HAPTER 1

INTRODUCTION

1.1 INTRODUCTION

Mechanical engineering without production and manufacturing is

meaningless and inseparable. Production and manufacturing process deals with
conversation of raw materials inputs to finished products as per required
dimensions specifications and efficiently using recent technology. Generally, it
discuss about the project background, problem statement, the objective, scope
of project, project flow and project Gantt chart.

1.2 BACKGROUND
Imagine two plain wheels fixed rigidly to two parallel shafts and pressed
tightly in contact with each other. If one wheel is rotated about its axis, the other
wheel will also rotate due to the friction between them. The rotary motion is
thus transmitted from one shaft to another. The surfaces of the two wheels will
move at the same speed if there is no slipping. It is obvious that with the
increase in Load to be transmitted, the wheels will begin to slip on each other.
To prevent slipping slots may be cut on the cylindrical surfaces of the wheels
and projections added between them. These slots and projections form the teeth,
and wheels with such teeth are called toothed wheels or gears.

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 Fig1.2.1 (Gear terminology)

1.3 PROBLEM STATEMENT

Lathe is suitable for operations like turning, boring, facing taper turning,
thread cutting, knurling, etc. but not suitable for operations like key way cutting
etc. Because in a conventional lathe as soon as the machine is switched on, the
work piece fixed to the chuck rotates. This is a major limitation of the
conventional lathe keeping in view of the present project work. Gear cutting is a
specialized form of milling, and the lathe is quite suited to this workpiecr for
smaller work (6" diameter or so) with the help of attachment.
1.4 OBJECTIVE
Our project design and fabrication of gear cutting attachment is used to
cut gear or spines over the cylindrical workpiece. Our main aim is to prove lathe
as a versatile machine and with the help of gear cutting attachment the object is
possible by lathe itself.
1.5 SCOPE
i. To cut gears without milling machine.

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 ii. To cut splines over shafts.
iii. To cut key ways & slots.
1.6 FLOW CHART
The project starts identify the problem. It is a first step for the project
flow in order to find the problem in conventional lathe . This step helps to create
a different design to improve the product. After identify the problem for the
project, project continues with identify the objective.
The objective is very important in every work because every procedure
to make a project will depend on it. It will help to know the main point to make
the project success or not. The project continues with identify the scope of the
project because this scope can help the progress to create the new product
design for the project and to make sure the method chose will be within the
range of achievable objective. Next continue it with literature review and
research about the title. This consist a review of the design and type of safety.
These tasks have been done through research on the internet. From the flow
chart, start to design new concept. Use datum as reference.
Then improve the design. Try to come with several concepts. Then
compare the criteria from 5 each design which the most best. If the design
chosen still needed to be improved go back to the previous steps. If no
improvement is needed go to next step. Produce the drawing together with
dimension of the product and the type of material needed. After completing the
previous task, start the fabrication process. Gather the parts needed for the
project to proceeds the fabrication process. Here come the testing and
evaluation process. During the testing, if problem occur, the process of
fabrication will step back to the previous process. The reason to step back is to
fix the error. After all part had been joined together and no error, here comes the
phase of result and discussion. Beside, how to achieve objective and solve
problem statement of the project will be discuss in this phase.

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 Fig1.6.1 (flow chart)
2.3 BASIC PRINCIPLES
GEAR PRODUCTION
Gears may be manufactured by casting, stamping, machining or by
powder metallurgical process. Out of all processes, the most common and
accurate method of production of gears is by machining. You are required to cut
gears on a Horizontal Milling Machine.Schematic diagram of this machine is
given.

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 Cutting of a Spur Gear on a Milling Machine involves the following
types:
 To determine the important dimensions and proportions of the gear
tooth element.
 Mounting the cutter and the workpiecr on the machine.
 Adjust the position of the table to the starting position.
 Indexing.
 Repeat the operation till the gear is complete.

