jurnal bubut Internasional.rtf

7/24/2019 jurnal bubut Internasional.rtf

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International Journal of Emerging Technology and Advanced Engin

Website: www.ijetae.com ISS !!"#$!% "&' IS( #):!##* +ertified Journal',olume %' Issue "' -

Investigation on Automation of Lathe Mach

Prakash N. Parmar , Prof. N. C. Mehta , Prof. Manish V. Trivedi1 2

1 2 3Student of M.E. (CAD/CAM), Head of Department, Professor, Department of Mechanca! En"neern", #o$!e En"

Co!!e"e, %una"adh, &u'arat, #DA.

Abstractow a days' /roducts can be /roduced by Though some e!ectrica! su"assem"!# is often $emodern technology' which uses com/uter software' hardwareat the retrofitter%s "usiness !ocation, most o f the &and firm ware in industries. It is nee de d to use ++ lathe"e com$!eted at the machine site, avoiding cost!# machine to get mor e accurate dimensions and irregular sha/e.rigging and trans$ortation costs, and minimi'ing So' ++ machines are becoming more and more im/ortant in

that the machine is out of commissimoderni0ed industriali0ation. There are many conventional

(e"ui!ding t#$ica!!# inc!udes the re$air or re$lathe machines in our country. To build a new modern

of some &orn mechanica! com$onents such as "a!develo/ed country' it is re1uired to convert these conventional!u"rication $um$s, safet# inter!ocks, guards, hoslathe machines into semi$automatic control lathe machine by

retrofitting. 2evelo/ing and changing into se mi$automaticand e!ectrica! &iring. The re"ui!d is t#$ica!!# $erf

control lathe machine' there are three re1uired /ortions' the re"ui!der%s faci!it#, so there ma# "e adnamely' mechanical electronics and hydraulic. In this /roject trans$ortation and rigging costs.we convert the convention lathes which have "ft bed length in (emanufacturing goes a ste$ further to re$air oto the semi$automatic lathe.

mechanica! com$onents to the origina!, as ne&

In mechanical side we re/lace the ball screw in /lace of s$ecification. It is !ike!# that the machinelead screw for better accuracy and remove some unnecessaryco m$!ete!# disassem"!ed , c!eaned, ins$ected, re$a

com/onent li3e gears for /r oviding s/ace for motors. We add$ainted. A!! $neumatic, h#drau!ic and e!ectrica! an e4tra /lates or structure for installation of mot ors. Also&i!! "e u$dated. The machine ma# a!so "e modified/rovides a hydraulic circuit for coolant. In electronic side we

mechanica! accessories added to re)$ur$ose it foused a servo5 ste//er motor for both 6 and 7 a4is and /rovidecontroller for the efficient o/eration. a$ $!icatio n. Practica!!# &itho ut e*ce$tion, remanuf

&i!! take $!ace at the remanufactureKeywordsAutomation' 8etrofitting' ++ Turning +enter The main o"+ective of the retrofitting in !athe m

to im$rove the e*isting conventiona! !athe maI. INT(-CTIN $rovide it features of CNC machine &ith ver# !o

than the ne& CNC machine.(etrofitting refers to the addition of ne& techno!og# orfeatures to o!der s#stems this definition gives an a!most a!! (ather than a" ove main o"+ective there a!so

o"+ectives of the retrofitting &hich is giveinformation a"out the &ord retrofitting. /hen &e sa# that

retrofitting re!ated to some com$onent that mean &e tr# to To Increased $roductivit# and im$roved cu$grade that com$onent and im$rove their efficac# through machine.a $resent techno!og#. 0ar su$erior re$eata"i!it#

