CHAPTER 1

INTRODUCTION

The wood lathe machine is introduced to lessen the human suffering and to improve
economical and technological standard, and for years now Nigeria recognized that she was
economically and technological poor and has been economically dependents on the western
world for survival in terms of technology. To discourage this importation of technological
equipment placed embargo on the importation of certain goods and this inspired our people
to recognised indigenous technology though our fore father used axe, cutlass and some other
sharp tools from designing woods.

But, as time goes on, technologist introduced wood lathe machine, which comes in various
designs and models as technology improves. Thus , the importance of wood lathe cannot be
over emphasized. It is the acknowledgement of this fact that led to the design of wood lathe
machine, even though this project of design and fabrication of wood lathe machine is a
copied design, we tried to improve more on this machine so that it can design wood with little
or no stress, utilizing the available material in order to reduced cost for production purposes
and durability being of utmost important..

Figure 1.1 Mini Lathe Machine

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Components 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 24V

Speed: 6000RPM Motor
Shaft Diameter: 3.17mm Mounting
Diameter of the Motor: 36mm Length of the Motor (Body): 50mm Length of Shaft: 16mm

Figure 1.2 DC Motor

2.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

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rotating work piece. 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
non-rotating tailstock.

Generally chucks are used to hold the work piece or objects.

Here chuck is fixed to the bearing shaft so that when the shaft rotates the work piece in the
chuck rotates by means of pulley.

Figure 1.3 Chuck

3.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.

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 Figure 1.4 Sliding frame

4.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..

Figure 1.5 Bearing

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5.Nuts/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 (nyloc 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.

Figure 1.6 Nut and Screw

6.Lathe Cutting Tool (Chisel)

A tool bit is a non-rotary cutting tool used in metal lathes, shapers, and planers. Such cutters
are also often referred to by the set-phrase name of single-point cutting tool, as distinguished
from other cutting tools such as a saw or water jet cutter. The cutting edge is ground to suit a

5
particular machining operation and may be resharpened or reshaped as needed. The ground
tool bit is held rigidly by a tool holder while it is cutting.

Figure 1.7 Chisels

The main parts of a mini lathe machine :

(1) Bed

It is a base or foundation of the wooden lathe . It is made up of wood in a trough shape so that
material removed from the wood can be easily collected on the bed . It hold and support the
other parts of the lathe such as motor.

Figure 1.8 Lathe Bed

(2) Headstock

The headstock is permanently fastened to the inner ways at the left hand end of the bed . It
severs to support the spindle and driving arrangements. Wood lathe receives their power

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through the headstock , which is equipped with a motor and also in order to control the speed
of the motor during operations a pedal controller is also attached to the motor. Spindle of the
motor is fitted with a socket which will be used as a chuck in micro wooden lathe for holding
the work piece in a proper alignment with a tailstock.

Figure 1.9 Headstock

(3) Tailstock

It is situated at the right hand end of the bed , which is provides a tailstock spindle for the
purpose of supporting the right end of the work piece . In a micro wooden lathe , tailstock is
fixed but only the spindle is moveable in order to support varying length of different work
piece . A bolt with coned end is used as a spindle in micro wooden lathe in which conned end
act as a dead center. Movement of the bolt is controlled by the means of two nuts which keep
the bolt at desired position.

Figure 1.10 Tailstock

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(4) Tool rest

The tool rest is similar to a mechanical arm with a metal guide bar to support the chisel or
knife used for turning the work piece. It usually can be adjusted by sliding the length of the
bed at its base, with an intermediate arm that can swing from a parallel to a perpendicular
position in relation to the lathe bed, and the upper arm, which holds the actual tool rest bar.

Figure 1.11 Tool Rest

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 CHAPTER 2

LITERATURE REVIEW

In 1984, Department of Mechanical Engineering, IIT, New Delhi , has taken a research topic
named as “Machine tool failure data analysis for condition monitoring application”. With the
development of modern manufacturing technology, Flexible Manufacturing Systems have
become key equipment in factory automation. Machine tool is heart of the Flexible
Manufacturing Systems. Ex example Lathe machine is the general type of machine tool used
by almost all the FMSs. During the operation of this machine tool, different kinds of failures
are faced by the industry. A systematic study of such failures can help in identifying the
critical sub-system of these machine tools. This will be useful for identifying the condition
monitoring needs of the machine tools. This deals with the identification of critical sub-
system based on the failure data analysis for different type of machine tools. Initially lathe
has been classified into various sub-systems as shown in Figure. In the frequency of failures
for each sub-system and failure modes have been considered for finding out the weakest sub-
system. In analysis, failure frequency and downtime have been taken into consideration for
deciding critical sub-systems of machine tools. It can be observed that the maximum failures
took place in headstock and carriage sub-systems. These sub-systems face failures in
components like gear, gearbox bearing, spindle bearing, clutch and cross-slide jib. Here it
could be observed that the bearing failures cause longer downtime.

