PRODUCTION OF PORTABLE LATHE MACHINE FOR

ENGINEERING STUDENTS OF COLEGIO DE DAGUPAN

 CHAPTER 1 – INTRODUCTION

Background of the Study

Machining is one of the most important material removal methods in the technology of

manufacturing. It is basically a collection of material working processes that involves other

processes such as drilling, shaping, sawing, planning, reaming, and grinding among others.

Machining is practically a part of the manufacture of all metals and other materials such as

plastics, and wood as well. An important machine that is useful in machining is the lathe

machine.

A lathe machine is used for rotating a workpiece in order to perform sanding, cutting, drilling,

knurling and turning operations on the workpiece. Lathes have been used on woodworking,

metal parts and also on plastic nylon parts for a long time in the industry. So here we study the

design and fabrication of a mini lathe machine. Our machine consists of a motor with belt

arrangement used to drive the lathe chuck. The machine consists of a bed with a movable

arrangement. It consists of a holder in order to hold the desired tool in desired position. We use a

chuck attached to the spindle shaft in order to run the motor. Our motor once powered transmits

this power to the spindle through a belt mechanism, which is then used to rotate the chuck. This

rotates the workpiece in chuck. The machine is built to hold and rotate the workpiece and move

the tool in a sliding mechanism, so as to achieve the desired operations. The machine outer frame

is designed to hold the workpiece firmly with tool in place so as to achieve desired operations

with ease. Thus, we successfully study the design and fabrication.

The first lathe was a simple lathe which was is now referred to as two-person lathe. One person

would turn the wood work piece using rope and the other person would shape the work piece

using a sharp tool. This design was improved by Ancient Romans who added a turning bow

which eased the wood work. Later a pedal (as in manual sewing machines) was used for rotating

the work piece. This type of lathe is called “spring pole” lathe which was used till the early

decades of the 20th century. In 1772, a horse-powered boring machine was installed which was

used for making canons. During the Industrial revolution, steam engines and water wheels were

attached to the lathe to turn the work piece at higher speed which made the work faster and

easier. After 1950, many new designs were made which improved the precision of work.

The purpose of this study is to have a clear answer on how big and important a Lathe machine to

an Institution with specially to Engineering students particularly Mechanical Engineering degree.

For practical, Lathe is one of the most important machines in any workshop. Its main objective is

to remove material from outside by rotating the work against a cutting tool. The simple design

and fabrication of this machine, makes it viable, reliable and easy to carryout maintenance

services at the minimized cost.

 PARTS OF MINI LATHE MACHINE

1. Motor

DC motor is any of a class of rotary electrical machines that converts direct current electrical

energy into mechanical energy. The most common types rely on the forces produced by

magnetic fields. Nearly all types of DC motors have some internal mechanism, either

electromechanical or electronic, to periodically change the direction of current flow in part of the

motor. DC motors were the first type widely used, since they could be powered from existing

direct-current lighting power distribution systems. A DC motor's speed can be controlled over a

wide range, using either a variable supply voltage or by changing the strength of current in its

field windings. Small DC motors are used in tools, toys, and appliances. The universal motor can

operate on direct current but is a lightweight motor used for portable power tools and appliances.

Larger DC motors are used in propulsion of electric vehicles, elevator and hoists, or in drives for

steel rolling mills. The advent of power electronics has made replacement of DC motors with AC

motors possible in many applications  High Torque Voltage Current: DC 12V

 Speed: 4000RPM Motor

 Shaft Diameter: 3.17mm Mounting

 Diameter of the Motor: 36mm Length of the Motor

(Body): 50mm Length of Shaft: 16mm

1. Chuck
A chuck is a specialized type of clamp. It is used to hold an object with radial symmetry, especially a

cylinder. In drills and mills it holds the rotating tool whereas in lathes it holds the rotating workpiece. On

a lathe the chuck is mounted on the spindle which rotates within the headstock. For some purposes

(such as drilling) an additional chuck may be mounted on the nonrotating tailstock. Many chucks have

jaws, (sometimes called dogs) that are arranged in a radially symmetrical pattern like the points of a

star. The jaws are tightened up to hold the tool or workpiece. Often the jaws will be tightened or

loosened with the help of a chuck key, which is a wrench-like tool made for the purpose. Many jawed

chucks, however, are of the keyless variety, and their tightening and loosening is by hand force alone.