ut here &e on!# ta!ks a"out the retrofitting in !athe To red uced machine do&

machine at time (etrofitting is the $rocess of re$!acing the 0ast machining c#c!es.CNC, servo and s$ind!e s#stems on an other&ise igh accurac#, high feedmechanica!!# sound machine too! to e*tend its usefu! !ife. To increased accurac# and $art finished(e"ui!ding and reman ufacturing t#$ica!!# inc!ude a CNC co ntro!!er.retrofit. The antici$ated "enefits inc!ude a !o&er cost ser friend!# $rogramming and siinvestment than $urchasing a ne& machine and an soft&are ena" !es - gra$hic re$resentatioim$rovement in u$time and avai!a"i!it#. ut there are often &ith auto matic generation ofother unantici$ ated "enefits to retrofitting inc!ud ing !o&er 4!iminate additiona! too!energ# costs, higher $erformance and a ne& !eve! of The $)gradation Package is !ess e*$enmanufacturing data accessi"i!it#. more readi!# +ustifia"!e.Assuming the machine too! is genera!!# in good sha$emechanica!!#, CNC retrofitting is t#$ica!!# the !o&est costso!ution to im$rove the overa!! $erformance of an o!dermachine too!. 526


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International Journal of Emerging Technology and Advanced

EngineeringWebsite: www.ijetae.com 9 ISS !!"#$!% "&' IS( #):!##* +ertified Journal',olume %' Issue "' -

II. L ( e has deve!o$ed attachment for an e*istiIT4(AT(4 4VI4/

machine. The CNC machine o$erates on mecIn 1786, -e$artment of Mechanica! 4ngineering, IIT,co ntro!s and a co m$uter interface ca!!ed CAM90

Ne& -e!hi , has taken a research to$ic named as:1 ;

used as a CNC Lathe after insta!!ing the re fa"ricated different mode!. e has sus

manufacturing techno!og#, 0!e*i"!e Manufacturingdesign > fa"ricated the mode!. The &orking of t9#stems have "eco me ke# e?ui$ ment in factor#

Lathe attachment is tested > checked "# makingauto mation. Machine too! is heart of the 0!e*i"!e

machining o$ eration !ike turning and thread cuttiManufacturing 9#stems. 4* e*am$!e Lathe machine is the

machining o$erations are successfu!!# done. Tgenera! t#$e of machine too! used "# a!most a!! the 0M9s.machine "ecomes mu!tifunctiona! &ith the $-uring the o$eration of this machine too!, different kinds

deve!o$ed !athe attachment and can "e used accordof fai!ures are faced "# the industr#. A s#stematic stud# ofinsta!!ing the res$ective attachmen t to it. The CNC

such fai!ures can he!$ in identif#ing the critica! su")s#stemis usefu! for research &ork in "oth the fie!ds, &hen of these machine too!s. This &i!! "e usefu! for identif#ing

&ith the $ro$er attachment. The figure of dethe condition monitoring needs o f the machine too!s. This

attachment is sho &n "e!o&,dea!s &ith the identification of critica! su" )s#stem "ased on

the fai!ure data ana!#sis for d ifferent t#$e of machine too!s.

Initia!!# !athe has "een c!assified into various su")

s#stems as sho&n in 0igure. In the fre?uenc# of fai!ures for

each su" )s#stem and fai!ure modes have "een consideredfo r finding out the &eakest su")s#stem. In ana!#sis, fai!ure

fre?uenc# and do&ntime have "een taken into

consideration for deciding critica! su")s#stems of machine

too!s. It can "e o"served that the ma*imum fai!ures took

$!ace in headstock and carriage su")s#stems. These su")

s#stems face fai!ures in com$onents !ike gear, gear"o*

"earing, s$ind !e "earing, c!utch and cross)s!ide +i". ere it

cou!d "e o"served that the "earing fai!ures cause !onger

do&ntime.ig. ) 2evelo/ed at

-eve!o$ed design is successfu!!# im$!emente

$ro$osed &ork for the deve!o$ment of the !athe att

inc!uding headstock, tai!stock and too! $ost. T

sho&s the $rocess of the conce$tua! design and

$ro$ er $rocess $!anning for the deve!o$men

different com$onents of the !athe attach m

$revious!# attachment and deve!o$ed !athe att

make the CNC machine mu!tifunctiona!. Thu

research can "e carried out in "oth the fie!ds res$

The CNC machine is "ased on the mechatronic Wearing ;arts of +onventional lathe and the com$uter interface CAM90T. Vario

n histogram different fai!ure modes and their re!ative o$erations !ike $!ain turning, ste$ turning, ta$er turfai!ure fre?uencies have "een grou$ed into four)fai!ure turning, threading o$erations and manufacturing modes, com$onent damage, fuse "urnt, circuit fau!t and are successfu!!# $erformed on the CNC machin!ooseness. It can "e o" served that the dominant fai!ure insta!!ed &ith !athe attachment. The sumode is "ecause of com$onent damage. The com$ onents deve!o$ment of the !athe attachment for the CNC are e!ectrica!, e!ectronics and of mechanica! categories. is done.In 2@1, V. (o# > 9. umar from B in stitute: 2; In 2@1, ar!)ein' 9chumachis invente4ngineering, India $u"!ished deve!o$ment o f Lathe Mu!ti 9$ind!e Lathe.machine attachment for CNC machine. 525