On histogram different failure modes and their relative failure frequencies have been grouped
into four-failure modes, component damage, fuse burnt, circuit fault and looseness. It can be
observed that the dominant failure mode is because of component damage. The components
are electrical, electronics and of mechanical categories. In 2013, V. Roy & S. Kumar [2] from
J institute Engineering, India published development of Lathe machine attachment for CNC
machine. He has developed attachment for an existing CNC machine. The CNC machine
operates on mechatronic controls and a computer interface called CAMSOFT, and is used as
a CNC Lathe after installing the respective attachment to it. He has design the attachment
using CAD software & fabricated different model. He has susseccfully design & fabricated
the model. The working of the CNC Lathe attachment is tested & checked by making proper
machining operation like turning and thread cutting. The machining operations are
successfully done. The CNC machine becomes multifunctional with the presently developed
lathe attachment and can be used accordingly by installing the respective attachment to it.

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The CNC machine is useful for research work in both the fields, when installed with the
proper attachment. The figure of developed attachment is shown below,

Developed design is successfully implemented in the proposed work for the development of
the lathe attachment including headstock, tailstock and tool post. The work shows the process
of the conceptual design and use of proper process planning for the development of the
different components of the lathe attachment. The previously attachment and developed lathe
attachment make the CNC machine multifunctional. Thus further research can be carried out
in both the fields respectively. The CNC machine is based on the mechatronic controls and
the computer interface CAMSOFT. Various lathe operations like plain turning, step turning,
taper turning, arc turning, threading operations and manufacturing of a bolt are successfully
performed on the CNC machine, when installed with lathe attachment. The successful
development of the lathe attachment for the CNC machine is done. In 2005, Kriangkrai
Waiyagan & E.L.J. Bohez [3] from Department of Design and Manufacturing Engineering,
Asian Institute of Technology, Thailand has published titled as Intelligent Feature Based
Process Planning for Five-Axis Lathe. The main objective of his paper is to propose a new
machining feature model focused on 5Dmachining features. The machining features
describing a Prisronal part, which includes both prismatic and rotational features, are
introduced. The model is not only taking into account geometric entities, manufacturing
aspects but also including machining processes and knowledge-based rules for intelligent
process planning system of five-axis lathe. Geometric entities are specified by defining
feature parameters corresponding to the shape of feature. Manufacturing aspects include
properties of blank part, settings up and technological data like tolerances and surface
finishing. Machining processes and knowledge based rules attached with each feature are
used as constraints to guide the system for automatically selecting suitable machining
operations. Finally the pilot implementation of machining features for operation selection is
demonstrated. The figure shows design configuration of five axis lathe machine.

In 2008, Department of Mechanical Engineering, University of Auckland [4] researched on

special issue on recent advances in flexible automation. Flexible automation has taken on
many new concepts, technologies and practices. This evolution process has resulted in
numerous new terminologies in replacement of flexible automation. The ultimate goal
remains - empowering the modern industry with different “versions” of automation
technologies in order to meet the ever-diverse and ever-changing market. There are twelve
articles included in this special issue. They can be grouped into three categories, (1) New

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Advances at the CNC Front, (2) Advancement in Automation Hardware, (3) Intelligent
Scheduling in FMS. Flexible Automation as a topic of research has been around for at least a
half century.

1. Over the many years, most of the flexible automation systems have Computer
Numerically Controlled (CNC) machine tools as the principal manufacturing equipment. G-
codes have been extensively used by the CNC machine tools for part programming and are
now considered as a bottleneck for developing next generation CNC machines. Data model
represents a common standard specifically aimed at the intelligent CNC manufacturing
workstation, making the goal of a standardized CNC controller and NC data generation
facility a reality.