INDEXING
Indexing is an operation of dividing the periphery of a piece of work into
any number of equal parts, for e.g. this operation can be adopted for producing
hexagonal and square headed bolts, cutting spines on shafts, fluting drills and in
gear cutting. All these works require a holding device which will permit the
rotation of the work about the axis so that periphery of the work piece can be
divided equally and accurately. Such a work holding devices is known as
DIVIDING HEAD OR INDEXING HEAD. METHODS OF INDEXING:
 Direct Indexing
 Simple Indexing

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  Compound Indexing
Differential Indexing Direct Indexing: It is also called Rapid Indexing.
This is used when a large number of identical pieces are indexed by very small
number of divisions. The rapid plate is generally fitted to the front end of the
spindle nose. The plate has 24numbers of equally spaced holes. Into any one of
which a spring loaded pin is pushed to lock the spindle with the frame while
indexing, the pin is taken out and the spindle is rotated by hand. After the
required position is reached, it is again locked by the pin. Now the dividing
head spindle and work are also turned through the same part of revolution. With
this type of indexing with a plate of 24 holes, the periphery can be divided into
2,3,4,6,8,12 or 24 parts which are all factors of 24.
Gears are toothed wheel used to transmit power for small distances. It is
positive types of drive and mostly preferred in machines. The important use of
various type of gears are as follows- Spur gear-sliding mesh gear box, machine
tool gearbox
 Helical gear- automobile gear box
 Rack & pinion- lathe carriage, steering gear box
 Worm & worm wheel- wiper mechanism, material handling equipments
gear box, steering gear box Bevel gear- automobile differential gear box
 Spiral gear-drives in textile machineries
1.1 Manufacturing of Gears
The various steps of gear manufacturing are:
1. Blank preparation
2. Heat treatment of blank
3. Turning of gear blank with desired face width and major diameter.
4. Gear tooth cutting by suitable manufacturing process.
5. Suitable Gear finishing process
6. Heat treatment of gear

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7. ID and face grinding of gear
1.2 Types of Gear Manufacturing
Manufacture of gears by rolling The spline on the shaft is created by cold
rolling of shaft between two circular dies as shown in fig-1. Such a small tooth
thickness is difficult to achieve by other process hence this type of method is
preferred.
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 generally used in metalworking, metal spinning,
woodturning, and glassworking. The various operations that it can perform
include the following: sanding, cutting, knurling, drilling, and deforming of
tools that are employed in creating objects which have symmetry about the axis
of rotation. Some of the most common products of the lathe machine are
crankshafts, camshafts, table legs, bowls, and candlestick holders
1.2.2 Extrusion Process
Accurate gears of soft material are done by extrusion process which saves
the further heat treatment process. A bar is extruded through a forming die and
cavity shape is like gear tooth profiles hence after coming out bar from cavity
achieve the shape of exact gear. By cutting this extruded bar with desired face
width we achieve the gear. This process saves other operations also hence suited
for mass production.
1.2.3 Wire EDM
In wire cut EDM process thin copper or brass wire is used instead of
electrode. Potential difference is created between work piece and wire and due
to this across gap electric field gets generated and gap breaks and current flow

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through it and heat is generate. Due to this work piece vaporize after melting.
With Numerical control of table movement the shape of work piece is
controlled and we get desired accurate and finished gear. This method suitable
for external as well as internal gear.

Gear by using wire EDM

Form milling:
From figure cutter is mounted on arbor with its axis right angle to work
piece. Indexing plate provided for indexing movement of work piece. In single
pass one tooth is finished hence it is time consuming process and suitable for
work piecr production.
Lathe:
Lathes are used in woodturning, metalworking, metal spinning, thermal
raying, parts reclamation, and glass-working. Lathes can be used to
shape pottery, the best-known design being the potter's wheel. Most suitably
equipped metalworking lathes can also be used to produce most solids of
revolution, plane surfaces and screw threads or helices. Ornamental lathes can
produce three-dimensional olids of incredible complexity. The work piece is
usually held in place by either one or two centers, at least one of which can
typically be moved horizontally to accommodate varying work piece lengths.
Other work-holding methods include clamping the work about the axis of
rotation using a chuck or collet, or to a faceplate, using clamps or dogs.
Examples of objects that can be produced on a lathe
include candlestick holders,  cue ticks, table legs, bowls, baseball bats, musical
instruments especially woodwind instruments), crankshafts, and camshafts.

