SPHERICAL TURNING ATTACHMENT

A Project Report

Submitted by

Ansari Mohammed Ubaid Mohammed Iqbal

Sansare Maaz Barkat

Shaikh Abdul Raashid Abdul Rehman

Mukadam Arshad Abdul Raashid

Under the guidance of

Prof. Dashrath Chaudhari

(Lecturer, Mechatronics Engg. Dept.)

Department of Mechatronics Engineering,

Terna Engineering College , Nerul,
Navi Mumbai , Maharashtra -400098
October- November 2018

0
 CERTIFICATE

This is to certify that the project entitled “Spherical Turning Attachment” being
submitted by Ansari Mohammed Ubaid , Sansare Maaz Barkat , Shaikh Abdul Raashid
Abdul Rehman , Mukadam Arshad Abdul Raashid is worthy of consideration for the
award of the degree of “degree in Mechatronics Engg. and is a record of original bonafide
carried out under our guidance and supervision

Ansari Mohammed Ubaid

Sansare Maaz Barkat

Shaikh Abdul Raashid Abdul Rehman

Mukadam Arshad Abdul Raashid

Mr. Dasharth Chaudhari Mr. Vikram S.Vyawahare

(Subject Incharge) (HOD, mechatronics Dept.)

(Principal, AIARKP)

1
 Declaration

We declare that this project report entitled “Spherical Turning Attachment”

represents our ideas in our own words and where others' ideas or words have been
included, we have adequately cited and referenced the original sources. We also declare
that we have adhered to all principles of academic honesty and integrity and have not
misrepresented or fabricated or falsified any data/fact in my submission. We understand
that any violation of the above will be cause for disciplinary action by the Institute and
can also evoke penal action from the sources which have thus not been properly cited or
from whom proper permission has not been taken when needed.

Ansari Mohammed Ubaid TU6S1718015

Sansare Maaz Barkat TU6S1718017

Shaikh Abdul Raashid Abdul Rehman TU6S1718018

Mukadam Arshad Abdul Raashid TU6S1718019

Date:

Place: Nerul

2
 ACKNOWLEDGEMENT

We consider myself lucky to work under guidance of such talented and

experienced people who guided me all through the completion of my dissertation.

We express my deep sense of gratitude to my guide , Lecturer of Mechatronics

Engineering Department, for his generous assistance, vast knowledge, experience, views
& suggestions and for giving me their gracious support. We owe a lot to them for this
invaluable guidance in spite of their busy schedule.

We are grateful to Mr. L.M.Ragha, Principal for his support and co-operation and
for allowing me to pursue my under graduation course besides permitting use to use the
laboratory infrastructure of the Institute.

I am thankful to to my H.O.D Mr. Vikram S.Vyawahare and Mr. Dasharth

Chaudhari (Subject Incharge) for his support at various stages.

Last but not the least my thanks also goes to other staff members of Mechatronics
Engineering Department, Terna Engineering college , Nerul , library staff for their
assistance useful views and tips.

We also take this opportunity to thank my Friends for their support and
encouragement at every stage of my life.

Date:

3
 PREFACE

The lathe is an ancient tool, with the first known representation dating to the
3rd century BC in ancient Egypt. Clear evidence of turned artifacts have been found from
the 6th century BC: fragments of a wooden bowl in an Etruscan tomb in Northern Italy as
well as two flat wooden dishes with decorative turned rims from modern Turkey. More
tenuous evidence exists from a Mycanean Greek site as far back as the 13th or 14th
century BC. There is also evidence of use in Assyria and India. The lathe was very
important to the Industrial Revolution. It is known as the mother of machine tools, as it
was the first machine tool that lead to the invention of other machine tools. The ancient
Chinese dating to the Warring States era also used rotary lathes to sharpen tools and
weapons on an industrial scale.

The origin of turning dates to around 1300 BCE when the Ancient Egyptians
first developed a two-person lathe. One person would turn the wood work piece with a
rope while the other used a sharp tool to cut shapes in the wood. Ancient Rome improved
the Egyptian design with the addition of a turning bow. In the Middle Ages a pedal
replaced hand-operated turning, allowing a single person to rotate the piece while
working with both hands. The pedal was usually connected to a pole, often a straight-
grained sapling. The system today is called the "spring pole" lathe. Spring pole
lathes were in common use into the early 20th century.

