CONTOUR ATTACHMENT FOR LATHE

SYNOPSIS
A concave attachment is a versatile one to cut concave-convex profiles. A set of rotating plates have T-slots for the T-bolts that hold the boring bar. These plates are rotated by a train of gears. The bar is held roughly yet free enough to rotate. When the tool is built, the boring bar is first clamped with both pivots at lead centre. So, the tool describes a zero radius when the crank is turned. At this time, one set up pin hole is drilled in each of the rotating plates, as indicated so that the pin touches the boring bar. Then to set the tool, for a desired radius, it is merely necessary to place a piece of flat stock the same thickness as the desired radius between the bar and the set up pins while securing the bar in position. At this point, data the flat stock and set up pin can be removed.

INTRODUCTION
The concave attachment is fixed to the carriage of the lathe. The compound rest that is locked solid with its base is removed and the attachment is fixed on the cross lied of the carriage with its axis parallel to the lathe bed. The work is secured rigidly in a chuck. By the concave-convex movement of the boring bar, the material is being removed. This attachment is used to produce contour profiles and round balls.

NEED FOR ATTACHMENT

In recent years, new fabrication techniques have been developed to satisfy the technological demands. Moreover, emphasis is stressed on attachments. Attachments are used in various fields and machines depending upon the needs to be fulfilled and mode of operation. An attachment eliminates the purchasing of a new unit which serves the same purpose. For example, a lathe occupies a place opposite to that of a milling machine, the ten machines mainly used to produce cylindrical and plain surfaces respectively. By implementing an attachment to a unit, the capacity of the unit can be increased which is very economical.

WORKING PRINCIPLE

The worm wheel is rotated with the help of a worm shaft. Rotating plates with Tslots that hold the boring are screwed to the worm wheel. The worm wheel in turn is screwed to its base with a simple gear train. The rotary motion is imported to the blank through two spur gears and an intermediate gear namely Idler Gear. The idler gear serves to keep the rotation of rotating plates in the same direction. The worm shaft is rotated in clockwise direction, the boring bar machines a contour profile in the clockwise direction and vice versa. Thus a concave-convex profile is machined by boring bar by simultaneous engagement of the two plates.

DESCRIPTION OF EQUIPMENTS

Base Plate:

The base plate is in I shape with drilled holes to suit the gear stems. The compound reset that is locked solid with its base of the crosslide of the carriage is removed and in its place, the base plate is so designed to seat. The base plates axis is parallel to the lathe bed.

Rotating Plate:

The rotating plate is a primary part of the unit. It is circular in shape. It has T slot along its diameter for the T bolts that hold the boring bar. It is screwed with the help of Allen screws to the worm wheel, so that the direction of the rotation of the worm wheel and the rotating plate is the same. A set up in hold is drilled in the rotating plate to set the tool for desired radius.

Worm and Worm Wheel:

The worm wheel is screwed between the spur gear and rotating plate with its axial to the lathe bed. The worm shaft is provided with a handle for easy rotation. The height of the worm shaft from base plate is the height of the worm from the base when the

handle is rotated; the worm shaft rotates the proportionate worm wheel. A seating is provided on the worm wheel to seat the rotating plate.

Spur Gear:

The spur gear is screwed between the worm wheel and the base plate. A step down bush is used to fit the worm wheel and the spur gear songly yet free enough to rotate.

Idler Gear:

The idler gear is screwed to the base plate by press fitting the idler gear and its stem to the hold provided in the base plate. The rotary motion between 2 spur gears is directed through the idler gear.

Seating Connecting Blanks:

This forms the base of the unit. The setting blank is screwed to the connecting blank by the help of Allen screws. The blanks are circular in shape. The connecting blank connects the setting blank and the base plate. These blanks are so designed that the

component reset is removed and the blanks are bolted to cross slide of the carriage. The whole unit resets on these blanks.

Boring Bar:

The boring bar is held songly in the T-slots provided in the rotating plates by the T-bolts. The tool that cuts the radial is screwed to the boring bar. The boring bar moves over a certain radius when the crank is turned or rotated.

