DUBLIN INSTITUTE OF TECHNOLOGY

Lathe Design
Mechanics Design Project

Team:

Shiyas Basheer (D10119909), Enda Brady (), Kevin OKeefe ()& Ciaran Balfe () Date: 26/04/12

Course: DT022/2 Lab Group: A

Lathe Design

Mechanics Project

Table of Contents
INTRODUCTION ................................................................................................................................. 3 SPECIFICATION .................................................................................................................................. 4 CALCULATION .................................................................................................................................... 4 DIAGRAM ........................................................................................................................................................... 4 (KEVS DOING THIS) ......................................................................................................................................... 4 CUTTING FORCE ............................................................................................................................................... 5 REQUIRED POWER OF THE MOTOR ................................................................................................................ 6 TORSION IN THE SHAFT ................................................................................................................................... 8 CLUTCH .............................................................................................................................................................. 9 CONCLUSION .....................................................................................................................................11 REFERENCE .......................................................................................................................................11

Lathe Design

Mechanics Project

Lathe Design
Introduction
Lathes have allowed man to reshape, machine and manufacture many precision cylindrical components made of various types of metal, wood, plastics, and other materials. Without the lathe, man would still be trying to produce cylindrical components in some crude fashion or another. However, because of advanced technology, the lathe has allowed man to become an important asset in developing and machining many precision components needed to operate and function in many areas of our industrial complex. All lathes, except the vertical turret type, have one thing in common for all usual machining operations; the work piece is held and rotated around a horizontal axis while being formed to size and shape by a cutting tool. The cutter bit is held either by hand or by a mechanical holder, then applied to the work piece. Principal capabilities of the lathe are forming straight, tapered, or irregularly outlined cylinders, facing or radial turning cylindrical sections, cutting screw threads, and boring or enlarging internal diameters. The typical lathe provides a variety of rotating speeds and suitable manual and automatic controls for moving the cutting tool. The purpose of this design project is to specify the requirements of the lathe based on the needs of our consumer and to design the main components of lathe based on calculations performed, particularly in regard to topics covered in the course of the module.(2012b)

Lathe Design

Mechanics Project

Specification
The type of lathe we have decided to design is known as either a center lathe, engine lathe, or bench lathe, but all refer to a basic type of lathe that may be considered the archetypical class of metalworking lathe most often used by the general machinist or machining hobbyist. We chose this class of lathe as it is the one most commonly encountered in industry and one in which we all have had hands on experience. There is no typical RPM for lathes so we decided, on the advice of a DIT lecturer in machining, to take a low range value of 120 rpm, a mid range value of 240 rpm and a high range value of 960 rpm which would be set by a lever which changed the gears in the gearbox. The maximum speed of the motor was specified at 1920 RPM. The chuck must also reach full speed in no more than 3 seconds for the given motor. The lathe will also have a clutch to control power transmission to the chuck, which should be suitable for the torques encountered. Similarly, with anything from nylon to alloys, there is no limit to the materials that can be machined in a lathe ranging from small to large diameters. Thus, it was decided to specify that the lathe could machine a 200 mm diameter cylinder of mild steel. In the limited scope of this design project, it was decided to just use hand wheels to control the tool post instead of having an additional lead screw.(2012a)

Calculation
Diagram

(Kevs doing this)

Lathe Design

Mechanics Project

Cutting Force
Cutting force of a lathe work may be defined as the rate in meters per minute at which the surface of the job moves past the cutting tool. Machining at a correct cutting speed is very important for good tool life and efficient cutting. The following factors affect cutting speed: The kind of material being cut Cutting tool material Shape of cutting tool Rigidity of machine tool and piece Type of fluid used

The cutting force was calculated using the formula:

Where: P is the specific cutting pressure or Shear strength of the material which is 248MPa for mild steel, and A is the area under cutting deformation Area was calculated using:

Where: v is the feed rate = 0.1mm per rev D0 is the diameter of the piece = 20cm D is the diameter of the final piece = 15cm Feed rate is the distance a tool advances into the work during one revolution of the headstock spindle. All are listed in a tabular form below: D (m) D0 (m) Shear strength (Pa) Feed Rate (m per rev) Area Force (N) 0.2 0.15 248000000 0.0001 0.0000025 620

Lathe Design

Mechanics Project

Required power of the motor

The power of the motor required was calculated for the 3 different spindle speeds of 120rpm, 240rpm and 960rpm with a 200mm diameter mild steel work piece in the chuck. The power required to speed the chuck up to a full speed of 960 RPM in 3 seconds was also calculated. The power transmission setup can be seen in the diagram, the efficiency of the gearbox and the belt drive are assumed to be 80% and 95% respectively. The Torque in the chuck is given by the following equation:

Where: F is the cutting force = 620N R is the radius of the work piece = 100mm ( ) This torque will be the same for all three-RPM calculations.