Keyless designs offer the convenience of quicker and easier chucking and un - chucking, but have lower

gripping force to hold the tool or workpiece, which is potentially more of a problem with cylindrical than

hexagonal shanks. Collet chucks, rather than having jaws, have collets, which are flexible collars or

sleeves that fit closely around the tool or workpiece and grip it when squeezed.
 2. Sliding Frame

The sliding frame is an elliptical welding construction made from solid steel and specially

developed as a silo discharge system for very difficult flowing bulk material. Through the back

and forth movement of the sliding frame, the stored product is compulsively transported to one

or more discharge screw conveyors.

The sliding frame is moved back and forth by means of a hydraulic cylinder mounted outside the

silo. The cylinder movement is activated by means of a compact hydraulic unit.

Applications

Thickened sewage sludge, wood, paper sludge, gypsum, waste, etc.

 3. Bearing

A bearing is a machine element that constrains relative motion to only the desired motion, and

reduces friction between moving parts. The design of the bearing may, for example, provide for

free linear movement of the moving part or for free rotation around a fixed axis; or, it

may prevent a motion by controlling the vectors of normal forces that bear on the moving parts.

Most bearings facilitate the desired motion by minimizing friction. Bearings are classified

broadly according to the type of operation, the motions allowed, or to the directions of the loads

(forces) applied to the parts.

Rotary bearings hold rotating components such as shafts or axles within mechanical systems, and

transfer axial and radial loads from the source of the load to the structure supporting it. The

simplest form of bearing, the plain bearing, consists of a shaft rotating in a hole. Lubrication is

often used to reduce friction. In the ball bearing and roller bearing, to prevent sliding friction,

rolling elements such as rollers or balls with a circular cross-section are located between the

races or journals of the bearing assembly. A wide variety of bearing designs exists to allow the

demands of the application to be correctly met for maximum efficiency, reliability, durability

and performance.
 4. Joint/Screw

A nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction with

a mating bolt to fasten multiple parts together. The two partners are kept together by a

combination of their threads' friction (with slight elastic deformation), a slight stretching of the

bolt, and compression of the parts to be held together.

In applications where vibration or rotation may work a nut loose, various locking mechanisms

may be employed: lock washers, jam nuts, specialist adhesive thread-locking fluid such

as Loctite, safety pins (split pins) or lockwire in conjunction with castellated nuts, nylon inserts

(nylon nut), or slightly oval-shaped threads.

Square nuts, as well as bolt heads, were the first shape made and used to be the most common

largely because they were much easier to manufacture, especially by hand. While rare today due

to the reasons stated below for the preference of hexagonal nuts, they are occasionally used in

some situations when a maximum amount of torque and grip is needed for a given size: the

greater length of each side allows a spanner to be applied with a larger surface area and more

leverage at the nut.

CONCEPTUAL FRAMEWORK

Boring Bar
Setup

Chuck Jaw
Flipping

Chuck Jaw
Removal and
Replacement

Digital Position
Readout
 STATEMENT OF THE PROBLEM

Lathe is suitable for operations like turning, boring, facing, parting etc., But not suitable for

cutting the material in between. Because the workpiece is fixed to the chuck as soon as the lathe

machine is switched on. This is a major limitation of the mini lathe machine since its objective is

remove material from outside by rotating the workpiece to the cutting tool, minimizing it to only

see a view of present output. This study will be discussing several problems of the lathe, which

beginners have faced. And how you can avoid or find possible solutions for those problems.

However, most of these problems can be avoided.

1. Avoid long-term Accidents

- Safety First, Metal working cannot be stressed enough. Safety is crucial whenever you are

working any kind of machinery, your clothes can get caught within the machine so you must

wear proper workshop clothes.

2. The Machine is not Working Properly

- Abruptly, you may find that your machine is not working perfectly. Don’t get panicked. This

can happen when the tailstock of the lathe machine is not fixed properly. There is no certain

purpose of this tailstock. Still, it needs to be locked down firmly before you begin cutting. The

cut of the metal will not be proper if the tailstock remains unattached or loose. However,

examine the screws properly to tighten the tailstock. If you find them loose, do tighten them

well.

