To reduce the operating height of a

lathe machine. The lathe machine

performs turning, facing and polishing
operations on work pieces ranging
from 4000mm to 5800mm in diameter.

Tool Post Slide

Lathe Headstock

Side View of Lathe

There were 2 approaches to designing the

table for turning various diameters :
Varying the angle and keeping the

operating height constant.

Keeping the angle constant and varying

the height of operation.

Design Considerations:

Height of the hand wheels must be roughly 1200mm

from ground level to ensure ergonomic operation.

The angle must be below a certain limit, such that the

overturning of the slide may be avoided.

The cross slide must have a clearance of at least

230mm to accommodate depth of cut while performing
facing operation on flanges.

The overhang of the tool holder must be kept as less

as possible to avoid vibrations.

w/p diameter = 4000mm ; Angle = 29

w/p diameter = 4200mm ; Angle = 28

w/p diameter = 4400mm ; Angle = 27

w/p diameter = 4600mm ; Angle = 26

w/p diameter = 4800mm ; Angle = 25

w/p diameter = 5100mm ; Angle = 24

w/p diameter = 5400mm ; Angle = 23

Variation in angle for machining various diameters makes

it impossible to utilize a common fixture and demands
manufacture of number of fixtures for various angles.

If d = diameter to be machined, and if d<4000 or 5800>d,

then more number of fixtures will have to be machined to
cater to these diameters. Hence scope for expansion is
limited.

For smaller diameters (3000<d>3500), the machining

angle increases to about 45. This high may cause the
slide to topple.

Design Considerations:

The operating height must within 800mm to 1400mm to ensure comfortable

operation.
The overhang of the inclined bed over the base must be kept to a minimum.

The cross slide must have a clearance of at least 230mm to accommodate

depth of cut while performing facing operation on flanges.

The overhang of the tool holder must be kept as less as possible to avoid
vibrations.

w/p diameters = 4000mm ; Angle = 25

Operating height 1 = 1063mm
Operating height 2 = 1355mm

w/p diameter = 4200mm ; Angle = 25

Operating height 1 = 1063mm
Operating height 2 = 1355mm

w/p diameter = 4400mm ; Angle = 25

Operating height 1 = 972mm
Operating height 2 = 1254mm

w/p diameter = 4600mm ; Angle = 25

Operating height 1 = 972mm
Operating height 2 = 1254mm

w/p diameter = 4800mm ; Angle = 25

Operating height 1 = 866mm
Operating height 2 = 1165mm

w/p diameter = 5100mm ; Angle = 25

Operating height 1 = 866mm
Operating height 2 = 1158mm

w/p diameter = 5400mm ; Angle = 25

Operating height 1 = 776mm
Operating height 2 = 1067mm

w/p diameter = 5800mm ; Angle = 25

Operating height 1 = 669mm
Operating height 2 = 962mm

As the angle is constant (25), the problem of overturning

of the slide is eliminated.

A common inclined table having 25 angle can be used

for machining all diameters.

However packing must be added underneath the inclined

table to achieve required height.

Operating height lies between desirable range for most

of the cases.

Design Considerations:

The operating height must within 800mm to 1400mm to

ensure comfortable operation.

The overhang of the inclined bed over the base must be

kept to a minimum.

The cross slide must have a clearance of at least

230mm to accommodate depth of cut while performing
facing operation on flanges.

The overhang of the tool holder must be kept as less as

possible to avoid vibrations.

w/p diameter = 4000mm ; Angle = 30

Operating height 1 = 1150mm
Operating height 2 = 871mm

w/p diameter = 4200mm ; Angle = 30

Operating height 1 = 1100mm
Operating height 2 = 821mm

w/p diameter = 4400mm ; Angle = 30

Operating height 1 = 1050mm
Operating height 2 = 771mm

w/p diameter = 4600mm ; Angle = 30

Operating height 1 = 1000mm
Operating height 2 = 721mm

w/p diameter = 4800mm ; Angle = 30

Operating height 1 = 950mm
Operating height 2 = 671mm

w/p diameter = 5100mm ; Angle = 30

Operating height 1 = 875mm
Operating height 2 = 596mm

w/p diameter = 5400mm ; Angle = 30

Operating height 1 = 800mm
Operating height 2 = 521mm

w/p diameter = 5800mm ; Angle = 30

Operating height 1 = 666mm
Operating height 2 = 421mm

 Due to larger machining angle, tool tip

height is reduced and subsequently,

vibrations decrease.

However, in many cases, the operating

height of the tool post lies below the

minimum permissible value.

Also hand wheel will be at a larger angle

making it more uncomfortable to turn.

 After comparing the advantages and

disadvantages of all three designs, it was

decided to keep the angle constant at 25.

It was decided to employ a welded

assembly in the form of an inclined table.

After obtaining the thickness of the plates

available in the inventory, assembly and

detail drawings were prepared as follows:

Added Bases
Diameter to be Machined

Required Height of Base

4000

393

4200

393

4400

303

4600

303

4800

197

5100

197

5400

106

5800

1.