120RPM at 16/1 gear ratios: ( ) ( )

The power of the motor is calculated as follows with the 0.8 and 0.95 being the efficiencies of the gearbox and belt drive respectively. ( ( )( ) ( )( ) )

240RPM at 8/1 gear ratios: ( ) ( )

The power of the motor is calculated as follows:

Lathe Design ( ( )( ) ( )( ) )

Mechanics Project

960RPM at 2/1 gear ratios: ( ) ( )

The power of the motor is calculated as follows: ( ( )( ) ( )( ) )

Time for the lathe to reach full speed: Once the motor is started the lathe must reach full speed of 960rpm in less than 3 seconds. The torque required to do that can be determined from the following equation

Where: I is the combined moment of Inertia of the power transmission system. is the angular acceleration of the chuck. can be worked from the following equation:

Looking at previous diagram, the various power transmission elements can be seen with their corresponding dimensions. I is the combined moment of

inertia of these element and thus each element has to be dealt with individually first.

I for chuck: The chuck can be treated as a solid cylinder with radius 0.15m and length 0.1m. 7

Lathe Design

Mechanics Project

The chuck is made from mild steel with a density of 7850kg/m 3. Thus the mass of chuck is given by: ( ( I for shaft: The shaft is a hollow cylinder with length 0.5m, outer radius of 2.5cm and inner radius 1.5cm. It is also made from mild steal with a density of 7850kg/m3. Thus the mass of chuck is given by: ( ) ( ) )( ) )

The moment of Inertia of a solid cylinder is given by:

The moment of Inertia of a hollow cylinder is given by: ( ) ( )( )

Thus, the combined moment of Inertia of the power transmission system excluding the gear and belt drive is given by:

The torque required to accelerate the power transmission system to 960 rpm is: ( )

Thus the power of the motor required to accelerate the power transmission system to 960 rpm is: ( ( )( ) ( )( ) )

It can be seen that this power is way below the power required to cut the work piece at 960 rpm and will easily reach full spindle speed in under 3 seconds. Thus, the motor required to meet the specification should be at least 8.2kW.

Torsion In the shaft

Tmax= Maximum Torque

max= Maximum Stress

Lathe Design Ip= The Polar Moment of Inertia of the Shaft R= Radius of Shaft

Mechanics Project

The equation given above is used to find the maximum torque allowable in a shaft before it will fail due to torsion. The equation is re-arranged to find the maximum stress in the shaft to see if it meets the requirements. The shaft is made from mild steel which has a maximum shear stress is 248 MN/m 2 .

Ip is the polar moment of Inertia of the shaft about its axis of rotation and is given by the following expression. ( ) ( )

Now that Ip was found, we can now sub that into our maximum stress equation. ( )( )

From the equation above, the maximum shear stress in the shaft due to torsion is 2.902 MN/m2 which is well inside the allowable stress of 248 MN/m2. The shaft meets the requirements for the lathe.

Clutch
We decided to use a single plate clutch as it would be the most practical to use on a lathe. We investigated different materials to use for the clutch plate to find a material that has the highest coefficient of friction. We 9

Lathe Design

Mechanics Project

found the best material to use would be an organic compound, containing Carbon, which has a coefficient of friction of 0.35. The clutch on a lathe is usually placed straight after the motor and before the gearbox as the torque will be at its lowest at this point. From before, we calculated the torque to be 62Nm at the chuck. At the highest speed, the gear ratio is 2:1. We used this because at this ratio the torque would be at its highest at the clutch and would be equal to 31Nm.We made the assumption that it was a uniform pressure clutch as the clutch would be relatively small and we believed the pressure would not vary by much along the radius of the clutch. We then used the equation below to find the force that needed to be exerted on the plate and the dimensions the plate to avoid slippage due to torque. We used an Excel spreadsheet to vary the dimensions of the plate until we got a force that we deemed reasonable. [ ] For Uniform Pressure Where, Tf = Torque F = Spring Force on the Clutch = Coefficient of Friction R = Outer Radius r = Inner Radius

We started by using a clutch with an inner diameter of 0.075m and an inner diameter of 0.025m. This calculation is shown below: ( )( )[ ]

F = 1635.165N

The table below shows the force applied when different radius are used. Outer Radius (m) Inner Radius (m) Force (N) 0.075 0.025 1635.165 10

Lathe Design 0.1 0.1 0.1 0.025 0.05 0.075

Mechanics Project 1265.306 1138.776 1005.405

To get the Force to be a minimum, while still using reasonable clutch dimensions, we decided on making the outer radius 100mm and the inner radius 75mm. This gives a force of 1005.405N which means the spring chosen would have to be able to exert at least this force for slippage to be avoided due to the torque.

Conclusion
All in all it can be said that the power calculated for the motor was reasonable and 8kW is a normal accepted motor. The spring chosen would be able to exert a minimum force of 1005N for slippage to be avoided due to the torque using a reasonable clutch dimensions. The maximum shear stress in the shaft due to torsion is 2.902 MN/m2 which is well inside the allowable stress of 248 MN/m2 and thus the shaft meets the requirements for the lathe.

Reference
Lathes, 2012a. Lathes. Available at: http://www.lathes.co.uk/hendey/page3.html [Accessed April 26, 2012]. Wikipedia, 2012b. Lathe (metal) - Wikipedia, the free encyclopedia. Wikipedia. Available at: http://en.wikipedia.org/wiki/Lathe_(metal) [Accessed April 26, 2012].

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