics of wood processing machines

The variety of types, sizes and shapes of wooden parts implies a variety of equipment on which processing takes place.

The list of types of woodworking machines includes:

Sawing

This group is used for sawing blanks and whole wood, as well as for shaping flat elements. Sawmills, in turn, should be divided into the following subgroups:

• Sawmills, with the help of which longitudinal and transverse sawing of material is carried out using linear saws that perform reciprocating movements relative to the workpieces. This equipment is not economical equipment, and it is also quite bulky, so it is quite rare.
• Circular saws, which are automatic and manual, perform sawing of wood in inclined and vertical planes using circular saws. Such equipment has found application in molding. Classified by the number of saws, their diameter, power and productivity.
• Belt, operating automatically and with manual control. The cutting of wood occurs with the linear movement of the belt. It is used both during harvesting and during further processing. The advantage of this equipment is ease of maintenance and cost-effectiveness, but lower accuracy when compared with circular saws.

Planing

Designed to remove the top layer of material when moving the cutting tool. The main types of machines of this type include:

• Thicknesser, single and double sided. Single-sided ones are capable of processing only the upper plane, so they are used only when processing large workpieces. They have become widespread due to the simplicity of their design, which means ease of management and maintenance. Double-sided can simultaneously process the lower and upper plane. Their advantage is greater productivity, but at the same time they are more difficult to maintain.
• Planers, which not only process planes, but are also capable of chamfering at a certain angle.

Turning

Lathes are divided into a large number of varieties, based on accuracy, dimensions of the machines themselves and the parts being processed, etc. Woodworking types of lathes are used for turning decorative elements, body parts and fasteners. The main classification parameter is the degree of automation and versatility. According to the degree of automation, there are the following varieties:

• Manually controlled machines require regulation of the spindle speed, feeding of parts and other parameters to the workers.
• Automated equipment is equipped with copied devices, which reduce the processing time of the part, but all processes are still under human control.
• Automatic processes involve performing all transitions automatically. All parameters are controlled by the machine computer. CNC lathes have become especially popular recently.

If we talk about versatility, it is worth highlighting:

• Universal equipment that allows you to produce parts of various shapes, sizes and complexity.
• Specialized, which provides processing of parts in a certain range of sizes.
• Special, intended for the manufacture of only one specific part.

Drilling

They are necessary for drilling holes that are in the axis or not in the axis of parts, as well as for processing holes. They are classified according to many parameters, but the main one can be called configuration, according to which they are divided into:

• Vertical drilling, which perform work only in the vertical plane;
• Horizontal drilling, performing processing only in the horizontal plane;
• Radial drilling, allowing you to change the angle of inclination of the tool.

Such machines are used for processing flat and shaped surfaces. Like drilling machines, they are divided according to the planes in which the cutter operates. They should be divided according to configuration:

• Horizontal milling machines, in which the spindle is located horizontally relative to the table surface;
• Vertical milling, the tool of which is located perpendicular to the table and the part fixed to it;
• Universal, allowing you to change the location of the workpiece without reinstalling it.

Grinding

These machines are designed for finishing and involve removing a thin top layer with an abrasive coated tool. There are:

• Surface grinders, which process flat surfaces;
• Cylindrical grinding machines designed for rotating bodies;
• Special grinding machines that are designed for processing complex surfaces;
• Edge grinding. Used for final processing of figured elements.

Gnutarnye

They are hydraulic presses with special clamps. Used to give an element a special shape.

Assembly

Most often, these are automatic devices for assembling individual elements into a semi-finished or finished product.

Work technology

Lathes are designed for processing bodies of rotation. The following work is performed on this equipment:

• End trimming;
• Turning of external surfaces;
• Thread cutting of any type;
• Cutting off parts;
• Application of corrugations;
• Drilling and boring internal holes.

However, this is not the only thing that can be done on this machine. In addition, it can be used for polishing and lapping holes. Polishing can be performed using a special felt wheel and GOI paste. With their help, the product acquires a mirror surface, but the accuracy of the surface is not ensured. The surface of the hole is fine-tuned using a lap. This operation allows you to obtain an accurate hole with a low roughness index.

Machining on a lathe is achieved by rotating the part relative to a fixed tool.

The tool can be fixed in the spindle or in centers. Centers are special devices that are fixed in the spindle and tailstock. To ensure this, it is necessary to first center (drill a hole in the axis with a special drill) the workpiece on both sides. The center machining setup allows all transitions to be completed in one setup.

