VERTICAL TURRET LATHE AND HORIZONTAL BORING MILL
CHAPTER 8VERTICAL TURRET LATHE AND HORIZONTALBORING MILLCHAPTER LEARNING OBJECTIVESUpon completing this chapter, you should be able to do the following:Describe and explain the use of a vertical turret lathe.Describe and explain the use of a horizontal boring mill.the diameter of the table. For instance, a 30-inch lathehas a table 30 inches in diameter. The capacity of aspecific lathe is not necessarily limited to the size ofthe table. A 30-inch vertical lathe (fig. 8-1) can holdand machine a workpiece up to 34 inches in diameterby using both the main and side turrets. If you useA vertical turret lathe works much like an enginelathe turned up on end. You can perform practicallyall of the typical lathe operations on a vertical turretlathe, including turning, facing, boring, machiningtapers, and cutting internal and external threads.A horizontal boring mill can be used for manykinds of shopwork, such as facing, boring, drilling,and milling. In horizontal boring mill work, the setupof the work, as well as the setting of the tools, issimilar to that found in lathe and milling machinework.As with any shop equipment you must observe allposted safety precautions. Review your equipmentoperators manual for safety precautions and anychapters of Navy Occupational Safety and Health(NAVOSH) Program Manual for Forces Afloat,OPNAV Instruction 5100.19B. that pertain to theequipment.VERTICAL TURRET LATHEThe characteristic features of the vertical turretlathe are (1) a horizontal table or faceplate that holdsthe work and rotates about a vertical axis; (2) a sidehead that can be fed either horizontally or vertically;and (3) a turret slide, mounted on a crossrail that canfeed nonrotating tools either vertically or horizontally.Figures 8-1 and 8-2 show vertical turret lathessimilar to those generally found in repair ships andshore repair facilities. The main advantage of thevertical turret lathe over the engine lathe is that heavyor awkward parts are easier to set up on the verticalturret lathe and, generally, the vertical turret lathe willhandle much larger workpieces than the engine lathe.The size of the vertical turret lathe is designated by(1)(2)(3)(4)Main turret headTurret slideSwivel plateSaddle(5)(6)(7)(8)Main railsUpright bedwaysSide turretSide headFigure 8-1.—A 30-inch vertical turret lathe.8-1
Figure 8-2.—A 36-inch vertical turret lathe.8-2
work manually. On the lathe in figure 8-2, you willuse an electric drive controlled by a lever. When youmove the feed control lever to the creep position, theturret head moves in the direction selected inincrements as low as 0.0001 inch per minute. Thiscreep feed is independent of table revolution and canbe made with the table stopped.only the main turret, you can machine a workpiece aslarge as 44 inches in diameter.The main difference between the vertical turretlathe and the horizontal turret lathe is in the designand operating features of the main turret head.Refer to figure 8-1. Note that the turret slide (2) ismounted on a swivel plate (3) which is attached tothe saddle (4). The swivel plate allows the turretslide to be swung up to 45 to the right or left of thevertical, depending on the machine model. Thesaddle is carried on, and can traverse, the main rails(5). The main rails are gibbed and geared to theupright bedways (6) for vertical movement. Thisarrangement allows you to feed main turret toolseither vertically or horizontally, as compared to onedirection on the horizontal turret lathe. Also, youcan cut tapers by setting the turret slide at a suitableangle.An attachment available on some machinespermits threading of up to 32 threads per inch witha single-point tool. The gears, as specified by thelathe manufacturer, are positioned in the attachmentto provide a given ratio between the revolutions perminute of the table and the rate of advance of thetool.The same attachment also lets the operator turn orbore an angle of 1 to 45 in any quadrant bypositioning certain gears in the gear train. You canthen engage the correct feed lever to cut the angle.Later in this chapter, we’ll explain in detail how youturn tapers on a vertical turret lathe without thisattachment.The side turret and side head of the vertical turretlathe correspond to the square turret and cross slide ofthe horizontal turret lathe. A typical vertical turretlathe has a system of feed trips and stops thatfunctions similarly to those on a horizontal turretlathe. In addition, the machine has feeddisengagement devices to prevent the heads fromgoing beyond safe maximum limits and bumping intoeach other.VERTICAL TURRET LATHE TOOLINGThe principles used to operate a vertical turretlathe are not very different from those for a horizontalturret lathe. The only significant difference is in themain turret. We said earlier that the main headcorresponds to the hexagonal turret of the horizontalmachine. You can feed it vertically toward theheadstock (down), horizontally, or at an angle. Todo this, you can engage both the horizontal andvertical feeds, or you can set the turret slide at anangle from the vertical and use only the verticalfeed.Vertical turret lathes have varying degrees ofcapabilities, including feed and speed ranges,angular turning limits, and special features such asthreading.You can expect to find a more coarse minimumfeed on