An important early lathe in the UK was the horizontal boring machine that was
installed in 1772 in the Royal Arsenal in Woolwich. It was horse-powered and allowed
for the production of much more accurate and stronger cannon used with success in
the American Revolutionary War in the late 18th century. One of the key characteristics
of this machine was that the workpiece was turning as opposed to the tool, making it
technically a lathe (see attached drawing). Henry Maudslay who later developed many
improvements to the lathe worked at the Royal Arsenal from 1783 being exposed to this
machine in the Verbruggen workshop

4
 CONTENT
Chapter No. Chapter Name. Page No.
1. ABSTRACT 07

2. INTRODUCTION 09

3. LITERATURE 11
REVIEW
4. METHODOLOGY 12

PROCESS SHEET 17

CUTTING TOOLS 18

CUTTING 21
PARAMETERS
5.
COMPONETS OF 23
LATHE
MATERIAL USED 25
ABOUT MATERIALS 26

6. CONCLUSION 30
7. BIBILOGRAPHY 31
8. REFERENCES 32

5
 Project Image:-

Fig1:-Spherical Turning Attachment(fixture) on Lathe.

6
 Abstract

Spherical Turning Attachment: On lathe machine it is not possible to

manufacture spherical objects but with the help of spherical turning attachment it
can be easily manufacture.

Earlier the spherical objects were made by various processes like annealing,
wire drawing, cold forging, flashing, heat treatment, grinding, lapping etc. but this
process were tedious, time consuming and comparatively cost of this process is
high.

The movement of tool post on normal lathe machine is restricted in only

two directions, by replacing the tool post with spherical turning attachment the
rotating motion can be achieved of about 360o.

The machine named ball turner which is available in the market for
manufacturing
spherical objects cost very high.

A lathe fixture consists of a base , location and clamping devices. A lathe fixture
can be fixed to the lathe either by holding in the chuck jaws or fixing to a face
plate.

Basic Design Principles for Turning or Lathe Fixtures:

1. To avoid vibration while revolving , the fixture should be accurately

balanced.

2. There should be no projections of the fixture which may causes injury to the
operator.

7
3. The fixture should be rigid and overhang should be kept minimum possible
so that there is no bending action.

4. Clamps used to fix the fixture to the lathe should be designed properly so that
they don’t get loosed by centrifugal force.

5. The fixture should be as light weight as possible since it is rotating.

6. The fixture must be small enough so that it can be mounted and revolved
without hitting the bed of the lathe.

Fig2:- Spherical Turning Attachment(fixture) on Lathe.

8
 INTRODUCTION

Turning is a form of machining, a material removal process, which is

used to create rotational parts by cutting away unwanted material. The
turning process requires a turning machine or lathe, workpiece, fixture, and
cutting tool. The workpiece is a piece of pre-shaped material that is secured
to the fixture, which itself is attached to the turning machine, and allowed to
rotate at high speeds.

The cutter is typically a single-point cutting tool that is also secured

in the machine, although some operations make use of multi-point tools. The
cutting tool feeds into the rotating workpiece and cuts away material in the
form of small chips to create the desired shape.

Turning is used to produce rotational, typically axi-symmetric, parts

that have many features, such as holes, grooves, threads, tapers, various
diameter steps, and even contoured surfaces. Parts that are fabricated
completely through turning often include components that are used in
limited quantities, perhaps for prototypes, such as custom designed shafts
and fasteners.

Turning is also commonly used as a secondary process to add or

refine features on parts that were manufactured using a different process.
Due to the high tolerances and surface finishes that turning can offer, it is
ideal for adding precision rotational features to a part whose basic shape has
already been formed.
9
 Turning machines, typically referred to as lathes, can be found in a
variety of sizes and designs. While most lathes are horizontal turning
machines, vertical machines are sometimes used, typically for large diameter
workpieces. Turning machines can also be classified by the type of control
that is offered.

A manual lathe requires the operator to control the motion of the

cutting tool during the turning operation. Turning machines are also able to
be computer controlled, in which case they are referred to as a computer
numerical control (CNC) lathe.