First metal plates were cut as specified in

detail drawing.

2.

Fit up of plates by arc welding.

3.

Final welding of structure

4.

Machining of contact surfaces.

 Plates were assembled before final

welding using arc welding process.

Keeping critical areas and ease of welding

in mind, the following procedure for fit up

was employed.

Cutting Forces:
Fz = 2146.3kN
Fy = 645.37kN
Fx = 1496.18kN

Now, the radial force Fx will act

upon the support plate and will be
resisted by the welds highlighted in
figure Now the shear stress acting
on a fillet weld is given by the
following formula:

= P / 0.707hl
Where, P = tensile force on plates
= Fy = 645.37kN = 645370N
h = leg of the weld (mm) =
8mm
l = total length of the weld
= 1980mm
= 645370 / (0.707 x 8 x 1980)
= 57.63MPa
Now the maximum yield strength
of IS 2062 Grade A steel is
240MPa > 57.63Mpa. Hence the
design of the welds on the support
plate ribs is safe.

= P / 0.707hl
Where, P = tensile force on
plates = Fh = 1672.46kN =
1672460N
h = leg of the weld
(mm) = 8mm
l = total length of the
weld = 1600mm
= 1672460 / (0.707 x 8 x
1600)
= 184.81Mpa
Now the maximum yield
strength of IS 2062 Grade A
steel is 240MPa >
184.81Mpa. Hence the design
of the welds on the rear plate
ribs is safe.

STEP 1: Marking of plate positions and fitting of

rear plate ribs

STEP 2: Attaching rear plate using rib support

STEP 3: Attaching side plates using rear

plate support

STEP 4: Attaching remaining rear plate ribs

STEP 5: Placing top plate on side plates

STEP 6: Welding all joints present

STEP 6: Welding all joints present

STEP 7: Attaching and welding front plate

and ribs

STEP 8: Attaching and welding support plate

and ribs

Step 9: Welding Plates for Carrying Fixture

Step 10: Machining M30 holes in top plae

Step 11: Machining 24mm holes in bottom plate

Step 12: Machining Contact Surfaces

Step 13: Machining support plate

Step 14: Machining Contact Surfaces

Inspection:
ThyssenKrupp Industries India

QUALITY ASSURANCE
FINAL INSPECTION REPORT

Job Description: Turning fixture for Lathe Machine

Page 1 of 1
Date: 7-12-2009

Quantity: 1

The item was inspected and the following are the observations
Sr. No.

Required Dimensions

Observed Dimensions

1.

Angle of the top plate = 25

25

2.

Distance of top plate location

point from front edge of bottom
plate = 462 mm

462 mm

3.

Height for top plate location

point = 526 mm

526 mm

4.

Distance of support plate from

top plate location point = 280
mm

280 mm

5.

Distance of M30 holes from top

plate location point = 245 mm

245 mm

Remarks

Costing:

The approximate weight of the fixture was calculated using the weights of the
plates used and the total weight of the filler material used. Now the total volume
of metal plates used was calculated to be 204999.41cm3. The plates used were
M.S. plates and the density of mild steel is = 7.86g/cm3.
V1 = 204999.41cm3
Therefore, the weight of the metal plates used was calculated as:
M1 = V1 x
M1 = 204999.41 x 7.86
M1 = 1611295.363g
M1 = 1611.29Kg
The cost of IS 2062 Grade A steel is Rs 52 per Kg
Hence the raw material cost can be calculated as
C1 = 52 x 1611.29
C1 = Rs 83,787
Weld specifications:
CO2 Welding at 220A 28V,
8 x 8 mm fillet welds
Filler Material: 1.2 mm FCAW wire fed at 9m/min

The total welded length in the fixture was calculated to be 53362mm.

The weld cross sectional area is
A = x 8 x 8 = 32mm2
Total volume of filler material used is
V2 = Total weld length x Weld cross section area
V2 = 53362 x 32
V2 = 1707584mm3
The filler material used was M.S. wire coated with anti-oxidant coating.
Hence the weight of the filler material can be calculated as
M2 = V2 x
M2 = 1707.584 x 7.86
M2 = 13421.61g
M2 = 13.42Kg
The cost of 1.2 mm FCAW wire is approximately Rs 90 per Kg
Therefore the total cost of filler material can be calculated as:
C2 = 13.42 x 90
C2 = Rs 1207.8

The total time taken for the fit up of the fixture was approximately 3hrs.
T1 = 3hrs
Wire feed rate = 9m/min = 150mm/sec
Wire cross section area = /4 x 1.22
Wire feed rate in terms of volume of filler material per second is
F = 150 x /4 x 1.22
F = 170mm3/sec
Weld time can be calculated as
T2 = V/F
T2 = 1707584/170
T2 = 10044.61sec
T2 = 173.3min or 2hrs 53min
Based on timings recorded during the welding, it was found that on an average,
50% of the weld time was required for slag removal and cooling of the welded
area.
Hence, Weld cooling and slag removal time
T3 = 0.5 x T1
T3 = 0.5 x 173.3
T3 = 86.65min or 1hr 27min
For welding the multi-pass weld, preheating was carried out for a period of
15min/pass. Therefore the time required for preheating is calculated as
T4 = 15 x 5
T4 = 75min or 1hr 15min