the earlier models of vertical turret lathes.Some models have a minimum of 0.008 inch perrevolution of the table or chuck, while other modelswill go as low as 0.001 inch per revolution. Themaximum feeds obtainable vary considerably also;however, this is usually less of a limiting factor in jobsetup and completion.The tool angles used for the cutters of the verticalmachine correspond to those on the horizontal turretlathe; they are an important factor in successfulcutting. It is equally important to set cutters on centerand maintain the clearance and rake angles in theprocess. Again, you must be sure the cutters are heldrigidly.The speeds on any given vertical turret lathe tendto be much slower than those on a horizontal lathe.This reduction in speed is often required because ofthe large and oddly shaped sizes of work done onvertical turret lathes. A high speed can throw aworkpiece out of the machine that may damageequipment and injure personnel.In vertical turret lathe work, you must often useoffset or bent-shank cutters, special sweep tools, andforming tools, particularly when you machineodd-shaped pieces. Many such cutting tools aredesigned to take advantage of the great flexibility ofoperation provided in the main head.One of the major differences between the lathesshown in figures 8-1 and 8-2 is in the method you willuse to position the cutter to the work. On the lathe infigure 8-1, you will use a handwheel to position theOn a repair ship, you normally will use thevertical turret lathe for jobs other than straight8-3
28.194Figure 8-3.—Refacing a valve seat in a vertical turret lathe.production work. For example, you can mount a largevalve on the horizontal face of its worktable or chuckeasier than on almost any other type of machine. Forother examples, figure 8-3 shows a typical valve seatrefacing job on a vertical turret lathe; figure 8-4shows the double tooling principle applied to amachining operation, and figure 8-5 shows astraight boring bar used to bore a large saltwaterstrainer body.28.461Figure 8-5.—Straight boring bar being used to bore a largesaltwater strainer.TAPER TURNINGThe following information is based on a Bullardvertical turret lathe. (See fig. 8-1.)There are several ways to cut a taper on avertical turret lathe. You can cut a 45 taper witheither a main turret-held cutter or a side head-heldcutter if you engage the vertical and horizontalfeeds simultaneously. To cut a taper of less than30 with a main turret-held tool, set the turret slidefor the correct degree of taper and use only thevertical feed for the slide. If you did this operationon an engine lathe, you would use the compoundrest and advance the cutter by manual feed. On avertical lathe, you would USC the vertical powerfeed.28.195Figure 8-4.—Double tooling.8-4
Formula:A 2B – 90 Example:B 56 Therefore,A (2 56 ) – 90 A 112 – 90 Angle:A 22 When you use the swivel method to turn a taper,use great care to set the slide in a true vertical positionafter you complete the taper work and before you usethe main head for straight cuts. A very smalldeparture from the true vertical will produce arelatively large taper on straight work. You may cut adimension undersize before you are aware of theerror.Another way to cut tapers with either a mainhead-held or side head-held tool is to use asweep-type cutter ground. Set it to the desired angleand feed it straight to the work to produce the desiredtapered shape. This, of course, is feasible only forshort taper cuts.Figure 8-6.—Head setting for 30 to 45 angles.If you swivel the main turret head on a verticalturret lathe, you can cut 30 to 60 angles withoutspecial attachments. To machine angles greater than30 and less than 60 from the vertical, engage boththe horizontal feed and the vertical feedsimultaneously and swivel the head. Determine theangle to which you swivel the head in the followingmanner. For angles between 30 and 45 , swivel thehead in the direction opposite to the taper angle youare turning, as shown in figure 8-6. The formula todetermine the proper angle is A 90 – 2B . Asample problem from figure 8-6 follows:Formula:A 90 – 2B Example:B 35 Therefore,A 90 – (2 35 )A 90 – 70 Angle:A 20 For angles between 45 to 60 . swivel the head inthe same direction as the taper angle you are turningas shown in figure 8-7. The formula to determine theproper angle is A 2B – 90 . A sample problemfrom figure 8-7 follows:Figure 8-7.—Head setting for 45 to 60 angles.8-5
HORIZONTAL BORING MILLThe horizontal boring mill (fig, 8-8) consists ofthe four major elements dscribed in the nextparagraphs.traversed the length of the ways. T-slots are machinedthe entire length of the table. They are used to holddown work and various attachments, such as rotarytable angle plates.4. BACKREST or END SUPPORT: Thebackrest is mounted on the back end of the ways. Itsupports arbors and boring bars as they rotate andtravel lengthwise through the work, such as the in-lineboring of a pump casing or large bearing. Thebackrest blocks have an antifriction bearing; theboring bar passes through and rotates within thisbearing. The backrest blocks travel vertically withthe head.1. BASE and COLUMN: The base contains allthe drive mechanisms for the machine and provides aplatform that has precision ways machinedlengthwise for the saddle. The column providessupport for the head and has two rails machined theheight of the column for full vertical travel of thehead.2. HEAD: The head contains the horizontal andauxiliary spindle and the mechanism to control them.The head also provides a station on which you canmount various attachments. The spindle feed andhand feed controls are contained in the head, alongwith the quick traverse turnstile and the spindle feedengagement lever.Navy machine shops and shore repair activitiesusually have two types of horizontal boring mills:The table type is used for small work, and the floortype for large work. The floor type is the mostcommon of the two. This machine is well suited forrepair work where you often machine large, irregularparts.3. SADDLE and TABLE: A large rectangularslotted table is mounted on a saddle that can beFigure 8-8.