CNC lathes rotate the workpiece and move the cutting tool based on
commands that are preprogrammed and offer very high precision. In this
variety of turning machines, the main components that enable the workpiece
to be rotated and the cutting tool to be fed into the workpiece remain the
same

10
 LITERATURE REVIEW

This invention relates to improvements in machine lathe attachments and more

particularly to a simple attachment designed to facilitate the cutting of spherical,
concave and convex shapes.

In the past a wide variety of devices designed to out such shapes has been
developed but they have been so massive in construction and high in cost that
the average lathe owner has not felt the purchase of such attachments would be
feasible.'

In addition, most of these prior art devices were so constructed and designed
that their very bulk and complexity of parts precluded their being utilized in
turning a work-piece close to the face of the chuck, which resulted in it being
necessary to use longer pieces of stock so that the required cuts could be made.
Therefore, short, pieces of stock and random lengths which would be most useful
in turning spheres could not be used with the prior art devices.

Many of the devices are limited to the cutting of either convexities or concavities
and require the purchase of an additional attachment to permit them to cut both.
Further, some of the prior art attachments are encumbered with
adjusting mechanisms which are required because of the method of construction
and mode of operation of the devices.

Nearly all of the prior art attachments embrace a large number of component
parts and since they do are high in cost and rather cumbersome to use.

It is, therefore, one object of this invention to provide a lathe attachment for
cutting spheres and concavities which is so constructed vthat the cuts may be
taken much closer to the chuck face than is possible at the present time with
conventional attachments designed to perform this type of work. The facility 'with
which shapes may be cut in the metal close'to the face .of the chuck permits
short lengths of

11
 METHODOLOGY

A common problem on the lathe is turning convex and concave surfaces. A

particular case of this is turning a ball. But, usually, it is not a complete ball
that is required but a ball on the end of a shaft.

Among the possible methods are:

using one or more form tools,

making a round surfaces by a series of straight cuts,

using a ball turning attachment,

using linkages to control position of the cross slide.

Using a one or more form tools

12
 Types of spherical Turning attachments

Fig : A worm-geared spherical turning appliance.

The worm gear provides an adequate turntable for the radial slide, with a
broad under-surface to form a thrust
bearing, with adjustment for end play from below, in the recessed bolster
plate. A removable gauge pin, cut away
to the centre to facilitate radial measurement, is fitted to the centre of the
worm wheel. The radial sliding member
is fitted with a gib for adjustment, and is moved by a feed screw with a
balanced handle, hating an indexed sleeve,
though the markings on it are not visible in the photograph. A lantern type of
tool post, with rocker adjustment
for the tool height, is anchored in a T-slot which enables

13
the latitude of radial movement to be extended. Smooth and steady motion
of the rotary traverse is facilitated by
the worm gearing, and the worm shaft is fitted with a flexible drive, so that it
can be operated from any convenient
position, or even coupled to a self-acting drive if required. A worm-geared
spherical turning appliance. often found that this does not give sufficient
clearance.

Fig : Spherical Turning Appliance With Oblique Wormshaft

The only thing to be done then is to slew the tool round to the left in the tool
post, but though this enables the arc
of surface to be increased, it reduces the advantages of fitting a slide which
gives direct radial tool adjustment. It
will be clear that the movement of the tool slide is no longer truly
proportional to the radial adjustment at the

14
actual tool point. As I have often had to carry out spherical turning,in the
course of solving those awkward little
machining problems which are passed on to me from time to time, I have
devoted a good deal of time to the design
of appliances which give maximum facility without serious limitations for
work of this nature. The photographs,
show one of the most useful of these which I have so far been able to
(produce. In the drawing, a few minor
modifications have been introduced in order to simplify construction with
materials most likely to be readily available.

Where a part of a cutting edge makes a cut on the workpiece then, where this
cut occurs, the shape of the surface of the workpiece at this point will be a
copy of the edge of the cutter at this point. A round, convex cutting edge will
cut a concave surface. A round concave cutting edge will cut a convex
surface. On a small lathe, the power and rigidity of the lathe will limit the
length of the cut even if the depth of cut is relatively short.