2. Hardware development for automation systems has not stopped and will perhaps never.
There are three papers in this issue discussing some of the advancements related to
automation hardware, e.g., Automatic Guided Vehicles (AGVs), Master Slave Manipulator
and flexible machining of non-cylinder piston pinhole. This type of FMS aims at high
production efficiency by self-controlling or decentralizing the plan, design and operation of a
FMS.

3. A decentralized optimization method for production scheduling, transportation routing for

AGVs and motion planning for material handling robots has been developed. The system
consists of a process agent that creates production schedule, AGV agents to generate collision
free routing for multiple AGVs, and a handling agent that determines motion planning for
material handling system

In 2013, Karl-Heinz Schumacher. is invented about Multi Spindle Lathe. Multi spindle lathe
comprising a machine frame as spindle drum which is arranged in the machine frame is
rotatable about a spindle drum axis and is made up at least partially of segments which are
cut out from flat material in a stacking direction parallel to the spindle drum axis and extend
in stacking planes transverse to the stacking direction these segments having receiving
cutouts and cooling channel cutouts which overlap with one another such that the spindle
drum has spindle motor receptacles for spindle motors and a cooling channel system
separated there from by wall webs characterized in that the cooling channel system has
several channel subsystems for a liquid cooling medium Which are fed in parallel. In 2013,
M. Moses & Dr. Denis Ashok. M. Tech, Mechatronic from School of Mechanical and
Building Science.

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 CHAPTER 3

AIM AND OBJECTIVES

The main objectives of this project are to:

1) Use available local materials in fabrication

2) Achieve a reduction in the cost of production of the machine.
3) Provide a life engine in the workshop which students could use for exhibition thereby
creating awareness for, and encouragement of indigenous technology.
4) Reduce the labour cost and time spent on using hand tools for wood design.
5) Increase productivity and creativity.

The vital need for the fabrication of a wood lathe is significant in the much delay and time as
well as energy wasted in using simple hand tools to carry out jobs. Moreover, the cost of
importation of a lathe machine, is too high for an average user. Also, wood lathe machine
will helps to reduce the cost and consequently increase the rate of production and craftsman’s
skill.

Scope Of Work
Essentially, the machine comprises of the frame made of metal, with the headstock fixed in
position, the tail stock moves along the bed of the machine by using a bolt supported by L
shaped frame which provide flexibility in order to fix work piece of various length and cross
section , and the toll rest mounted on a tool post which is fixed to bed of micro wooden lathe
and tool can rest on this tool rest allow the operator to freely work on the workpiece by
placing the tool on the tool rest. It is located between the head stock and the tailstock.

In operations, the machine is limited to only scarping and cutting of any type of wood.
Drilling operations cannot be performed on this machine. but in our micro wooden lathe we
allow such arrangement such that we can drill work piece with the help of cone ended
threaded bolt by rotating the bolt from the head portion . in this micro wooden lathe we can
not only perform turning operations but also can perform parting as well as knurling
operations .

The general scopes for this project are:-

1) To Do the literature reviews on lathe machine
2) To Develop Gantt chart and flow chart for this project.

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3) To Design the lathe machine by using Pro-E software.
4) To Motor holder designed by using Pro-E software.
5) To Testing the lathe machine.

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 CHAPTER 4

WORKING PRINCIPLE

The lathe is a machine tool which holds the work piece between two rigid and strong supports
called centres or in a chuck or face plate which revolves. The cutting tool is rigidly held and
supported in a tool post which is fed against the revolving work. The normal cutting
operations are performed with the cutting tool fed either parallel or at right angles to the axis
of the work.

LATHE OPERATIONS

The engine lathe is an accurate and versatile machine on which many operations can be
performed. These operations are:

1) Plain Turning and Step Turning

2) Facing
3) Drilling
4) Grooving
5) Forming
6) Polishing
7) Taper Turning

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 CHAPTER 5

METHODOLOGY AND CALCULATION

Step 1 Base

The core of the lathe is the base. It needs to be very solid and heavy to counteract vibrations
and strong to overcome the different forces applied during turning. The plans called for two
pieces of 3/4 inch birch plywood to be laminated together, but I ended up using three pieces
of 1/2 inch spruce plywood. They were glued together using polyurethane construction
adhesive. It is important to cut the pieces slightly oversized, and after they are glued, rip them
to the final width.

I used all the clamps I had when gluing the boards together, and even then, the construction
adhesive expanded a little which made gaps in the plywood in some areas.