—Horizontal boring mill.8-6
The reference to the size of horizontal boringmills differs with the manufacturer. Some use spindlesize. For example, Giddings and Lewis model 300Thas a 3-inch spindle. Others use the largest boring barthe machine will accept. In planning a job, considerboth of these factors along with the table size and theheight the spindle can be raised. Always refer to thetechnical manual for your machine.1. Retract the spindle of the machine into thesleeve. Engage the spindle ram clamp lever.2. Disengage the overrunning spindle feed clutchto prevent accidental engagement of thespindle power feed while you mount thecombination head on the machine. If the slideis centered and locked, you may run thespindle through it for use in other operationswithout removing the attachment, but be sureyou disengage the spindle overrunning clutchagain before you resume use of the slide.It is most important that you set up the workcorrectly. Mistakes cost man-hours and material.Often you will find it’s better to set up a casting to thelayout lines than to a rough surface since the layoutlines will always be used as a reference.3. Set the spindle for the speed to be used.4. When the combination head is mounted on thesleeve, follow these steps: Before you shiftthe spindle back-gear to neutral, or make anyspindle back-gear change, rotate the sleeve byjogging it until the heavy end of the head isdown. Any spindle back-gear change requiresa momentary shift to neutral which allows thesleeve to turn freely. The sleeve may rotateunexpectedly until the heavy end of the facinghead is down, hitting you or the work.Be sure the holding clamps used to secure a pieceof work are tight. If you use braces, place them sothey can’t come loose. Fasten blocks, stops, andshims securely. If a workpiece is not properlysecured, you could ruin the material or the machineand injure personnel.Different jobs may require different types ofattachments. These attachments include angularmilling heads, combination boring and facing heads,thread lead arrangements, and so forth. Boring headsare available in a variety of diameters. These boringheads are particularly useful to bore large diameterholes and face large castings. You also can use locallymade collars, and you can use stub arbors to increasediameters.5. Lift the head into position on the machine atthe sleeve by inserting an eyebolt into thetapped hole in the top of the head.6. To line up the bolt holes in the sleeve withthose in the head, jog the spindle into position.COMBINATION BORING AND FACINGHEADThe boring and facing head (fig. 8-9) is used toface and bore large diameters. It is mounted andbolted directly to the spindle sleeve, and it has a slidewith automatic feed that holds the boring or facingtools. (This attachment can be fed automatically orpositioned manually.) There are various sizes, buteach is made and used similarly. The heads arebalanced to permit high-speed operation with the toolslide centered. Whenever you use tools off center, besure you counterbalance the head, or use it at lowerspeeds.Generally, the boring and facing head will comeequipped with several toolholders for single-pointtools, a right-angle arm, a boring bar, and a boring barholder that mounts on the slide. Use the followinginstructions to set up and operate the boring andfacing head:Figure 8-9.—Combination boring and facing head.8-7
7. After you have tightened the mounting bolts,rotate the feed adjusting arm on the backingplate until the arm points directly toward thefront.RIGHT-ANGLE MILLING ATTACHMENTThe right-angle milling attachment is mountedover the spindle sleeve and bolted directly to the faceof the head. It is driven by a drive dog insertedbetween the attachment and the spindle sleeve. Thisattachment lets you perform milling operations at anyangle setting through a full 360 . You can performboring operations at right angles to the spindle axisusing either the head or the table feed depending onthe position of the hole to be bored. You may usestandard milling machine tooling held in the spindleby a drawbolt that extends through the spindle.Figure 8-10 shows a right-angle milling attachment.8. Mount the restraining block on the head.9. Set the slide manually; insert the tee-handledwrench into the slot in the slide adjusting dialand turn the wrench until the slide is positioned. The dial is graduated in thousandths ofan inch and one complete turn equals a0.125-inch movement of the slide.After the slide is clamped in place, a springloaded safety clutch prevents movement of the slideor damage to the