WORKING OF THE UNIT

When the worm shaft is rotated in a clockwise direction, the worm wheel rotates in the clockwise direction and vice versa. Idler gears are used to rotate the rotating plates in the same direction. When the boring bar is bolted to only one of the I slots in the rotating plate and when the crank is turned, the material is removed at a certain radius depending on the extension of the boring bar. When the boring bar is bolted to the T-slots provided in the rotating plates and when the worm is rotated, the boring bar described a concave-convex profile. This movement of the bar is used to produce spherical balls also.

DESCRIPTION OF EQUIPMENTS

Base Plate:

The base plate is in I shape with drilled holes to suit the gear stems. The compound reset that is locked solid with its base of the crosslide of the carriage is removed and in its place, the base plate is so designed to seat. The base plates axis is parallel to the lathe bed.

Rotating Plate:

The rotating plate is a primary part of the unit. It is circular in shape. It has T slot along its diameter for the T bolts that hold the boring bar. It is screwed with the help of Allen screws to the worm wheel, so that the direction of the rotation of the worm wheel and the rotating plate is the same. A set up in hold is drilled in the rotating plate to set the tool for desired radius.

Worm and Worm Wheel:

The worm wheel is screwed between the spur gear and rotating plate with its axial to the lathe bed. The worm shaft is provided with a handle for easy rotation. The height

of the worm shaft from base plate is the height of the worm from the base when the handle is rotated; the worm shaft rotates the proportionate worm wheel. A seating is provided on the worm wheel to seat the rotating plate.

Spur Gear:

The spur gear is screwed between the worm wheel and the base plate. A step down bush is used to fit the worm wheel and the spur gear songly yet free enough to rotate.

Idler Gear:

The idler gear is screwed to the base plate by press fitting the idler gear and its stem to the hold provided in the base plate. The rotary motion between 2 spur gears is directed through the idler gear.

Seating Connecting Blanks:

This forms the base of the unit. The setting blank is screwed to the connecting blank by the help of Allen screws. The blanks are circular in shape. The connecting

blank connects the setting blank and the base plate. These blanks are so designed that the component reset is removed and the blanks are bolted to cross slide of the carriage. The whole unit resets on these blanks.

Boring Bar:

The boring bar is held songly in the T-slots provided in the rotating plates by the T-bolts. The tool that cuts the radial is screwed to the boring bar. The boring bar moves over a certain radius when the crank is turned or rotated.

ADVANTAGES
The unit is compact in size. Less maintenance is essential The unit gives long life with proper alignment of gears. Jobs can be easily handled in this unit.

APPLICATIONS
Concave and convex profiles of desired radius can be easily turned.

 Round balls can be produced.

DESIGN OF SPUR GEAR

SPEEDS IN GEAR BOX: Measured Specifications: N1/N2 Where, N1 N2 D2 D1 = = = = Motor speed in RPM---40 RPM Output speed Diameter of the roller gear wheel = 88 mm Diameter of the motor gear wheel = 35 mm N2 = = (D1/D2) x N1 (35 / 88) x40 = 16 rpm = D2/D1

SPUR GEAR:

The spur gears, which are designed to transmit motion and power between parallel shafts, are the most economical gears in the power transmission industry. APPLICATION:

Material handling Feed drives Machine tools Conveyors Marine hoists

INTERNAL SPUR GEAR: The internal gears are spur gears turned "inside out." In other words, the teeth are cut into the inside diameter while the outside diameter is kept smooth. This design allows for the driving pinion to rotate internal to the gear, which, in turn, allows for clean operation. Intended for light duty applications, these gears are available only in brass. When choosing a mating spur gear, always remember that the difference in the number of teeth between the internal gear and pinion should not be less than 15 or 12. APPLICATIONS:

Light duty applications Timing

Positioning Rollers Indexing

EXTERNAL SPUR GEAR: Perhaps the most often used and simplest gear system, external spur gears are cylindrical gears with straight teeth parallel to the axis. They are used to transmit rotary motion between parallel shafts and the shafts rotate in opposite directions.

