contour turning attachment for lathe pdf
#1

DESIGN AND FABRICATION OF GRINDING
ATTACHMENT FOR LATHE MACHINE TOOL

ABSTRACT
Grinding operation is performed to obtain a fine surface finish after performing turning operation on lathe
machine for cylindrical jobs. This is done to obtain required dimensions of part to be used in any assembly.
Thus to perform these two operations on same machine the attachment is designed. To verify the design the
attachment is fabricated.
This work describes an attempt to decrease the time in loading and unloading of workpeice with desired surface
finish. The report describes the selection of wheel for grinding. It also considers the rigidity of design, damping
of vibration due to motor speed and stress analysis of critical part of design, which is analyzed on INVENTOR
software and compared with theoretical calculations. It also lists the various operations performed to fabricate
the attachment. The results are obtained in form of tolerance limits which are compared with results of
individual grinding machine operation on different machine and the conclusion are stated.

INTRODUCTION
Lathe has always been the mother of all machines before the invention of CNC machines. The turning operation
on lathe is most frequently performed, and then it’s transferred to grinding machine for fine surface finish. The
time required to do this is generally high and loading and unloading of job causes human fautige. Thus
combining these two operations on single machine would benefit and this led to think of grinding on lathe
machine. The grinding operation is done using abrasive wheel, grinder which provides fine surface finish. The
grinding wheel differs for different materials to be grinded which is made up of abrasives, bond, grit, grade and
structure [1]. In this paper we have selected the required grinding wheel depending on workpeice to be used.
The main aim of project is to obtain an accuracy of 20microns. Since grinding requires high surface finish thus
proper motor speed is selected as required . Since the motor will run at high rpm lot of vibrations will be
generated, thus it will be necessary to damp these vibrations using damper .Additional to it appropriate
rigidity should be provided to clamp the motor on lathe bed.

II. SELECTION OF GRINDING WHEEL
Grinding wheel is specified by its grit, grade and structure. For different type of work material and for different
dimensions, the requirements of a grinding wheel are different. Thus it is important to select a proper grinding
wheel. Following are some major specifications of grinding wheel.
1.1 Abrasives
For high tensile strength the abrasive should be tough and should not get fractured easily. Thus Aluminium
oxide was selected as an abrasive, assuming maximum work to be done on mild steel.
1.2 Grit
Grit is grain size. Smaller the grit finer is the surface finish. For high stock removal rate and better control of
surface finish Grain size should be 30-60. Therefore grit is selected as 60.
1.3 Grade
Grade is to define hardness of the bond holding the grains together. For better compromise between soft and
hard bond so that wheel wear and cost will be less intermediate grade P is selected.
1.4 Structure
Structure is the void spacing between the grains. Lesser the structure, higher is the density of grains on the
wheel. Densely packed grains are required for fine cuts. Therefore structure is selected as 5.
1.5 Bond
Bond is the type of adhesive used to hold grains together on the wheel. It depends on rate of stock removal,
rigidity and required precision. For high stock removal, rigidity and suitable precision grinding vitrified bonds
are preferred. Therefore V99 bond is selected.
Selected wheel specification is A60P5V99
III. SELECTION OF MOTOR
For this attachment, it is necessary to select drive with proper speed and torque. The dimensions of grinding
wheel and speed of the motor are interrelated. For grinding wheel with 150mm diameter, desired speed is 2880
rpm. Thus 3phase AC motor with power of 0.75 HP and 2880 rpm is selected.
IV. DESIGN
To achieve the objective of this project some important issues must be focused which will guarantee accuracy of
20microns and desired fine surface finish. Following are three major issues
4.1 Absorption of Vibrations
Due to a very high speed of motor, there are a lot of vibrations involved. Static deflection was found to be
0.0126m. The effectiveness of the isolaton produced by the isolator is characterized by transmissibility which is
defined as the ratio of force transmitted by an isolator to the exciting force due to machine. Selection of an
isolator is done on the basis of damping ratio. Following graph shows the relation between transmissibility and
damping ratios from the graph shown below, suitable damping ratio was found to be 0.05. Thus rubber was
selected as an isolator.
Rigidity of Attachment
Due to high speed of motor, rigidity of attachment becomes the major concern. The forces acting due to motor
were calculated. And it was found necessary to clamp the motor. For clamping the lathe has cross slide which
has provision of T slots. Thus an external attachment can easily be mounted on the cross slide. So that for feed
and depth of cut extra efforts are not required. So the frame of mild steel was designed according to the
dimensional constraints of the cross slide. Motor was to be mounted on this frame. Thus it was important to
ensure the rigid clamping of motor on the frame. Four bolts which are holding the motor were simulated and
tested for failure. Software analysis was verified by mathematical calculations. Thus ensured the rigidity of the
attachment.
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