15
The cutter is set to just touch this on one side as shown.

Fig: spherical turning process

Having done this it is possible to set the attachment along the bed of the
lathe. It is not easy to set this accurately. But in most cases it is possible to
set the cutter in one of the in/out position and align the point of the cutter
to the end of the workpiece. This sets the vertical axis of rotation of the
attachment to the end of the workpiece. The saddle is locked. The top of
the dovetail on the attachment is moved right away from the workpiece by
very slightly more than the radius required. The saddle is then moved till
the cutter touches the workpiece. The saddle is locked again. The tip of the
cutter is now very near the last cut that will be made. The cutter is moved
away from the workpiece so the first cut will just clip the corners of the end
of the workpiece.

16
 PROCESS SHEET

SR. DESCRIPTION OF MACHINE MEASURING TIME

NO. OPERATION USED DEVICE REQUIRED
USED

1 Cutting M.S Plate To Simple Steel Rule 12 mins

Length Of 145mm Hacksaw
and Width Of 90mm Machine
2 Surface Finishing Surface __ 9 mins
Grinder
3 Drilling 2 Holes Of Drill Machine __ 5mins
12mm On M.S Plate
4 Grooving On M.S Lathe Vernier 30mins
Plate Machine Caliper
5 Turning Of Round Lathe Vernier 10mins
Bar To a Diameter Of Machine Caliper
70mm &Length
40mm
6 Making Slot Of Milling Vernier 20mins
26mm in Round Bar Machine Caliper
7 Material Removal Of Milling 29mins
M.S Plate Of 30mm Machine
From Both Sides
8 Turning Of a Round Lathe Vernier 7mins
Bar Of 10mm Dia Machine Caliper
and Length 155mm
9 Drilling 3 Holes Of Drill Machine 6mins
4mm In Round Bar
For Srew

17
 CUTTING TOOLS

One of most important components in machining process

Performance will determine efficiency of operation

Two basic types (excluding abrasives)

 Single point and multiple point

Must have rake and clearance angles ground or formed on them

• Toolbits generally made of seven materials

• High-speed steel

• Cast alloys (such as stellite)

• Cemented carbides

• Ceramics

• Cermets

• Cubic Boron Nitride

• Polycrystalline Diamond

Cutting Tool Properties:

 Wear Resistance
18
  Able to maintain sharpened edge throughout the cutting
operation
 Same as abrasive resistance
 Shock Resistance
 Able to take the cutting loads and forces
 Shape and Configuration
 Must be available for use in different sizes and shapes.

High-Speed Steel:

• May contain combinations of tungsten, chromium, vanadium,

molybdenum, cobalt

• Can take heavy cuts, withstand shock and maintain sharp cutting
edge under red heat

• Generally two types (general purpose)

• Molybdenum-base (Group M)

• Tungsten-base (Group T)

Cast Alloy:

 Usually contain 25% to 35% chromium, 4% to 25% tungsten

and 1% to 3% carbon
o Remainder cobalt
 Qualities
o High hardness

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 o High resistance to wear
o Excellent red-hardness
 Operate 2 ½ times speed of high-speed steel
 Weaker and more brittle than high-speed steel

Carbide Cutting Tools:

 First used in Germany during WW II as substitute for

diamonds
 Various types of cemented (sintered) carbides developed to
suit different materials and machining operations
o Good wear resistance
o Operate at speeds ranging 150 to 1200 sf/min
 Can machine metals at speeds that cause cutting edge to
become red hot without loosing harness

20
 CUTTING PARAMETERS

Cutting parameters

In turning, the speed and motion of the cutting tool is specified through
several parameters. These parameters are selected for each operation based
upon the workpiece material, tool material, tool size, and more.

Cutting feed - The distance that the cutting tool or workpiece advances
during one revolution of the spindle, measured in inches per revolution
(IPR). In some operations the tool feeds into the workpiece and in others the
workpiece feeds into the tool. For a multi-point tool, the cutting feed is also
equal to the feed per tooth, measured in inches per tooth (IPT), multiplied by
the number of teeth on the cutting tool.

Cutting speed - The speed of the workpiece surface relative to the edge of
the cutting tool during a cut, measured in surface feet per minute (SFM).

Spindle speed - The rotational speed of the spindle and the workpiece in
revolutions per minute (RPM). The spindle speed is equal to the cutting
speed divided by the circumference of the workpiece where the cut is being
made. In order to maintain a constant cutting speed, the spindle speed must
vary based on the diameter of the cut. If the spindle speed is held constant,
then the cutting speed will vary.