According to the degree of accuracy, equipment should be divided into: normal accuracy; accurate; especially accurate; increased accuracy; ultra-precision.

By type they are divided into:

• lobotocarny;
• carousel;
• screw-cutting lathes;
• turning-turret.

The first two varieties are designed for processing large-sized parts, from half a meter to several meters. Screw-cutting lathes are the most common because they are universal and are designed for processing parts up to five hundred millimeters. Turret lathes are semi-automatic machines. Processing on such equipment is carried out using stops.

Source: https://VseOChpu.ru/rabota-na-tokarnom-stanke/

Metal Turning for Beginners: The Basics

The profession of a turner is gaining increasing popularity among working specialties.

The invention of computer-controlled machines turned the process into a unique art of engineering.

There are more and more young specialists who are ready to expand their theoretical knowledge and master the practical side of turning production.

Basics for Beginners

Turning specialists produce parts for various machines and mechanisms. Their work involves processing workpieces using the cutting method, during which a layer of material of a certain thickness is removed in the form of chips.

All work is carried out on machines that process various parts using cutters and other tools. When starting a task, the turner clearly sees the sequence of work, the method of manufacturing and processing.

In this case, the specialist must consider the possibility of a certain type of fixation of the workpiece, select devices and tools, and also select a cutting mode. This set of measures is reflected in the content of the production technology process.

Types of equipment for metal work

Any type of lathe involves cutting, but some devices may have additional functions and capabilities.

Screw-cutting lathe - used for turning profiles, producing grooves and recesses, drilling holes and making threads in various ways.

Turning and milling machine - used for turning a workpiece in a continuous way, as well as producing threads, chamfering, cutting straight and curved grooves.

Vertical lathe - it is used to process large diameter workpieces.

Turret lathe - used to produce parts from calibrated rods.

A CNC machine is equipment that performs many operations specified by the program. The specialist’s job is to observe, adjust and remove finished products.

Turner ranks

In the process of professional growth, a turner can receive a higher rank, which requires knowledge, improvement of work technique and tool proficiency.

• 1st category - given to a student who does not have professional skills;
• 2nd category - acquired by a specialist who has experience in processing parts of 12–14 qualifications on universal machines;
• 3rd category - the employee is able to process parts on machines with 8–11 qualifications and has confirmed knowledge of setting up equipment, sharpening tools and designing a plasma torch;
• 4th category - a turner who has knowledge of special devices, heat treatment rules, calibration of profiles and preparation of cutting tools for operation;
• 5th category - a specialist who has the skills to process complex parts up to 6–7 qualifications, the correct sequence of checking lathes and adjusting tools;
• 6th category is the highest mark, reflecting the professional training of the employee, his knowledge and practical skills in working, servicing and setting up machines.

To obtain the next rank, a turner must undergo training and pass the appropriate exam.

How to become a professional

Turning can be studied throughout your life, since in addition to the theoretical part, a specialist must understand modern technology.

Progress does not stand still, which means there will always be an object of study. In addition, new samples of composite and polymer compounds are appearing among the materials being processed.

To master a profession, there are educational institutions and courses where highly qualified specialists pass on their experience to young students.

Information can also be gleaned from the Internet, where a variety of literature on turning is openly available.

The work requires good physical training, since very often turners suffer from a number of diseases. We can say that excellent health, advanced training courses and the ability to set up equipment will help you achieve the desired heights in your career.

Turning

Turning appeared at the dawn of the industrial revolution and has come a long way since then. Nowadays, the profession of a turner has lost its attractiveness for young people. But on the other hand, with the advent of a large number of computer-controlled machines, turning takes on a new meaning and moves into the category of engineering art. Turning parts are used in mechanical engineering, electrical power engineering, construction and other areas of industry and technology.

Turning

Basic principles of turning

For beginners, turning seems like a dark forest full of incomprehensible terms. Although in fact the essence of the turning process is quite simple. The main tool of a lathe is a machine in which the clamped part rotates at high speed, and the cutting element carries out processing processes on wood, metal or plastic.

A wide variety of materials can be processed. The most popular material in turning is undoubtedly steel.

But historically, everything began with wood processing; 12 still operating lathes of Peter the Great are still preserved in the Hermitage collection. The Russian Tsar was fond of crafts, but turning wooden and metal parts was his favorite pastime.

Modern machines, of course, are much more complex than the first wooden models. But the basic principle remains the same, despite the advent of an electric motor instead of a manual drive and a multiple increase in size.

