International Journal of Emerging Engineering Research and Technology

Volume 6, Issue 7, 2018, PP 18-25

ISSN 2349-4395 (Print) & ISSN 2349-4409 (Online)

Spur Gear Cutting Attachment for Lathe Machine: A Key to

Increased Productivity, Decreased Cost and Floor Area
Requirement
Pullagura Pushpalatha1, G. Suresh2, K. Balaji2, P. Kumar Babu3
1
P.G. Student, Department of Mechanical Engineering, VEMU Institute of Technology, Chittoor
District, Andhra Pradesh, India
2
Associate Professor, Department Of Mechanical Engineering, VEMU Institute Of Technology,
Chittoor District, Andhra Pradesh, India
3
Professor,Department Of Mechanical Engineering, Pragati Engineering
College,Surampalem,Kakinada East Godavari District, Andhra Pradesh, India
*Corresponding Author: Pullagura Pushpalatha, P.G. Student, Department of Mechanical
Engineering, VEMU Institute of Technology, Chittoor District, Andhra Pradesh, India

ABSTRACT
Lathe is a very important manufacturing subsystem in many sectors.Even though it is a versatile machine, it
has some limitations while performing certain operations like a spline, gear cutting. The use of milling
machines in the production of spline and gear cutting is well recognized. If an attachment on general
purpose lathe is made available, the cost of production of a product could be reduced. A CNC machine can
perform the many operations more effectively and the human involvement is limited. However, due to
increase in the cost of a CNC machine and the indirect costs associated with these machines, they are
considered as white elephants in a certain class of manufacturing units. The main objective of this paper is
to Design and Analysis of Spur gear cutting attachment for Lathe machine to increased Productivity,
Increased flexibility of Lathe, Decreased Cost, and Floor area Requirement. The developed design is
modelled by using CATIA V5 and the model is simulated in Solid works motion simulator software. By using
ANSYS Software we tested the strength of the spur gear cutting attachment in Lathe machine.
Keywords: Spur Gear, Lathe machine, Milling machine, Optimization, Ansys

INTRODUCTION LITERATURE REVIEW

Workshops and small-scale industries are S. Amar conducted to a reviewed on the
heavily constrained to use general purpose attachment is a good tool for contemporary
machines due to financial limitations. Machines industrialization which is able to undoubtedly
such as Lathes and Milling machines are facilitate to enhance the productivity and can
versatile with these groups as they required facilitate the industries to enhance the standard
minimum funding and are easy to maintain. of keyway operation. The compact style of
Researchers always attempt to help these attachment can facilitate simple operation of the
industries through innovative methods to keyway.
enlarge the ambit their production using these
general purpose machines. A variety of Dr. G. Naga MalleshwarRao conducted a study
attachments are already in use by these industries. on overview of eccentric turning attachment.
with the help of V-block, studs, center plate,
Even though various attachments like keyways, center rod, base plate, nuts, scale etc., they have
slotting, internal keyway, grinding wheel and implemented this design successfully and executed
eccentric turning for lathe machine. Still, it is this attachment might helpful to reduce time
facing some difficulties like machining of gear while performing desire operation.
cutting and sp lines on the shaft. To overcome
this difficulty it is necessary to design an M.Narasimha1 review done adjustable multi-
attachment for the lathe. Which is able to spindle attachment. The main motto of this
overcome these difficulties and flexible to use it project is machining 3 t-slots at a time, which is
in standard lathes. in the range of 40 mm to 320 mm. In initial

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Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

stage this attachment was designed in CAD vertical milling operation there are different
model letter this attachment was fabricated milling operation is available in now a days and
based on there recent to accomplish. The most of them are operated by CNC machines to
accomplished of the requirements in the range get much precision and reduce time in production.
of 40 mm to 160 mm in a single pass to cut T-
slots by implementing three different cutters on MACHINING
an arbor in a milling machine Tool. Machining covers a good style of actions that
J.C.Harbison focused on a milling attachment take a material and switch it into one thing else.
for lathes. He modified the attachment that It is outlined as a controlled method that takes
cutting tool fitted to the arbor and that is the material and transforms it into a desired final
supported by chuck and tailstock. He modified form and size. This may embrace material-
direct indexing to compound indexing. removal as seen with such actions as cutting,
drilling, boring, or material addition. Although
J.W.Bracus states that a gear cutting attachment. machining is most ordinarily used with the
He was studied and modified smith’s attachment metal product, machining can even be through
and he tried to initiate indexing in the with materials like wood, ceramic, plastic, and
attachment. composite materials.
T.E.Smith said that a keyway and gear cutting SPUR GEAR
attachment for lathes. He is the initiator for this
concept he builds a gear and keyway cutting Spur gears consist of parallel teeth to the axis
attachment for lathe by adding another motor to and are utilized for transferring power between
the cutting tools and chuck modified as holding two parallel shafts. They are simple to
and indexing device but this attachment is heavy manufacture and low cost. They need the most
and complex. effective potency and smart accuracy rating.
They are used in high speed and high load
MILLING application altogether varieties of trains and an
Milling is a machining operation that will do honest sort of velocity ratios. Hence, they
machining by fixing workpiece at a certain perceive wide applications right from clocks,
position and then doing operation by guiding organization gadgets, motorcycles, vehicles, and
cutting tool towards the workpiece. That is a railways to aircrafts.