3. Improper Metal Cuts

- This usually happens when the cutting tool has not been set properly. This study discusses that

before you begin working, always check the cutting tool installed. While preparing, we found out

that the trick to perfect installation is to remember to get accurate and immaculate cuts.

4. The Machine is not working properly

- Based on our research, it may cause by tailstock of the metal working lathe may not be fixed

properly. Although the tailstock does not have any specific purpose, it has to be locked down

properly before the chuck can be fed into the metal. When the tailstock remains loose, the metal

may not be cut. We tighten the tailstock, inspect the screws, and if they are loose, we tighten

them up properly.

5. Carriage is not moving

- During work, we got a ‘stuck carriage’ in your lathe machine. Along with the carriage, the

power feed handles also have to be worked properly. It is we found out how to move or unstuck

the carriage. Because it has a particular track to move within. Based on our experience, it is

better to be well versed in fixing the carriage to get efficient work from the machine.
 SIGNIFICANCE OF THE STUDY

The lathe is one of the most essential machine tools. This multi-purpose equipment is commonly

used for executing a wide range of functions that includes shaping many solid substances such as

wood, metal, etc. It is an important workshop tool which is extensively utilized in several

industrial segments and especially in the metal shaping industries.

1. Importance of having Lathe Machine at Workplace

- The lathe is one of the most essential machine tools. This multi-purpose equipment is

commonly used for executing a wide range of functions that includes shaping many solid

substances such as wood, metal, etc. It is an important workshop tool which is extensively

utilized in several industrial segments and especially in the metal shaping industries.

2. How Lathe Machine make Work easier

- Contrary to popular belief, machines do not increase the amount of work that is done. They just

change how the work is done. Machines make work easier by increasing the amount of force that

is applied, increasing the distance over which the force is applied, or changing the direction in

which the force is applied.

3. Importance of learning how to use Lathe Machine

-It is an important workshop tool which is extensively utilized in several industrial segments and

especially in the metal shaping industries. Based on experienced Lathe Operators, it is so

important to know the accurate procedure to use a Lathe machine, its first requirement is always

safety, and it can make the work easy but also increasing the chance of accident. It is important

to know what accurate speed to specific material to cut, drill, bore, etc.
 SCOPE AND LIMITATIONS

The limitations on the lathe are the size of the chuck and length of the bed. Regardless of the

material or stock used, only radially symmetrical parts can be produced. The shape of the parts

made on a lathe must be symmetric. Since the lathe spins the part while taking material off of the

radius, no shapes other than those with a circular cross section can be made.

1. This project can only spin one work piece at a time

2. You can only use required cutting tools.

3. Bearings and gears must be lubricated when needed. doing this can prolong the project.

4. This project must be operated at a table top above the waist to prevent back pains or being

harm by the moving parts

 DEFINITION OF TERMS

Stand (or legs) - This is used in holding the lathe machine and in elevating the lathe bed to a

working height.

Bed - This is usually a horizontal beam that holds the chips and the swarf.

Headstock - The headstock contains the high precision bearings which hold the horizontal axle,

more commonly known as the spindle.

Spindle - This is a hollow horizontal axle with interior and exterior threads on the inboard by

which the woodworking pieces can be mounted on.

Tailstock - This is the counterpart of the headstock which contains a non-rotating barrel that can

slide in and out directly in line with headstock spindle parallel to the axis of the bed.

Carriage - This is composed of a saddle and an apron and is used as a mount to the cross-slide.

Cross-slide - This is a flat piece that sits crosswise on the bed which can be cranked at right

angles with the bed.

Tool Post - Sits on top of the cross-slide and holds the cutting tool in place.

Tool Rest - A horizontal area in line with the spindle and the tailstock from which hand tools are

braced against and levered into the workpieces.