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Mu!ti s$ind!e !athe co m$rising a machine frame as e has conc!uded that the addition of surface fi

s$ind!e drum &hich is arran ged in the machine frame is in turning $rocess he!$s to im$rove the surface fin

rotata"!e a"out a s$ind!e drum a*is and is made u$ at !east this setu$ increases the too! !ife of the turning too

$artia!!# of segments &hich are cut out from f!at materia! in the e*$erimenta! resu!ts, it is confirmed that the

a stacking direction $ara!!e! to the s$ind!e drum a*is and change of $o&er consum$tion even after the a

e*tend in stacking $!anes transverse to the stacking usage of surface finish too!. ence, the set u$

direction these segments having receiving cu touts and he!$fu! in im$roving the?ua!it# $roduct, &ith !es

coo!ing channe! cutouts &hich over!a$ &ith o ne another and $o&er consum$tion.

such that the s$ind!e drum has s$ind!e motor rece$tac!es

fo r s$ind!e motors and a coo!ing channe! s#stem se$arated III. (4T(0ITTIN(Cthere from "# &a!! &e"s characteri'ed in that the coo!ing

ere I have divide the com$!ete construction $channe! s#stem has severa! channe! su"s#stems for a !i?uid into five ste$s. In &hich I have deve!o$ed the ccoo!ing medium /hich are fed in $ara!!e!.

(etrofitted !athe machine from conventiona! !athe m:6;In 2@1, M. Moses > -r. -enis Asho k M. Tech, Theses a!! ste$s are !isted "e!o&,

Mechatronic from 9choo! of Mechanica! and ui!ding

Step 1* Purcha sn" of e!ectron c p9cience, VIT niversit#, Ve!!ore, India $u"!ished tit!ed as

-eve!o$ment of a ne& machining setu$ for energ# efficient I have $ urchased e!ectronic $arts !ike ste$$eturning $ rocess. In the $rod uction unit, !athe is one o f the ste$$er drive, s$ind!e drive, $ro*imit# s&itch andim$ortant $rotection machines. This $a$er fo cuses on $ane!.

$roducing a ?ua!it# $roduct in !athe machine &ith !ess Step 2* Dsassem$!e some parts from con+enton$o&er consum$ tion. In order to achieve that, a s$ecia!machne

setu$ is deve!o$ed in the !athe machine for turning and

finishing of the com$onents, to achieve ?ua!it# $roduct and As $er definitio n of retrofitting $rocess, I

remove non )used $arts from conventiona! !athe ma!so to im$rove the $roductivit#. As a resu!t of this ne&

a$$roach, $rofuse amount of energ# can "e saved, ?ua!it# 9o I have removed ead stock gearing mechanism

Lead scre&, Lead scre& mounting "racket, and$roduct can "e o"tained and too! !ife can "e increased. The

stud# aimed at eva!uatin g the "est $rocess environment etc.

0or decreasing friction on the s!ide and increasin&hich cou!d simu!taneous!# satisf# re?uirements of "oth

?ua!it# and as &e!! as $roductivit#. # conducting man# $art !ife I have used turcide &hich is made from $

f!uro eth#!ene PT04D and "ron'e.e*$eriments it &as found that this s$ecia! setu$ $rocess

im$roves the ?ua!it# and a!so reduces the $o&er

consu m$tion as com$ared &ith the e*isting $rocess.