Figure1. Spur gear

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Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

METHODOLOGY

Figure2. Methodology flow chart

CALCULATIONS
Spur Gear Creation

Figure3. Spur gear nomenclature

Whole Depth (W) = 2.157/P Circular Pitch (CP) = 3.1416/P
Addendum (a) = 1/P Diametric Pitch (P) = N/D1
Tooth Radius(R) = ¾(CP) Teeth number (N) = D1xD
Pitch Diameter (D1) = N/P Dedendum (d) = W-a

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Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

Outside Diameter (D) = (N+2)/P = 3.922 mm

Cordial Thickness (T) = D1sin(90/N) Work piece diameter 50 mm
Work piece diameter 50 mm
For this work piece if number of teeth 24 then
For this work piece if number of teeth 18 then the gear parameters will be
the gear parameters will be
1) Outside Diameter OD = (N+2)/P
1) Outside Diameter D = (N+2)/P
Outside Diameter = 50 mm
Outside Diameter D = 50 mm
Teeth number = 24
Teeth number = 18
50 = (24+2)/P
50 = (18+2)/P
P = 26/50
P = 20/50
= 0.52 mm
= 0.4 mm
2) Pitch Diameter D1 = N/DP
2) Pitch Diameter D1 = N/P
P = 0.52
P = 0.4
D1 = 24/0.52
D1 = 18/0.4
= 46.15 mm
= 45 mm
3) Addendum a = 1/DP
3) Addendum a = 1/P
= 1/0.52
= 1/0.4
= 1.92 mm
= 2.5 mm
4) Dedendum d = w-A
4) Dedendum d = w-A
5) Whole Depth W = 2.157/P
5) Whole Depth W = 2.157/P
= 2.157/0.52
= 2.157/0.4
= 4.15 mm
= 5.3925
d = 4.15 – 1.92
D = 5.3925 – 2.5
= 2.23 mm
= 2.8925 mm
6) Circular Pitch CP = 3.1416/P
6) Circular Pitch CP = 3.1416/P
= 3.1416/0.52
= 3.1416/0.4
= 6.04 mm
= 7.854 mm
7) Tooth Radius R = ¾(CP)
7) Tooth Radius R = ¾(CP)
= ¾ (6.04)
= ¾ (7.854)
= 4.53 mm
= 2.94 mm
8) Module m = D1/N
8) Module m = D1/N
= 46.15/24
= 45/18
= 1.922
= 2.5
9) Chordal thickness T = D1 sin(90/N)
9) Chordal thickness T = D1 sin(90/N)
= 46.15 sin (90/24)
= 45 sin (90/18)
= 26.38 mm
MODEL DEVELOPMENT
The mode was developed by Solid works software and is imported to ANSYS software for carrying
out further analysis and it is shown below.

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Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

Figure4. Modified model

MOTION SIMULATION
All motions are applied to the assembly parts and the final animated video was recorded.Motions
applied to the assembly parts are illustrated in below table.
Table1.Motion simulation details
X linear X rotation Y linear Y rotation Z linear Z rotation
S.NO PARTS
(mm) (RPM) (mm) (RPM) (mm) (RPM)
1 Cross slide -200 0 0 0 0 0
2 Centers 0 0 0 0 -100 0
3 Cross slide 0 0 150 0 0 0
4 chuck 0 600 0 0 0 0
5 other 0 0 0 0 0 0

All parameters are taken from general purpose lathe and milling machine now these values will be
applying on the modified model assembly structure and analyzed by using ansys software.

Figure5. Simulation frame image A Figure6. Simulation frame image B

SIMULATION CALCULATIONS
𝜎𝑚𝑎𝑥
Hence stress concentration factor F1 (α˳) = 𝜎

International Journal of Emerging Engineering Research and Technology V6 ● I7 ● 2018 22

Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

247
= 7.76
=31.8
𝜎𝑚𝑎𝑥
Hence stress concentration factor F2 (α˳) = 𝜎
247
= 77.87
=3.17

Figure7. Equivalent elastic stress in MPa

Figure8. Max shear stress in MPa

Figure9. Maximum principal elastic strain

CONCLUSION  A lot of investment is saved instead of
buying a milling machine.
The following conclusion can be drawn
 Produced samples might competitive with
milling accuracy.

23 International Journal of Emerging Engineering Research and Technology V6 ● I7 ● 2018

Spur Gear Cutting Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and
Floor Area Requirement

 Cost of manufacturing is also reduced. [7] J.C.Harbison, Milling Attachment For Lathes,
 Floor area requirement is also reduced. No: 2453315, Nov. 9, 1948.
[8] S. GadakhRamesh, G. Londhepradip, A. Shaikh
 Tool life and productivity can be increased.
Bilal and S. Shaikhfiroj,Gear Manufacturing by
 Flexible in operation. Using Conventional Lathe Machine, International
 Simple in operation and no need for a skilled Journal of Research in Engineering and
operator. Technology, ISSN: 2319-1163.
 Good accuracy can be achieved. [9] T.E.Smith,Keyway and Gear Cutting Attachment
for Lathes, US; No: 2188447, Jan30, 1940.
FUTURE SCOPE
AUTHOR’S BIOGRAPHY
 Other operations can also be incorporated in
to the machine. PULLAGURA PUSHPALATHA, A final year
 Cost can also be reduced to some extent by P.G. (M Tech) Student (Machine Design) of
manufacturing it on a mass scale. VEMU Institute of Technology, P. Kothakota,
Chittoor District. She has done her B Tech in
REFERENCES IIIT RGUKT, R.K. Valley in Kadapa district.
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Citation: Pullagura Pushpalatha, G. Suresh, K. Balaji, P. Kumar Babu (2018). “Spur Gear Cutting
Attachment for Lathe Machine: A Key to Increased Productivity, Decreased Cost and Floor Area
Requirement”. International Journal of Emerging Engineering Research and Technology, 6(7), pp.18-24.
Copyright: © 2018 Pullagura Pushpalatha, et al. This is an open-access article distributed under the terms
of the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction
in any medium, provided the original author and source are credited.

International Journal of Emerging Engineering Research and Technology V6 ● I7 ● 2018 24