A lathe consists of several basic elements:

• the frame on which all other elements are attached;
• headstock with motor and spindle for fixing the part;
• a caliper moving along guides in the frame, with a cutter located on it;
• tailstock with locking dimensional parts.

The part is clamped, the drive imparts rotation to it and, by adjusting the position of the cutting or milling tool, the material is processed.

Lathe device

Standard turning operations that are used in both metalworking and woodworking are:

1. turning of spheres, conical and cylindrical workpieces;
2. trimming;
3. cutting grooves inside and outside parts;
4. cutting;
5. alignment;
6. drilling;
7. thread cutting, external and internal;
8. countersinking.

Each operation requires a special tool, which is selected in accordance with the material, the required processing accuracy and the design features of the machine.

In Soviet times, there was an extensive network of vocational schools in which young people after school could learn the profession of a turner completely free of charge. The training program included a theoretical part, practical work on a training machine within the walls of the school and industrial practice. One of the most important elements of theoretical training, along with the study of the properties of metal, was learning to use a tool.

A professional turner cannot do without understanding why each type of cutter is needed, how it is installed in the machine and at what angle the processing takes place. Now catalogs of turning tools and milling cutters are multi-volume reference books and manuals for turners in a huge format. The variety of equipment designed for any subtlety of metalworking operations is comparable to the classification of species in biology.

The main tools that no production can do without and most operations can be carried out are cutters:

• pass-through, used for grinding;
• boring, allow you to sharpen blind holes;
• cutting, for slicing;
• threaded ones are needed for cutting threads on workpieces;
• shaped;
• slotted;
• fillets.

Types of turning tools

Lathe training includes preparation for working with all types of these cutters. And each tool requires precise tool holding specifications. The sharpening angle, the angle at which the cutter approaches the part, the feed speed. In this case, all parameters will change with a change in material. Even with steel, depending on the presence of various additives, the processing process is adjusted separately.

The machines that can now be found among manufacturers vary greatly in a number of parameters:

• by size: from desktop machines for a home workshop, to industrial machines weighing tens of tons for processing parts of hydroelectric power plants;
• by control method: manual, CNC, fully automatic systems;
• according to processed materials: for wood, metal, hard plastics.

The first experiences of a novice turner begin with studying a lathe, general principles of operation and the simplest operations for cutting parts. Further, with the growth of skills, working with the machine and theoretical training, you can move on to new work, for example, thread cutting or grooving.

Types of turning work

But progress in skills is far from quick; you will have to get used to the idea of ​​long, painstaking training. In vocational schools, the training period takes 3 years plus industrial practice, which presents theoretical knowledge in a completely different way.

How to become a metalworking professional

Training in turning, as, for example, in the profession of a doctor, lasts a whole life, in addition to a significant amount of theoretical information, books and practical skills that need to be mastered, there is a constantly updated fleet of equipment that requires study, lathes are developing. The range of processed materials is also increasing, and new composite and polymer materials with unstudied properties are appearing.

Download turning tutorial

Lessons in turning and metal processing from more experienced colleagues and teachers can help in mastering the profession. Now a library of technical literature on metal processing has become available on the Internet: reference books, turner’s manuals and textbooks. Additional education requires time, which is always in short supply, and money, which will also not be superfluous, but these costs will more than pay off in the future.

Turning work requires, among other things, training in lathe safety. The first thing that training begins with is the basic concepts of safety precautions; if they are violated, there is a risk of injury to hands and eyes, and in the saddest cases, neglect of safety precautions can result in death.

• overalls must fit snugly to the body; work must be done in safety glasses and work boots with a metal toe cap;
• there should be no foreign objects in the work area, and the workplace should not be cluttered;
• it is necessary to control the reliable fastening of the workpiece in the clamp;
• It is strictly forbidden to pass anything over a working machine, remove chips with your hands and not with a sweeper, stop the chuck while moving, or move away from a working machine;
• after completing the working day, the turner tidies up the workplace, clean it of metal waste and scraps, wipe it and put the tools and equipment in tool cabinets;
• The technician constantly monitors the level of the cutting fluid, the integrity of the electrical wiring, and the absence of damage to the housing.

Safety precautions in turning production

Turning is an interesting, but complex activity that requires constant training, which is a fun activity to master. The attractiveness of this skill is not only in obtaining a profession or auxiliary use, but also in an original hobby.

Turning original crafts on a machine is no less enjoyable than collecting stamps or knitting, and original steel souvenirs can truly surprise your friends.

And the value of real turning professionals in the labor market will ensure permanent employment.