They tend to be noisy at high speed as the two gear surfaces come into contact at once. Internal spur gears: The internal spur gear works similarly to the external spur gears except that the pinion is inside the spur gear. They are used to transmit rotary motion between parallel shafts but the shafts rotate in the same direction with this arrangement.

BASIC SHAFT DESIGN FORMULA

The drive shaft with multiple pulleys experience two kinds of stresses, bending stress and shear stress. The maximum bending stress generated at the outer most fiber of the shaft. And on the other hand, the shear stress is generated at the inner most fiber. Also, the value of maximum bending stress is much more than the shear stress. So, the design of the shaft will be based on the maximum bending stress and will be driven by the following formula:

Maximum bending stress Tb = (M * r) / I.Eqn.1.1 Where, M is maximum bending moment on the shaft. r is the radius of the shaft. I is area moment of inertia of the shaft.

Design Procedure

Draw the bending moment diagram to find out the maximum bending moment (M) on the shaft. Calculate the area moment of inertia (I) for the shaft. Replace the maximum bending stress (Tb) with the given allowable stress for the shaft material. Calculate the radius of the shaft.

Shaft Design Problem

Refer the above picture, where a steel shaft is supported by two bearings and a pulley is placed in between the bearings. You have to design the shaft. Weight of the pulley is 1000 N. Input data: Maximum allowable shear stress for the shaft material= 40 N/mm2 Solution:

From the bending moment diagram, the maximum bending moment (M) is calculated as 66666.67 N/mm2. Area moment of inertia (I)of the circular shaft is:

I = pi * r^4 *0.25 = 0.785*r^4..Eqn. 1.2

From Eqn1.1 we can write:

40 = (66666.67 *r)/ (0.785*r^4) r= 12.85 mm

So, the minimum radius of the shaft should be 12.85 or 13 mm.

DESIGN OF IDLER GEAR: Pressure Angle No. of Teeth (N) Diameteral Pitch (DP) = = = 14 25 18

PCD

= = =

( N / DP ) x 25.4 ( 25 / 18 ) x 25.4 35.28 mm

Outer Diameter (OD)

= = =

{ ( N+2 ) / DP } x 25.4 { ( 25 + 2) / 18} x 25.4 38.1 mm

Depth of Cut (or) Tool depth = = =

( 2.157 /DP ) x 25.4 ( 2.157 / 18 ) x 25.4 3.044 mm

Dedendum

= = =

( 1.157 / DP ) x 25.4 ( 1.157 / 18 ) x 25.4 1.633 mm

DESIGN OF WORM SHAFT:

Outer Diameter Modulo

= =

20 mm 2

OD OD PCD

= = = = = =

20 mm

= 0.7874015

PCD + Working Depth OD Working Depth OD ( Pitch x 0.636 ) 0.7874015 0.159 0.628 = 15.95 mm

TO FIND ANGLE AND LEAD: { Lead / ( PCD x T) } Lead Lead Angle Where, ( 0.628 x II = 1.9741818 ) Angle = = 0.250 / 1.9741818 7 R.H = = = pitch x No. of Start 0.250 x 1 0.250 { 0.250 / ( 0.628 x II ) }

To milling machine held is tilted at an angle of 7 R.H To find No. of thread = = = ( NB : The angle of the form tool is 30 ) Inch / pitch 1 / 0.25 4

DESIGN OF WORM WHEEL:

Bore Diameter No. of teeth Pitch circle diameter

= = = = = =

25.4 mm 42 No. of teeth x module ( No. of teeth + 2 ) x 2 ( 42 +2 ) x 2 88

Throat diameter

= = =

PCD + 2 module 88 + ( 2 x 2 ) 92 mm Throat diameter + (1.5 module) 92 + ( 1.5 x 2 ) 95 mm ( x PCD of worm ) + ( x PCD of worm )

Tip diameter

= = =

Centre Distance

= = =

( x 23 ) + ( x 88 ) 11.50 + 44 55.50 mm

ASSEMBLY

A train of simple gears is press fitted to the base plate by bushes. These gears are hence held singly. Yet free enough to rotate. A worm wheel is screwed to one of the spur gear a circular blank is screwed with the help of Allen screws. A worm shaft is fitted to the base plate with the help L clams.