Taking into account the various stoppages in work such as replacement of wire
spool as well as relaxation of the worker, the contingency and relaxation allowance
must also be considered. This allowance is assumed to be 10% of the weld time.
Therefore,
T5 = 0.1 x 173.3
T5 = 17min
The total time required to weld the fixture can be calculated as
Tw = T1 + T2 + T3 + T4 + T5
Tw = 9hrs 52min
The wage rate of a welder is Rs 350 per day for an 8hour shift.
Therefore the total labour cost associated with the welding of the fixture can be
calculated as :
C3 = 9.866 x 350/8
C3 = Rs 432
The time required for drilling 30mm holes in top plate can be calculated as :
T6 = d x N / sr x n
Where sr = Feed per revolution
n = rpm
d = depth of hole = 32mm
N = No. Of holes to be drilled
Therefore,
T6 = 32 x 12 / 0.3 x 150
T6 = 8.53min

Similarly, the time required for drilling 24mm holes in bottom plate can
be calculated as:
T7 = d x N / sr x n
Where sr = Feed per revolution
n = rpm
d = depth of hole = 32mm
N = No. Of holes to be drilled
Therefore,
T7 = 32 x 10 / 0.3 x 150
T7 = 7.11min
Time required for milling top plate can be calculated as:
T8 = Lm / s
Where Lm = Length of machining
s = Feed per min
Lm = 22050mm
s = 1200mm/min
T8 = 22050/1200
T8 = 18.375min

Similarly, Time required for milling support plate can be calculated as:
T9 = Lm / s
Where Lm = Length of machining
s = Feed per min
Lm = 4800mm
s = 1200mm/min
T9 = 4800/1200
T9 = 4min
Similarly, Time required for milling bottom plate can be calculated as:
T10 = Lm / s
Where Lm = Length of machining
s = Feed per min
Lm = 38700mm
s = 1200mm/min
T10 = 38700/1200
T10 = 32.25min
The total time required to machine the fixture is calculated as :
Tm = T6 + T7 + T8 + T9 + T10
Tm = 70.265min or 1hr 10min or 1.17hrs
Cost operating the machine tool is Rs 1500 per hour
Hence, total machining cost is calculated as :
C4 = 1.17 x 1500
C4 = Rs 1,755
Therefore the total cost of the fixture is
C = C1 + C2 + C3 + C4
C = Rs 87182

Trials and Testing:

On completion of manufacture of fixture
trial run was conducted on 15 December
2009. The fixture was set up using the
dimensions shown in the layout diagrams
(Fig 6.2). It was observed that the speed
reduction in the existing system was not
sufficient to obtain the required feed rate.
As a result further speed reduction was
required and an additional speed
reduction gearbox was to be added.
Trial Run .MP4

It was found that with the existing system, a feed

of 8mm/min was obtained when motor rpm was
350.
As the speed reduction is 25:1,
Feed rod rpm = Motor rpm / 25
= 350 / 25
= 14rpm
Hence, when feed rod rpm is 14, feed obtained
is 8mm/min.
Now, the required feed rate was 0.4mm/rev for
rough turning and 0.1mm/rev for finishing.
Work piece rpm = 4
Therefore, required feed rate = 0.4 x 4 =
1.6mm/min

The gearbox used was a worm gearbox having reduction

ratio of 15:1.
Now according to the new system when motor rpm is 350,
Feed rod rpm = 350 / 25 / 15 = 0.933
When feed rod rpm is 14, feed rate obtained is 8mm/min
Hence when feed rod rpm is 0.933, feed rate obtained will
be
= 8 x 0.933 / 14
=0.533mm/min
= 0.133mm/rev
Therefore with the help of the additional gearbox, a feed
rate of 0.133mm/rev can be obtained. The additional
gearbox used is shown is shown below.
Additional Gearbox

Conclusion:
After addition of second gearbox the required feed rate
was achieved resulting in satisfactory performance of the
fixture. The addition of the third fixture enabled
simultaneous machining operations to be carried out at
both the bearing support tyres as well as the girth gear
flange. Such an integration of the third machining
process led to machining time reduction. Also the new
fixture was lighter in weight than its previous
counterparts. As a result, there was greater ease in
setting up the operation and time required for non-valueadded activities was greatly reduced.

Production Technology, H.M.T.

An Introduction to Workshop Technology, W.
Chapman
Westermann Tables for the Metal trade
Work Study, I.L.O.
Machine Tool Design and Numerical Control, N.K.
Mehta
Process Engineering for Manufacturing, Eary and
Johnson
Machine Tool Design Handbook, Central Machine
Tool Institute