21
Feed rate - The speed of the cutting tool's movement relative to the
workpiece as the tool makes a cut. The feed rate is measured in inches per
minute (IPM) and is the product of the cutting feed (IPR) and the spindle
speed (RPM).

Axial depth of cut - The depth of the tool along the axis of the workpiece as
it makes a cut, as in a facing operation. A large axial depth of cut will
require a low feed rate, or else it will result in a high load on the tool and
reduce the tool life. Therefore, a feature is ty

Turning machines, typically referred to as lathes, can be found in a variety of

sizes and designs. While most lathes are horizontal turning machines,
vertical machines are sometimes used, typically for large diameter
workpieces. Turning machines can also be classified by the type of control
that is offered. A manual lathe requires the operator to control the motion of
the cutting tool during the turning operation.

Turning machines are also able to be computer controlled, in which case

they are referred to as a computer numerical control (CNC) lathe. CNC
lathes rotate the workpiece and move the cutting tool based on commands
that are preprogrammed and offer very high precision. In this variety of
turning machines, the main components that enable the workpiece to be
rotated and the cutting tool to be fed into the workpiece remain the same.

22
 COMPONETS OF LATHE

Bed - The bed of the turning machine is simply a large base that sits on the
ground or a table and supports the other components of the machine.

Headstock assembly - The headstock assembly is the front section of the

machine that is attached to the bed. This assembly contains the motor and
drive system which powers the spindle. The spindle supports and rotates the
workpiece, which is secured in a workpiece holder or fixture, such as a
chuck or collet.

Tailstock assembly - The tailstock assembly is the rear section of the

machine that is attached to the bed. The purpose of this assembly is to
support the other end of the workpiece and allow it to rotate, as it's driven by
the spindle. For some turning operations, the workpiece is not supported by
the tailstock so that material can be removed from the end.

Carriage - The carriage is a platform that slides alongside the workpiece,

allowing the cutting tool to cut away material as it moves. The carriage rests
on tracks that lay on the bed, called "ways", and is advanced by a lead screw
powered by a motor or hand wheel.

Cross slide - The cross slide is attached to the top of the carriage and allows
the tool to move towards or away from the workpiece, changing the depth of
cut. As with the carriage, the cross slide is powered by a motor or hand
wheel.

Compound - The compound is attached on top of the cross slide and

supports the cutting tool. The cutting tool is secured in a tool post which is

23
fixed to the compound. The compound can rotate to alter the angle of the
cutting tool relative to the workpiece.

Turret - Some machines include a turret, which can hold multiple cutting
tools and rotates the required tool into position to cut the workpiece. The
turret also moves along the workpiece, feeding the cutting tool into the
material. While most cutting tools are stationary in the turret, live tooling
can also be used. Live tooling refers to powered tools, such as mills, drills,
reamers, and taps, which rotate and cut the workpiece.

24
 MATERIAL USED

NAME OF MATERIAL PROPERTIES

MILD STEEL PLATE GOOD HARDNESS ,DUCTILITY

EN9 ROUND BAR

MILD STEEL ROD GOOD HARDNESS ,DUCTILITY

OHNS BLOCK

CARBIDE TOOL

MILD STEEL BASE PLATE GOOD HARDNESS ,DUCTILITY

25
 ABOUT MATERIALS

MILD STEEL:

Mild steel is the most widely used steel which is not brittle and cheap in
price. Mild steel is not readily tempered or hardened but possesses enough
strength.

Mild steel Composition :

Mild steel contains –

Carbon- 0.16 to 0.18 % (maximum 0.25% is allowable)

Manganese -0.70 to 0.90 %

Silicon maximum- 0.40%

Phosphorous maximum- 0.04%

Mildest grade of carbon steel or mild steel contains a very low amount of
carbon - 0.05 to 0.26%

The use of mild steel is huge and a person who is into manufacturing or
production business need to know a lot about the important characteristics of
mild steel.

The study of mild steel becomes more significant for a student of

mechanical engineering or metallurgical engineering. Mild steel is an alloy.
And alloy is a product made by mixing metals and non metals. Sometimes a
pure metal cannot fulfill all the properties needed for manufacturing product.
So additives are included in the pure metal to obtain some specific properties
necessary for the production. Mild steel is made by adding carbon and other
26
elements in the iron. These elements improve the hardness, ductility and
tensile strength of the metal.