Step 2 Dadoes and Dovetails

The top rail is attached to the base with two strips of plywood that are nested in dadoes on
both sides. My table saw does't accept a dado stack, so I just ran the heavy chunk of wood
through the saw a bunch of times to get the perfect width.

The top rail is shaped like a long dovetail, with the sides angled at 20°. I again had to glue
two other piece of plywood to get the right thickness. After all the parts were cut out, I glued
it all together, this time with wood glue.

Step 3 Headstock

The first part in building the headstock (the thing that drives the wood), was to make the
bearing mounts. If you follow the specifications in the plans, it will go without a problem.
The plans called for two layers of plywood on either side, but the bolt that I had wasn't long
enough to handle that, so I had to use a piece of oak instead. I found an old spade bit that was
slightly oversized for the bearing, and ground it down slightly so it would make a tight fit in
the wood.
The next step was to make a support block. It was as straight forward as gluing a block of
plywood and sanding it down flush.

Step 4 Ball Bearing

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This next part is probably the most difficult part of the build, but also probably the most
important. It is basically two blocks of wood with two bolts running through embedded nuts
on both sides. When you turn the bolt, it pushes against a strip of metal that moves outward,
and locks the carriage against the slide. The strips are cut at a 20 degree angle as well.

Step 5 Setup Bed

The motor was simply bolted on a piece of 3/4 inch plywood, which was mounted on hinges
onto the base. I ended up using two hinges to make it more rigid.

The belt is tensioned by the weight of the motor, which ended up being plenty of tension.

To finish the lathe, I painted it white and grey on the sides and edges. After it was painted, a
couple coats of water-based varnish are brushed on. REMEMBER TO LEAVE THE SLIDE
UNTOUCHED as it would become sticky, and unable to slide.

Step 6 Tool Rest and tailstock

After it is dried, the lathe is complete! I still do not have any turning tools to work with, but
with a lot of difficulty I was able to use some bench chisels to turn a block of wood round.

I (badly) welded a washer to a bolt and drilled some holes in it to make a small faceplate.
Then I welded two nuts together and cut teeth on one end and screwed in some threaded rod
to make a drive center. Both of the two pieces easily screw onto and off of the shaft.

Dimensions And Specifications

Below are the dimensions and specifications as regards the fabricated wood lathe.

Total length of the machine 600mm

Total height of the machine 200mm
Width of machine bed 150 mm
Angle of inclination of the tail stock 900
The electric motor RPM 2800 rpm
Frequency 50 Hz
Power 50 w
Capacity 1/12 hp
Voltage 12v dc

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 Current .32 amp
Diameter of motor shaft 7.39mm
Maximum length of work 150mm
Minimum length of work 100 mm
Diameter of work piece 20 mm

Calculation of cutting parameters

Cutting Speed

When metal is cut, the workpiece surface is driven with respect to the tool, or the tool with
respect to surface, at a relatively high rate of speed. This is called cutting speed (Cs). Mostly
the tool or work piece revolves. Almost all such machine tools are calibrated in revolutions per
minute (rpm).

The cutting speed is related to the rpm and thus is conveniently expressed in meter per minute
(m/min).Spindle speed (rpm) is the rotational frequency of lathe machine spindle and its
determined based on the type of material to be cut. Soft steel such as aluminium alloy is
suitable with high spindle speed during machining. If hard steel such as bronze applied
excessive spindle speed, it will cause premature tool wear, breakage, and can cause tool
chatter. Using the correct spindle speed for the material and tools will affect tool life and the
quality of the surface finish.
Cutting speed (in Wooden lathe for turning operation) is the peripheral speed of the work
piece past the cutting tool.

Mathematically, V = πDN/1000 m/min

Where , V = Cutting Speed , m/min

D = Diameter of the job , mm

N = Spindle Speed ,r.p.m

In a Micro wooden Lathe

D = 20 mm

N = 2800 r.p.m

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Then we can calculate the cutting speed which is :-

V = ( π×20×2800 ) /1000

v = 175.93 m/min

Factor which influence the selection of a proper cutting speed are :-

1. Material of the cutting tool

2. Hardness and Machinebility of the wood to be machined
3. Tool Shape
4. Depth of cut
5. Rigidity of the tool and work

Depth Of Cut (d)