Source: https://stankiexpert.ru/stanki/tokarnye/tokarnoe-delo.html

How to use a metal lathe

Turning is one of the common metal processing methods by which an ordinary steel blank becomes a suitable part for a mechanism.

For turning operations, lathes, tools and devices in the form of cutters are used, which are multifunctional and are capable of creating parts of any geometric shape: cylindrical, conical, spherical from all metals: titanium, bronze, stainless steel, cast iron, copper, etc.

Turning technology

Metal turning is carried out on a lathe, which has drills, cutters and other cutting devices that cut off the metal layer from the product to a specified size. It is optimal for working with stainless steel parts.

The rotation of the workpiece is called the main motion, and the constant movement of the cutting tool is indicated by the feed motion, ensuring continuous cutting to specified values.

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The ability to combine different movements allows you to turn parts of threaded, conical, cylindrical, spherical and many other surfaces on a turning device.

Also, on turning devices, threads are cut, parts of parts made of different metals and stainless steel are cut off, and various holes are machined by drilling, reaming, and boring. All processes are presented in detail on the video.

For these types of cutting, it is imperative to use a variety of measuring devices (calipers, bore gauges, etc.).

These tools and devices determine the shapes and sizes, and other parameters of parts made of various materials: lead, iron, titanium, stainless steel, etc.

The turning technology is as follows. When, under the influence of force, the edge of a cutting tool cuts into a workpiece, this edge marks the clamping of the workpiece.

At this time, the excess layer of metal is removed with a cutter, turning into chips. The cutting principle can be seen in the video.

Chips are divided into the following types:

• fused - occurs during high-speed processing of tin, copper, plastic, mild steel;
• elemental - formed during low-speed processing of hard metal, for example, titanium;
• fracture - formed during processing of low-plasticity workpieces;
• stepped - formed during medium-speed processing of metals of medium hardness.

For productive cutting, you need to correctly calculate the mode.

Calculation of modes is made on the basis of reference and regulatory information, which is combined in a special table.

The table displays cutting speed modes for different materials: copper, cast iron, titanium, brass, stainless steel, etc. The table also displays the density and other physical parameters of the material.

Calculation of modes guarantees the selection of optimal values ​​of all indicators and ensures highly efficient cutting of steel.

Any calculation begins with selecting the cutting depth, after which the feed and speed are set.

The calculation must be performed strictly in this sequence, since the speed most affects the stability and wear of the cutter.

The calculation of the modes will be ideal if we take into account the geometric shape of the cutter, the metal used to make the cutter and the material of the workpiece being processed.

First of all, the roughness value of the workpiece is calculated.

Based on this indicator, the optimal method for turning the surfaces of the workpiece is selected; the table contains these values.

It should be borne in mind that the table also contains illustrations demonstrating rational methods for turning surfaces of various metals: tin, aluminum, titanium, copper, stainless steel.

The depth calculation is calculated by the allowance for turning surfaces. The calculation of the feed rate is influenced by the level of required turning cleanliness.

The maximum values ​​are set for roughing, the minimum for finishing.

Calculation of surface processing speed is based on the obtained values ​​using formulas. It is allowed to take the speed whose values ​​are contained in the table.

It is also necessary to calculate the cutting force using empirical formulas established for each type of processing.

The advantages of turning cutting include:

• the ability to produce parts of the most complex shapes: spherical, cylindrical, etc.;
• the ability to process any metals (and parts made from them) and alloys: bronze, stainless steel, cast iron, titanium, copper;
• high speed, quality and accuracy of metal and parts processing;
• minimal amount of waste, since the resulting chips can be re-melted and used to create parts.

What kind of cutters are used?

A wide range of turning operations is provided by a variety of machining tools. The most common tools are cutters.

The key difference between all cutters is the shape of the cutting edge, which affects the type of processing.

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All cutting devices are made of metals whose strength exceeds the strength of the workpiece: tungsten, titanium, tantalum.

You can also find ceramic and diamond cutters used for turning that require high precision.

The efficiency of equipment operation is affected by the depth and speed of processing, and the amount of longitudinal feed of the workpiece.

These parameters provide:

• high speed of rotation of the mechanism spindle and turning of the part;
• high stability of the cutting device;
• the maximum permissible amount of chips generated.

The cutting speed depends on the type of metal, the type and quality of the cutting device. The turning index and cutting speed set the spindle speed.

The turning mechanism can have finishing or roughing cutters.

The geometric dimensions of the cutting device allow you to cut small and large areas of the layer. According to the direction of movement, the incisors are divided into right and left.