CHAPTER 2 – REVIEW OF LITERATURE

The lathe machine is introduced to lessen the human suffering and to improve economic and

technological standard, and for years recognized that she was economically and technological

poor and has been economically dependent on the western world for survival in terms of

technology. To dis-encourage this importation of technological equipment placed enlarge on the

importation of certain goods and this inspired our people to recognized indigenous technology

through our fore father used, cutlass and some other sharp tools for designing. But, as time goes

on, technologist introduced mini lathe machine, which comes in various designs and models as

technology improves. Thus, the importance of lathe cannot be over emphasized. It is the

acknowledgement of this fact that led to the design of mini lathe machine, even though this

project of design and fabrication of mini lathe machine is a copied design, we tried to improve

more on this machine so that it can design metal with little or no stress, utilizing the available

material in order to reduced cost for production purposes and durability being of utmost

important. For the mini lathe machine to function and perform its operations, various important

parts are integrated together. These essentials parts make up the lathe machine and include the

following Stand. Stand is used in holding the lathe machine and in elevating the lathe bed to a

working height.
 CHAPTER 3 – METHODOLOGY

RESEARCH DESIGN

Our machine consists of a motor with belt arrangement used to drive the lathe chuck. The

machine consists of a bed with a movable arrangement. It consists of a holder in order to hold the

desired tool in desired position. We use a chuck attached to the spindle shaft in order to run the

motor. Our motor once powered transmits this power to the spindle through a belt mechanism,

which is then used to rotate the chuck. This rotates the workpiece in chuck. The machine is built

to hold and rotate the workpiece and move the tool in a sliding mechanism, so as to achieve the

desired operations. The machine outer frame is designed to hold the workpiece firmly with tool

in place so as to achieve desired operations with ease.

 SOURCE OF DATA

This data shows the survey results that we gather from the 43 Engineering Students of Colegio

de Dagupan.

The Category 1 shows that 13 students are familiar of Lathe Machine and 11 students says that

they heard of it and 20 students has no idea about Lathe Machine. This shows that most of the

respondents is not familiar with Lathe Machine.

The Category 2 shows that 15 students think that workers are not suitable for operating the

machine because they lack of training to operate the machine, 3 of them says that workers are

comfortable with hand saw and drills to get the job done, and psychologically they think that if

they use a lathe it will take more time. 26 students suggest that workers need a lathe machine in

reducing the costs of maintenance in our facilities.

The Category 3 suggests that 17 respondents are conscious in what field of work lathe machine

will be use, base on respondents that mostly consists of other engineering fields except

mechanical engineering students. 24 students are interested in operating the machine and wants

to learn how the machine works. 3 of them is not interested.

The Category 4 is letting the students rally by convincing top management to buy a lathe

machine considering its cost, 23 respondents says. 19 says that the institution is capable in

investing in a lathe machine and can produce top class education by hands on.

The Category 5 majority is in favor of using a portable machine instead of using the traditional

large scales machine, but performs the same process, compromising the size of the workpiece.
 SURVEY RESULTS:
45

40

35

30

25

20

15

10

0
Category 1 Category 2 Category 3 Category 4 Category 5

Series 1 Series 2 Series 3

 DATA COLLECTION AND TOOLS FOR DATA ANALYSIS

In this study, discusses how the data analyzed and include some any statistical treatments.

Below are the data and procedures on how the research results:

1. EXPERIMENTAL PROCEDURE

- The experimental procedure includes the selection of the specific material, machine and

machining operation required for the capability study.

2. METHODS

The process capability study involves the generation of data from the shaft turning. The

procedure for the study includes

: Selection of the candidate material, evaluating the measurement system, preparing the control

plan, analyzing data samples, estimating the process capability and establishing a plan for

continuous turning process improvement.

The straight turning operation shown schematically in Figure 1 was done for ninety (90) test

piece at spindle speed of 300 rpm - 500 rpm, with feed rate 0.25 - 0.5 mm/rev at a depth of cut of

0.01 mm for nominal diameter of 40 mm with specification limit of 40f7 (tolerance of 0.025 ±

0.050). Roughly drilled hole are finished to specification H8 on each test piece to exact size by

using a reamer which was mounted on the lathe tailstock. The cutting operation for the steel was

performed at room temperature of 25˚C.