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 The lathe is a machine tool used principally for shaping articles of metal
(and sometimes wood or other materials) by causing the work piece to be held
and rotated by the lathe while a tool bit is advanced into the work causing the
cutting action. The basic lathe that was designed to cut cylindrical metal stock
has been developed further to produce screw threads. tapered work. drilled
holes. knurled surfaces, and crankshafts. The typical lathe provides a variety of
rotating speeds and a means to manually and automatically move the cutting
tool into the work piece. Machinists and maintenance shop personnel must be
thoroughly familiar with the lathe and its operations to accomplish the repair
and fabrication of needed parts.
Lathes can be divided into three types for easy identification: operator
can accomplish more machining jobs with the engine lathes, turret lathes, and
special purpose lathes. Small engine lathe than with any other machine tool.
Turret lathes lathes can be bench mounted, are lightweight, and can be and
special purpose lathes are usually used in production or transported in wheeled
vehicles easily. The larger lathes are job shops for mass production or
specialized parts. while floor mounted and may require special transportation if
they basic engine lathes are usually used for any type of lathe must be moved.
Field and maintenance shops generally use a work. Further reference to lathes in
this chapter will be about lathe that can be adapted to many operations and that
is not too the various engine lathes. large to be moved from one work site to
another.
Various types of Lathe Machine Tools
• Engine lathe
• Tool room lathe
• Speed lathe
• Turret lathe
• Chucking lathe
• Automatic screw machine or a bar machine

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 • Numerically controlled lathe

LATHE
ENGINE LATHES SIZES:
The size of an engine lathe is determined by the largest piece of stock that
can be machined. Before machining a work piece, the following measurements
must be considered: the diameter of the work that will swing over the bed and
the length between lathe centers
LATHE COMPONENTS
Engine lathes all have the same general functional parts, even though the
specific location or shape of a certain part may differ from one manufacturer
The bed is the foundation of the working parts of the lathe to another (Figure 7-
3). Ways provide the means for holding the tailstock and carriage, which slides

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along the ways, in alignment with the permanently attached headstock the
headstock is located on the operator’s left end of the lathe bed. It contains the
main spindle and oil reservoir and the gearing mechanism for obtaining various
spindle speeds and for transmitting power to the feeding and threading
mechanism.
The headstock mechanism is driven by an electric motor connected either
to a belt or pulley system or to a geared system. The main spindle is mounted on
bearings in the headstock and is hardened and specially ground to fit different
lathe holding devices.
The spindle has a hole through its entire length to accommodate long
workplaces. The hole in the nose of the spindle usually has a standard Morse
taper which varies with the size of the lathe. Centers, collets, drill chucks,
tapered shank drills and reamers may be the main feature of its construction is
the ways which are inserted into the spindle. Chucks, drive plates, and
faceplates formed on its upper surface and run the full length of the bed. May be
screwed onto the spindle or clamped onto the spindle nose.
Working of a Lathe:
A typical lathe consists of bed, head stock, tail stock, tool post, carriage
and feeding mechanism. Lathe is capable of performing a number of operations.
The simplest operation performed on a lathe is straight turning. The working of
lathe can be easily understood if we understand straight turning.
Straight Turning:
A cylindrical work piece is mounted on a suitable work holding device
(e.g: chucks, centres). A single point cutting tool is mounted on the tool post.
The work piece is rotated continuously by rotating the head stock spindle. The
single point cutting tool is fed against the circumferential area of the work
piece. Unwanted material is removed and a cylindrical job with smooth surface
finish is obtained.

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 Apart from straight turning, a number of turning operations can be
performed using lathe. The following video explains some common forms of
turning

Lathe components
SAFETY:
All lathe operators must be constantly aware of the safety hazards that are
associated with using the lathe and must know all safety precautions to avoid
accidents and injuries. Carelessness and ignorance are two great menaces to
personal safety.
Other hazards can be mechanically related to working with the lathe, such
as proper machine maintenance and setup. Some important safety precautions to
follow when using lathes are:
Correct dress is important, remove rings and watches, and roll sleeves above
elbows.
o Always stop the lathe before making adjustments.