Based on the placement of the blade and shape, the cutters are of the following types:

1. bent;
2. straight;
3. drawn out (when the width of the cutter is less than the width of the fastening).

According to their purpose, cutting devices are divided into:

• threaded;
• boring;
• shaped;
• checkpoints;
• groove;
• pruning;
• cut-off

The efficiency of turning increases significantly with proper selection of cutter geometry, which affects the quality and speed of processing.

To make the right choice, you need to know about the angles, which are the angles between the feed direction and the edges of the cutting tool.

Angles are of the following types:

• auxiliary;
• main;
• at the top.

The apex angle is set depending on the boring of the cutter, and the main and auxiliary angles depend on the installation of the cutter.

With large values ​​of the main angle, the durability of the cutter will decrease, since only a small part of the edge will be used.

At low primary angles, the cutter will be stable, which will ensure effective cutting with the cutter.

For thin parts of medium hardness, the main angle is set to 60-90°; for parts with a large cross-section, the angle is set to 30-45°.

The auxiliary angle for creating parts should be 10-30°. A large angle will weaken the tip of the cutter.

For end, spherical and cylindrical surfaces of parts, thrust cutters are simultaneously used.

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For external surfaces, bent and straight cutters are used; cutting cutters are used for turning grooves and cutting off certain parts of the product.

Turning of shaped surfaces, which form a line up to 4 cm long, is carried out using round, rod, tangential and radial shaped cutters in the direction of feed.

What equipment is used?

The most popular equipment for cutting surfaces is a screw-cutting lathe, which is considered highly versatile.

The main components of this equipment are:

• a headstock on the machine, which has a gearbox and a spindle, and a tailstock, equipped with a housing, a longitudinal slide and a quill;
• support – top and middle flange, longitudinal bottom slide on the machine, cutter holder;
• a horizontal frame with pedestals in which the motors on the machine are located;
• feed box on the machine.

The main criterion for a lathe is speed, which directly increases productivity.

Programmable CNC machines are often used to obtain high-precision linear and diametric geometric quantities.

The advantages of cutting with a CNC mechanism are:

1. high anti-vibration stability;
2. the presence of preheating programs for components, which reduces thermal deformation of workpieces;
3. absence of machine drives-clearances in transmission devices;
4. high processing speed;
5. cutting any metals: cast iron, copper, titanium, stainless steel, etc.;
6. turning surfaces of any shape: spherical, cylindrical, etc.

All CNC machines are equipped with wear-resistant guides with low friction, which ensures high accuracy and processing speed.

In a CNC device, guides can be located vertically and horizontally.

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To make the most of a CNC lathe, the entire process must be carefully prepared and a control program drawn up.

An important point is the correct connection of the coordinate system of the mechanism with the CNC, the position of the workpiece being processed and the starting point of movement of the cutting tool.

The basis for programming a CNC mechanism is the movement of the cutting device in relation to the motor coordinate system, which is at rest.

Parts are processed using a CNC mechanism as follows:

1. Dividing the process into 3 stages: roughing, finishing and additional finishing. If possible, then both types of finishing should be combined, which will increase productivity and reduce labor intensity;
2. Compliance with design and technological rules to reduce errors in fastening and placement of parts;
3. Ensuring complete processing of the part with a minimum number of installations;
4. Rational work with details.

An important part of the cutting process on a CNC device is the so-called separate operation, which involves processing one product on one machine.

The process consists of several transitions, which are divided into independent passes.

  How to remove cold weld from metal

Proper programming of a CNC mechanism requires the development of a process sequence.

To do this, you need to set the total number of installations, the number of transitions and passes, and the type of processing.

Also used for cutting are such types of machines as turret lathes designed for complex products, rotary lathes, semi-automatic multi-cutters, screw-cutting lathes, lathe-milling machines, and lobotowers.

Screw-cutting and rotary machines are often used. Rotary machines are distinguished by their ability to process large workpieces; this is not possible with a screw-cutting mechanism.

In turret turning equipment, the cutting devices are fixed in the drum.

This type of equipment is equipped with drive units that expand the range of work in contrast to standard devices, such as drilling holes, tapping, milling.

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Similar machines are used in large enterprises.

Turn-mill machining is often used for titanium, aluminum and other difficult-to-process materials.

Metal turning is one of the popular methods of cutting any metals: aluminum, titanium, copper, tin and others, but such processing can only be carried out at the enterprise, due to the use of machine tools.

The cutting technology is presented in the video in our article.

Source: http://ooo-asteko.ru/kak-rabotat-na-tokarnom-stanke-po-metallu/