EN9 :

EN9 is a medium carbon steel usually supplied in the black condition

untreated annealed. EN9 can be surface hardened to produce a high surface
hardness with excellent wear resistance for a carbon steel. EN9 is general
engineering applications including blades for axes, knives, and sickles as
well as shafts, bushes, crankshafts, screws, and wood working drills. In the
normalised condition EN9 can be used for gears, sprockets and cams.

EN9 (070M55) Specification

Chemical composition

Carbon 0.50-0.60%

Silicon 0.05-0.35%

Manganese 0.50-0.80%

Sulphur 0.06 Max

Phosphorus 0.06 Max

27
OHNS(Oil Hardening Non Shrinking Die Steel):

Blanking and stamping dies, Punches, Rotary shear blades, Thread cutting
tools, Milling cutters, Reamers, Measuring tools, Gauging tools, Wood
working tools, Broaches, Chasers.

An ideal type oil-hardened steel which is economical and dependable for

gauging, cutting and blanking tools as well as can be relied for hardness and
good cutting performance.

EN9 is not easily abraded, has high surface hardness post tempering, does
not deform during hardening and can be machined well. Further, it also has
a low hardening temperature (and, therefore, can be heat treated in homes
and shops), and does not lose shape during quenching. It is inexpensive and
readily available.

Physical Properties:

Property Quality

Max Hardness 60-64

Heat Resistance Low

Wear Resistance Medium

Machinability Good

Deformation During Hardening Medium

Hardening Temperature 760-870

Resistance To Decarburization Good

Micro Hardness 280Vhn

28
STRENGHT OF OHNS:

Strength of a metal determines the extent to which it may deform when load
is applied on it. Strength can be measured based on various parameters, such
as the maximum ability to take strain, resistance to wear and tear, impact
handling, or how the material performs when subjected to frequently
changing load conditions. Strength generally increases as the carbon and
manganese content increases. Given the high percentage of both of those, O1
Tool Steel is strong.

Hardness of a material indicates its resistance to get indented that is not

temporary (i.e.; it persists even after the load conditions are removed, as
opposed to the strength that is an indication of its performance only when
the load is applied), and carbon is also the primary hardening element in
steel. The Rockwell method measures the hardness of O1 Tool Steel to be in
the range of 64 RC to 58 RC (this is the most commonly used measurement
technique).

Application :

All press cutting tools & punching tools for thinner materials. Small tools of
complicated design for reforming, bending & drawing. Small plastic &
rubber moulds.

29
 CONCLUSION

Jigs and fixtures are manufacturing tools that are employed to produce
interchangeable and identical components.
They eliminate the need for a special set-up for every work-piece
thereby facilitating production and also ensuring
that every work piece is manufactured within a predetermined
tolerance. The design of jigs and fixtures is
dependent on the operation type as well as the machine tool to be used
for the operation. There are numerous
advantages that are associated with the use of jigs and fixtures, they
include: production increase, low variability
in dimension thereby leading to consistent quality of manufactured
products, manufacturing cost reduction,
interchangeability and high accuracy of parts, reduces the need for
inspection and quality control expenses,
reduces accident as safety is improved, semi-skilled machine operators
can easily use them thereby saving the
cost of manpower.

30
 BIBILOGRAPHY

SR.NO MATERIAL QTY RATE

1. M.S PLATE 4.5Kg 700

2. ROUND BAR(EN9) 3.5Kg 820

3. OHNS(Oil Hardened 2.5 610

Non-Shrinking Steel)

4. MILD STEEL ROD 700gm 130

5. BLOCK 500gm 130

6. M.S BASE PLATE 1Kg 160

7. C.S.K SCREW 3Pcs 80

8. C.S.K SCREW 1Pcs 60

9. ALLEN KEYS 2Pcs 130

10. CARBIDE TOOL 1Pcs 490

11. FABRICATION COST 1200

12. FABRICATION OF 200

SLOT (MILLING M\C)

TOTAL COST 5200

31
 REFERENCES

www.google.com

www.howtomechatronics.com

www.ieee.com

www.engineeringdata.com

www.enggproject.com

www.mechproject.com

www.allaboutproject.com

www.stupidsid.com

www.lathedetail.com

www.materialtech.com

www.youtube.com

www.miniproject.com

www.makemyproject.com

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