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 o Does not change spindle speeds until the lathe comes to a complete
stop?
o Handle sharp cutters, centers, and drills with care.
o Remove chuck keys and wrenches before operating
o Always wear protective eye protection.
o Handle heavy chucks with care and protect the lathe ways with a
block of wood when installing a chuck.
o Know where the emergency stop is before operating the lathe.
o Use pliers or a brush to remove chips and sward, never your hands.
o Never lean on the lathe.
o Never lay tools directly on the lathe ways. If a separate table is not
available, use a wide board with a cleat on each side to lay on the
ways.
o Keep tools overhang as short as possible.

MICROMETER COLLAR
Graduated micrometer collars can be used to accurately measure this tool
bit movement to and away from the lathe center axis. Thus. the depth of cut can
be accurately measured when moving the tool bit on the cross slide by using the
cross slide micrometer collar.
The compound rest is also equipped with a micrometer collar. These
collars can measure in inches or in millimeters, or they can be equipped with a
dual readout collar that has both. Some collars measure the exact tool bit
movement. While others are designed to measure the amount of material
removed from the work piece (twice the tool bit movement). Consult the
operator’s instruction manual for specific information on graduated collar use.

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Graduated micrometer collar
Feed:
Feed is the term applied to the distance the tool bit advances along the
work for each revolution of the lathe spindle. Feed is measured in inches or
millimeters per revolution, depending on the lathe used and the operator’s
system of measurement. Table 7-3 in Appendix A is a guide that can be used to
select feed for general roughing and finishing operations.
A light feed must be used on slender and small workplaces to avoid
damage. If an irregular finish or chatter marks develop while turning. Reduce
the feed and check the tool bit for alignment and sharpness. Regardless of how
the work is held in the lathe, the tool should feed toward the headstock. This
results in most of the pressure of the cut being put on the work holding device.
If the cut must be fed toward the tailstock. use light feeds and light cuts to avoid
pulling the work piece loose.

Depth of Cut:
Depth of cut is the distance that the tool bit moves into the work. Usually
measured in thousandths of an inch or in millimeters. General machine practice

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is to use a depth of cut up to five times the rate of feed, such as rough cutting
stainless steel using a feed of 0.020 inch per revolution and a depth of cut of
0.100 inch. Which would reduce the diameter by 0.200 inch? If chatter marks or
machine noise develops. Reduce the depth of cut.
A lathe is a machine tool which turns cylindrical material, touches a
cutting tool to it, and cuts the material. The lathe is one of the machine tools
most well used by machining.
As, a material is firmly fixed to the chuck of a lathe. The lathe is switched
on and the chuck is rotated. And since the table which fixed the byte can be
moved in the vertical direction and the right-and-left direction by operating
some handles It touches a byte's tip into the material by the operation, and
makes a mechanical part.

Lathe Bed arrangement

Three Important Elements
In order to get an efficient process and beautiful surface at the lathe
machining, it is important to adjust a rotating speed, a cutting depth and a
sending speed. Please note that the important elements cannot decide easily,
because these suitable values are quiet different by materials, size and shapes of
the part.
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Rotating Speed:
It expresses with the number of rotations (rpm) of the chuck of a lathe.
When the rotating speed is high, processing speed becomes quick, and a
processing surface is finely finished. However, since a little operation mistakes
may lead to the serious accident, it is better to set low rotating speed at the first
stage. 
Cutting depth:
The cutting depth of the tool affects to the processing speed and the
roughness of surface. When the cutting depth is big, the processing speed
becomes quick, but the surface temperature becomes high, and it has rough
surface. Moreover, a life of byte also becomes short. If you do not know a
suitable cutting depth, it is better to set to small value.
Sending speed (feed)
The sending speed of the tool also affects to the processing speed and the
roughness of surface. When the sending speed is high, the processing speed
becomes quick. When the sending speed is low, the surface is finished beautiful.
There are 'manual sending' which turns and operates a handle, and 'automatic
sending' which advances a byte automatically. A beginner must use the manual
sending. Because serious accidents may be caused, such as touching the rotating
chuck around the byte in automatic sending,.