The Spindle speed, N, for the cutting process was obtained from Equation (1)
Figure 1: Turning single

point tool process

Where: v is the cutting speed measured “m/min” and D is the work-piece diameter measured in

“mm”. Moving range of two successive observations were used to determine the variability

employed in deriving the control limits for the process. The variability of the process was

measured in terms of the distribution of the absolute value of the difference of every two of the

successive observations. The control limit was obtained from Equations (2)-(8)

∑ xj
x= j−1
n

Where x the process mean, j is the number of observations ranging n observation, and n is the

subgroup size.

n
Moving range: R = ∑ x 1−xj−1
j

Average Moving Range: R =

∑ x 1−xj−1
j −1
N
Where A2, D3, D4 are control chart constants which depends upon the size of the subgroup of the

data. The process capability indices, process average, and the standard deviation were obtained

from the process data assuming that the data is normally distributed. The capability indices are

obtained from the following expressions.

UCL−LCL
Cp=
6σ

UCL−x x −LCL
Cpk= min ( , )
3σ 3σ

Where Cp is the process capability for two-sided specification limit, irrespective of process

center, Cpk is the process capability for two-sided specification limits accounting for process

centering and σ is the standard deviation. The statistical process control (SPC) technique was

used to assure that the process remains stable. The output of the turning process was compared

with the specification limit using the capability indices.

3. RESULTS

TABLE 1 Shows the data obtained for three attempts of the turning process at various speed and

feed rate of the operation.

Figure 2 shows the control chart for machining operation. The process control Chart

shows that the data points fell within control limits. The moving range chart also indicates that

all the data points are within the control limits indicating that the process is in statistical control

and hence is under control and stable. Consequent upon this premise, the process capability

evaluated by the use of capability indices via the SPC software is shown in Figure 2(b).
For the subgroup size of n = 3, the control chart constants are obtained as, A2 = 1.023, D3 = 0,

D4 = 2.574, d2 = 1.693. The control limits are thus obtained as shown in TABLE 2. The process

capability indices were obtained for the process data as Cp = 0.58 and Cpk = 0.58. This implied

that the process is placed exactly at the center of the specification limits. And since C p < 1 the

process is considered not adequate. The machine capability for industrial application is therefore

not adequate and the process

centering is also considered inadequate. In this circumstance, the Cpk index is used to interpret the

capability of the process. It therefore could be deduced that the process at varying feed rate and

spindle speed is not capable of producing the quality required for the specified shaft. The
machine settings are therefore not favorable and the process need be revisited to take the mean

back towards the center.

Figure 2:

The result of analysis of the data collected indicates that, the process is not capable of

consistently bringing out shafts with diameter falling well within the customer’s expectation,

even though it remained in statistical control.

Also, the process is not acceptable. The process owner cannot claim that the customer will not

experience difficulty in the use of products which translate into losses. The reliability of such

product resulting from the process cannot therefore be guaranteed.

CHAPTER 4 – DISCUSSION OF FINDINGS

This chapter presents the results of the questionnaire/ structured interviews of this survey data.

This data analysis involved the administration of questionnaire survey as a means of intervention

to gain a broad spectrum of opinions from project managers working in machining industry. The

results are presented systematically to address research aims and objectives and to answer the

research questions.

The metal cutting is done by a relative motion between the work piece and the hard edge of a

cutting tool. Metal cutting could be done either by a single point cutting tool or a multi-point

cutting tool. There are two basic types of metal cutting by a single point cutting tool. They are

orthogonal and oblique metal cutting. If the cutting face of the tool is at 90o to the direction of

the tool travel the cutting action is called as orthogonal cutting. If the cutting face of the tool is

inclined at less than 90° to the path of the tool then the cutting action is called as oblique cutting.

The differences between orthogonal and oblique cutting is given below

The cutting characteristics of most turning applications are similar. For a given surface only one

cutting tool is used. This tool must overhang its holder to some extent to enable the holder to

clear the rotating workpiece. Once the cut starts, the tool and the workpiece are usually in contact

until the surface is completely generated. During this time the cutting speed and cut dimensions

will be constant when a cylindrical surface is being turned. In the case of facing operations the
cutting speed is proportional to the work diameter, the speed decreasing as the center of the piece

is approached. Sometimes a spindle speed changing mechanism is provided to increase the

rotating speed of the workpiece as the tool moves to the center of the part.