The depth of cut‘d’ is the perpendicular distance measured from the machined surface to the
uncut surface of the work piece . For turning operation, the depth of cut is expressed as:

d = (Di – Df ) / 2 mm

Where , Di = Initial diameter of the work piece , mm

Df = Final diameter of the work piece , mm

In a Micro wooden Lathe

Di = 20 mm

Df= 18mm

Then we can calculate the Depth of cut which is

d= (20 – 18) / 2

d = 1mm

Depth of cut generally depend on following factors :

1. Type of work piece material

2. Type of tool material
3. Type of surface finish required

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Material Removal Rate (MRR)

The material removal rate, MRR, can be defined as the volume of material removed divided
by the machining time. Another way to define MRR is to imagine an "instantaneous" material
removal rate as the the rate at which the cross-section area of material being removed moves
through the workpiece

MRR = 1000 ×V ×d × f

In a Micro wooden Lathe

V = 263.83 m/min (Calculated above)

d = 1 mm

f = 0.1 mm / revolution

Then we can calculate the cutting speed which is:-

MRR = 1000 × 175.93× 1×0.1

= 17592.92 mm^3 / min

RESULT
Cutting Speed
v = 175.93 m/min

Depth Of Cut

d = 1 mm

Material Removal Rate

MRR= 17592.92 mm^3 / min

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Flow chart :

Review of Literature

Designing of Project Work

Selection of Material

Selection of Tool

Procurement of Material and Tool

Sub assembly of Machine

Final Assembly of Machine

Inspection of Machine

Testing of Machine

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 CHAPTER 6

ADVANTAGES AND DISADVANTAGE

Advantages:

1. Cost of machine is less and hence more no. of people can afford.
2. Both the pedaling and turning operations can be performed by same person.
3. Normal lathe has more overhead and operating cost.
4. And mini wooden lathe has too less overhead and operating cost .
5. No. of operations can be performed anywhere.
6. Handling and transportation is easy
7. The sideways of Mini Lathe Machine are coated with students which checks
corrosion and ensures smooth stirring of machinery parts ultimately boosting the life
of the product.
8. Application of this machine is directly proportionate to economization as being low
cost miniature model, acquiring less space comparatively and perfectly suited for
small pocket budget.

Disadvantages:

1. Initial costs of machine and tooling are very high.

2. Sometimes a scam is left around the product where the mould closes.
3. Products sometimes need to have flashing removed.
4. Hot extrusion of metals such as steel leaves oxidized surface finish.
5. We cannot turn hard metals.
6. Operations are limited to some of the metals.

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 CHAPTER 7

CONCLUSION

The lathe can be used in the production of wheels and making parts for many types of
furniture and tableware, parts for mills and pumps, and many other important technological
developments. Wood lathes cut down drastically on the time required to make carved wooden
vessels and other implements. The items you can make using a wood lathe are more evenly
carved and finished than would be possible by hand. It can also be use to hollow out the
wood to make vessels such as cups, bowls, vases and decorative objects. In this project report
we provide an overview of the issues concerning different aspects of micro wooden lathe
.The project report focus on the principle of conventional lathe , type of micro wooden lathe
tooling and machining parameters and process performance measure, which include cutting
speed , depth of cut ,material removal rate . different type of micro wooden lathe and tool
used to fabricate the workpiece In micro wooden lathe has been presented . the presented
results can help to plan the machining of work piece expected tolerance.

The following major conclusions may be drawn from the present project report.

1. Micro wooden lathe is derived from wood turning lathe which has been a well
establish industrial processes offering attractive capabilities for handling work piece
of various length to be used at micro level
2. We have presented historical development of micro wooden lathe from ancient time
to modern time
3. We have explained the various parts and components of micro wooden lathe
4. Different type of micro wooden lathe and tool for micro wooden lathe has been
discussed
5. We have discussed the entire time line and process chart

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 REFERENCES

1. Richard A. Maker (1993) Milling machine lathe attachment.

2. Philip H Buehrle (Jul 2, 1929) Grinding attachment for lathes.
3. Designing and Fabrication of Multipurpose Tool Post for Lathe Machine (IJSRD/Vol.
2) All rights reserved by www.ijsrd.com 117 Daniel M. Spohn, Jr., Spohn Jr
4. Daniel M (1978)Attachment for a rotary drive machine.
5. Atsushi Senoh, Washino Engineering Company, Limited (1988)Machine tool for
multiple surface machining.
6. RichardL.Harris, Ralph W.Blader (1982) Multipurpose tool Gary F. Thompson,
Thompson.
7. Gary F. (1995) Multi-purpose lathe.

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