0igure of deve!o$ed attachment as sho&n "e!o&,

ig. < Turcide on slidinStep 3* Dmensona!! Des"n and fa $rcaton of mechanca! partsI have dimensiona!!# design some $arts &re?uired for retrofitting > fa" ricated andEor manu9ome of $arts design are sho&n "e!ig. ! -achine set u/ 52F


4/6



ig. % 2imensionally design 7$a4is ball screw

ig. = 6$a4is ball screw attached on m

ig. " 2imensionally design 6$a4is ball screw

ig. * 6$a4is -ounting brac3et > Ste//

ig. ? Assembly of 6$a4is ball screw with brac3et

Step * Assem$!e a!! manufactu red parts e!ectroncs

parts at desred p!ace

After manufacturing andEor fa"ricating a!! re?uired $arts,

assem" !# $rocedure carried out. A!! the mechanica! >

e!ectronics $arts are attached to their desired $!ace. 9o me

of $arts are sho &n "e!o&,ig. & 7$a4is mounting > ste//52G


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ig. )# ;ro4imity switch

ig. )! 2evelo/ed retrofitted lathe

IV. CMP

0or com$arison I have co m$are +o" manufacco nventiona! !athe machine > +o" manufactu

deve!o$ed retrofitted !athe machine

And I have conc!uded that surface roughness, $r

rate, dimensio n sta"i!it#, one time set u$ cost is

retrofitted !athe machine &hi!e machining time,

s!ide &ear is too much !o&.

ig. )) +ontrol /anel

Step 0* n specton testn" of ne de+e!op ed etroftted

athe Machne

In this ste$ I have checked a!! com$onents are $ro$er!#ig. )< +om/arison of machining time between job manufa

fitted &ith machine "od# and a!ignment of "o th "a!! /ro/osed > e4istscre&s. A!so checked " oth s!ide &orking $ro$er!# "#

ste$$er.

Then I have manufactured +o" on deve!o$ed retrofitted

!athe machine "# using turning o$eration $rogram &hich isfrom manua! $art $rogram method. And checked surfacefinishing of the +o". ig. )% +om/arison of job dimension between /ro/osed >lathe ma528


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A!so I have tested three sam$!es 2 sam$!es from V. CNC

retrofitted !athe > 1 sam$!e from conventiona! !atheD for # deve!o$ing automation in conventiona! !athe surface roughness in Tirth Agro P. Ltd.

"# retrofitting ste$$er "ased method , the machine The +o" manufactured on "oth the machine are sho &n

CNC trainer for teaching, !earning of the student "e!o &,

A!so Cost of machine is minimi'es a$$ro*imate

"e!o& the origina! CNC trainer.

As automation ne& deve!o$ed retrofitted !athe

"# re$!acing or removing the com$one

co nventiona! !athe machine, therefore setu$ cost i

co m$are &ith standard !ath e mach ine "ut $rod uctio

too much high. 9o it is ver# usefu! for mass $ro

The accurac# of the +o" manufactured in retrofit

machine is a!so high so re$eata"i!it# and dim

sta"i!it# of manufactured $art is achieved. At !a

co m$!e* +o" &hich is not manufactured in conv

!athe machine can "e manufactured in ne& d e

retrofitted !athe machine.

ig. )" Job Sam/le (404(4NC49

The certificate of surface roughness is sho&n " e!o&, :1;Machine Too! 0ai!ure -ata Ana!#sis for Condition MA$$!ication, -e$artment of Mechanica! 4ngineering, Indian

of Techno!og#, Ne& -e!hi. egs. (. L., n)!ine Mac

Process -iagnostics, Anna!s of the CI(P. , 22D, 6F7)6

:2;V. (o# H 9. umar from Inst. 4ng. India 9er. CA$ri!Bu762DJ18G175 -IJ [email protected]@@GEs6@@2)@1

:;ar!)ein' 9chumacher 2@1D, Mu!tis$ind!e Lathe. 92@1@@8G@2E2@1

:6;In 2@1, M. Moses > -r. -enis Ashok M. Tech, Mechatr9choo! of Mechanica! and ui!ding 9cience, VIT

Ve!!ore, India 7G8)1)6FG)F15@)GE1E1.@@ 2

:5; /e have a!so used fo!!o&ing !ink

htt$JEEen.&iki$edia.orgE&ikiENumerica!

htt$JEEen.&iki$edia.orgE&ikiELathe

htt$JEE&&&.e$a.govEo'oneEtit!eFEF@7EtechniciansEretr

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