feed mechanism if the feed isinadvertently engaged. This is not provided to allowcontinuous operation of the head when the slide isclamped and the feed is engaged—it is a jammingprotection only. A distinct and continuous ratchetingof the safety clutch warns you to unlock the slide or todisengage the feed. Do not confuse this warning withthe intermittent ratcheting of the feed driving clutchesas the head rotates. The same safety clutch stops thefeed at the end of travel of the slide that preventsjamming of the slide or the mechanism throughovertravel.BORING MILL OPERATIONSYou can use the boring mills for drilling, reaming,and boring operations. You also can use it to facevalve flanges, and bore split bearings and pumpcylindrical liners. We will explain these in the nextparagraphs.Drilling, Reaming, and BoringDrilling and reaming operations are done thesame way with both a horizontal boring mill and aradial drill. The major difference is the way the tool isheld in the machine. It’s horizontal in the horizontalboring mill (fig. 8-11) and vertical in the radial drill.The slide directional lever is located on thebacking plate beneath the feed adjusting arm. Thearrows on the face of the selector show which way itshould be turned to feed the slide in either direction.There are also two positions of the selector todisengage the slide feed. The direction of the spindlerotation has no effect on the direction of the slidefeed.The slide feed rate adjusting arm scale isgraduated in 0.010-inch increments from 0.000 to0.050 inch, but the first two increments are each 0.005inch. Set the feed rate by turning the knurledadjusting arm to the desired feed in thousandths perrevolution.When you mount the single-point toolholders, besure the tool point is on center or slightly below centerso the cutting edge has proper clearance at the smalldiameters. You may damage the feed mechanism ifyou operate the head with the tool above center.After you mount the facing head, perform themachining operation using the instructions in theoperator’s manual for your boring machine.Figure 8-10.—Angular milling head.8-8
Figure 8-11.—Drilling in the horizontal boring mill.provides the rotary motion for the tools mounted inthe boring bar. Align the work with the axis of theboring bar and bolt and/or clamp it to the table. In thecutting operation, the spindle usually moves while thework is held stationary. However, there may be timeswhen you need to hold the bar in a fixed position andmove the table lengthwise to complete the operation.(See fig. 8-12.)In-Line BoringTo set the horizontal boring machine for a lineboring operation, insert a boring bar into the spindleand pass it through the work. The boring bar issupported on the foot end by the backrest assembly.Depending on the size of the bore, you can use eitherstandard or locally manufactured tooling. The headFigure 8-12.—Boring bar driven by the spindle and supported in the backrest block.8-9
The table can be power driven to provide travelperpendicular to the spindle. This makes it possibleto bore, elongate, and slot when you use the table inconjunction with vertical movement of the head.6. Be sure the actual shaft size has not beenmodified from the blueprint.After you have completed these steps, send thebearing to the foundry to be rebabbitted. When youreceive the rebabbitted bearing from the foundry,rough machine the bearing on a shaper to remove theexcess babbitt extending above the horizontal flanges.Be extremely careful that you do not damage the basemetal of the horizontal flanges during this operation.After rough machining, blue the remaining excessbabbitt and scrape it until no more excess babbittextends above the horizontal flanges.You can use a horizontal boring mill to line bore asplit casing pump. You can use a standard boring bar,but it is preferab
TAPER TURNING The following information is based on a Bullard vertical turret lathe. (See fig. 8-1.) There are several ways to cut a taper on a vertical turret lathe. You can cut a 45 taper with either a main turret-held cutter or a side head-held cutter if you engage the vertical and horizontal feeds simultaneously.To cut a taper of less than
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MODULE II: Lathe Machine 10 Periods Lathe Machine: Principle of working, Specification of Lathe- types of Lathe- Work holders, tool holders-Box tools, Taper turning, thread cutting for Lathe attachments. Turret and Capstan lathe- collet chucks- other work holders- tool holding devices- box and tool layout. Principal features of
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Individual points regarding the work-holding devices shown in the illustrations will be discussed. We shall consider holding devices for the horizontal turret or chucking lathe, the vertical turret lathe, and the vertical boring mill. In describing these devices, the work and its requirements will be considered, as well as the important locat
2.1.2 CNC Controller Ensure that the CNC Controller and it's software will either handle a turret (or ATC) for a lathe. In some cases, the CNC Controller and/or it's software may need updated. Check the documentation for your CNC Controller. 2.1.3 Lubrication The turret shaft bearings and pin lock mechanism were greased at the factory. 2.1. .
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