Interpretation and Discussion

The definition phase resulted from the natural use of Lathe itself. Lathes are machine tools for

metal cutting processes (metal-cutting process). The basic operation of the lathe involves rotating

the work piece and the cutting tool linear moves. Authentic lathe operation that is used to process

the workpiece with the result or the shape of circular cross section or cylindrical work piece

The thesis presents a theoretical analysis of the task, while practical knowledge of selected parts

of the dynamics is used to solve individual involved transfers. Further for the two types of

programs includes detailed diagrams that is rev/min (rpm) increasing and rev/min reduction.

The center lathe is the object of exploring. Specifically, transmission parts such as shafts, gears

and pulleys then it is electric drive device, and finally driven parts such as spindle and chuck.

Analyze of angular velocities, moments of inertia, kinetic energy, performance and labor of each

part of the kit is performed using reduction method, and the system is reduced to a first member,

which is an electric motor.

Lathes are devices that are used primarily for machining rotating parts, where the main cutting

rotary motion carries the workpiece clamped in the chuck and side cutting movement infeed

movement and provides a tool clamped in the cutter head.

These machines can be machined outer and inner rotary or conical surface, the outer spherical

surface, tapping and threading, drilling holes, or we can create keyway on the shaft. In addition

to cutting operations with these machines can twist robust spring diameter.

Lathes are machines with a spindle that turns along with the workpiece. The workpiece may be

supported between a pair of points called centers, or it may be bolted to a faceplate or held in a

chuck.

A chuck has movable jaws that can grip the workpiece securely. The lathe knife or other cutting

tool changes the shape of the workpiece.

Lathes are primarily used to manufacture rotary parts. A lathe can be used to produce parts made

of ferrous and non-ferrous metals, plastics and wood. The workpiece is clamped in the lathe

either in a chuck, between a chuck and a center or between two centers.

 CHAPTER 5 – SUMMARY, CONCLUSION AND
RECOMMENDATIONS

SUMMARY

This study aimed mini lathe machine is very important machine of engineering which is used in a

most fields. This purpose of study is to help some ordinary worker to reduce or lessen the work.

The analysis is the main and the most important part of any designing phase, without analysis we

cannot determine the failure point of any tool or object. Knowing the failure point helps us to do

some improvement in design before manufacturing which will save a lot of money.
 CONCLUSION

Advantages

 Mobility

 Perform every operation, considering with conventional lathe

 Simple and compact

 Easy to handle

 To increase productivity and creativity

 No need extra manpower

 Less power consumption

 Fixed everywhere

In this project a study has been done on mini lathe machine to know about its portability,

reliability and cost reduction. A basic design of mini lathe machine has been made and analysis

has been done of the tool to determine the cause of failure of the tool. The fabricated model of

the design will be portable, cost efficient and can be assembled and dismantle according to the

use which will increase the mobility of the machine and can be easily carried. The ordinary

workers who can’t afford the conventional lathe

machine can use this portable mini lathe machine and can perform their machining operation

effectively. This mini lathe machine can reduce the capital cost of machining reducing the labor

cost. The machine would be easy to handle because of its mobility and portability and can easily
be maintained. Because of its portability and small in size it will consume less power than

conventional lathes.

RECOMMENDATION

After obtaining the results discussed the answer to the problem presented in determining if the

mini lathe machine is very efficient and reliable in the industry and small scale. Based on all of

the results and finding of this study, researchers recommend several ideas to be considered an

have arrived at the following recommendation to further improve the study.

 The study focused on the small scale, portability and small in size it will consume less

power than conventional lathes

 The developer recommends a high-quality brand like cutting tools or other parts for better

output and performance of the prototype

 In the future researcher may come into probability of making this effective portable and

reliable reducing work in small scale researcher recommend to use high quality brand

parts for better performance outputs.

 REFERENCES

https://www.mechanicalbooster.com/2016/11/what-is-lathe-machine-main-parts-operations-

working.html (Nov. 2016)

https://www.lathematters.com/lathe-machines-problems-and-solutions/

https://www.researchgate.net/publication/298330490 Process Capability Analysis of a Centre Lathe

Turning Process (March 2016)

https://www.seasshops.ucla.edu/standard-operating-procedure-sop-lathe/ (Copyright 2020)

http://pubs.sciepub.com/ajme/4/7/10/index.html# (2016)

https://www.yashmachine.com/blog/history-of-lathe-from-beginning-of-machine-tool-invention/