This worm shaft in engagement rotates the worm wheel. Rotating circular plates are screwed to the worm wheel and the circular plates are Allen screws. Seating is also provided on the worm wheel and the circular blank to hold the rotating plates. The rotating plates have T-slots for T-bolts that secure the boring bar. Setting end connecting blanks are provided to the bottom of the base plate to fasten entire unit to the crosslide of the carriage.

4. Step down bushes:

For songly holding and to enable free rotation of the train of gears the step down bushes are machines to suit the design values M.S. material of 35 x 601 is turned on a

lathe as per the drawing specification. A press fit is obtained on the town portion of the bush by choosing a shaft hole combination of H7 P6.

5. Idle Gear Bush:

Similar to the other bush the same tolerance range is observed on 30 x 351 M.S. rods and the bush is turned lather. A press fit of P6 tolerance is closely maintained to enable the location of the idle gear.

6. Worm Gear:

As it is already said, the hand feed eliminates the need for materials like EWS to be used as the gears. Hence C.I. of roughly 90.50 x 15f is turned on a chuck. To enable the seating of the rotating plate on the gear a boss of 45 x 3mm is turned on the face of the gear.

Directly opposite of the boss a recess is cut an undercutting rod is used to recess 35.1.25c on this recessed portion rests the primarily spur gear.

For a pitch of 0.250 and 90.50 OD the lead, depths of cut are calculated. For these design values the worm gear is cut on a milling machine using to form relived cutter.

The marking of the step down bushes with the worm gear is checked beforehand. For a 35mm shaft combination a bore of slightly less in size is made on the worm wheel blank to obtain a press fit. Once the seating is aer, four tapes are done on the outer face of the worm wheel blank to grip the rotating slot firmly (by means of Allen screw)

7. Spur Gear: a) Primary secondary spur gear: The gears are cut similar to that of the worm. For an OD of 73.37mm and 50 T the DP is calculated. The gears are cut on a milling machine using form relived cutter. Here too C.I. is preferred to minimize the material cost. Prior to cutting the gear a boss 1 x 44 is turned and a 1 bore is done to a close tolerance of H7.

The seating of the other rotating plate is carried out similar to that of the previous blank.

8. Rotating Plates:

C.I. of 1 x 44.02 mm is turned on a lathe to suit the boss of the making parts. For holding the boring tool T slot of 3/8 is done on a slotting machine using a key way slotter. 9. Bearing bar:

The boring bar is fabricated in mild steel. It has a T slot to suit the T bolt. The T slot is machined in a slotting machine with the help of a T slot cutter. It has screws provided at the side of the slots to tighten on loosen the tool that is placed in the slot.0

10. Maintenance and Lubrication:

Lubrication is an important performance factor in power transmission because of its influence on operating efficiency. The contact of a spur gear pair involved maximum sliding action and minimum roll between engaging teeth. Such combinations aid film formation in a favorable environment, being most effectively early and late in a typical contact and less efficient as pitch line is approached. A necessary characteristic of a gear lubricant is its resistance to thermal degradation and chemical change. Grease is

used as the chief lubricant since its a nonconductor of heat thus achieving temperature limitations.

Maintenance aids to good precision, longer life and higher efficiency. following precautions should be followed:

The

1. Proper handling is necessary to avoid the teeth damage in the gears. 2. Periodic lubrication is necessary to avoid film formation. 3. On any account there should not be any novelty in gear blanks 4. While machining, proper dead centre should be maintained. 5. The axis of the unit should be always paralleled to lathe bed.

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