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Easy Processing and Hard Processing

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 CHAPTER 2
LITERATURE REVIEW
2.1 INTRODUCTION
CHAPTER 2 is the literature review of the project. In this chapter,
various literatures on gear cutting attachment in lathe, basic principles which
use for fabrication of attachment, fabrication planning& machine used for
fabrication are described.
2.2 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 subsystems 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 subsystems face failures in components like gear,

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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 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.
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,

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 DEVELOPED ATTACHMENT
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
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

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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,
VIT University, Vellore, India published titled as Development of a new
machining setup for energy efficient turning process. In the production unit,
lathe is one of the important protection machines.
This paper focuses on producing a quality product in lathe machine with
less power consumption. In order to achieve that, a special setup is developed in
the lathe machine for turning and finishing of the components, to achieve
quality product and also to improve the productivity. As a result of this new
approach, profuse amount of energy can be saved, quality product can be
obtained and tool life can be increased.
The study aimed at evaluating the best process environment which could
simultaneously satisfy requirements of both quality and as well as productivity.
By conducting many experiments it was found that this special setup process
improves the quality and also reduces the power consumption as compared with
the existing process. Figure of developed attachment as shown below

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 Machine set up
He has concluded that the addition of surface finish tool in turning
process helps to improve the surface finish and this setup increases the tool life
of the turning tool. From the experimental results, it is confirmed that there is no
change of power consumption even after the additional usage of surface finish
tool. Hence, the set up will be helpful in improving the quality product, with
lesser load and power consumption.
I. Keyway &GEAR-CUTTING ATTACHMENTS TO LATHES on Jan.
30, 1940 by T. E. SMITH. (USA Patent No. 2188447 A) – First of all
T.E.SMITH proposed the principle of gear and keyway cutting attachment on
lathe machine. He used a separate motor for rotating cutting tool and indexing
was done on lathe chuck. This attachment was very complex and large in
construction
ii. GEAR CUTTING ATTACHMENT by John w. Barons, Baltimore,
"Application Serial No. ‘131,002.
” John w. barons Baltimore used screw for giving feed while T.E.SMITH
used intermittent feed device..
MILLING ATTACHMENT FonLÀfrHEsJoseph C. Harbison, Eldorado, Ill.,
assignor offorty-three and onefthird per cent to . ObeRoberts, Eldorado, Ill.

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 Joseph c. Harbision eliminated the use of motor and replaced the chuck
indexing by compound indexing .Cutting tool was mounted on arbor and arbor
was mounted between chuck and tail stock 8

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 CHAPTER 3
COMPONENTS USED

 INDUCTION PLATE
 WORK HOLDING DEVICE
 BASE OR STRUCTURE

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 CHAPTER – 4
COMPONENTS DESCRIPTION
INDUCTION PLATE;
An indexing head, also known as a dividing head or spiral head, is a
specialized tool that allows a work piece to be circularly indexed; that is, easily
and precisely rotated to preset angles or circular divisions. Indexing heads are
usually used on the tables of milling machines, but may be used on many other
machine tools including drill presses, grinders, and boring machines. Common
workpiecrs for a dividing head include machining the flutes of a milling cutter,
cutting the teeth of a gear, milling curved slots, or drilling a bolt hole circle
around the circumference of a part.
The tool is similar to a rotary table except that it is designed to be tilted as
well as rotated and often allows positive locking at finer gradations of rotation,
including through differential indexing. Most adjustable designs allow the head
to be tilted from 10° below horizontal to 90° vertical, at which point the head is
parallel with the machine table.
The work piece is held in the indexing head in the same manner as a
metalworking lathe. This is most commonly a chuck but can include
a collect fitted directly into the spindle on the indexing head, faceplate, or
between centers. If the part is long then it may be supported with the help of an
accompanying tailstock.
Manual indexing heads:
Indexing is an operation of dividing a periphery of a cylindrical work
piece into equal number of divisions by the help of index crank and index plate.
A manual indexing head includes a hand crank. Rotating the hand crank in turn
rotates the spindle and therefore the work piece. The hand crank uses a worm
gear drive to provide precise control of the rotation of the work. The work may
be rotated and then locked into place before the cutter is applied, or it may be
rotated during cutting depending on the type of machining being done.

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 Most dividing heads operate at a 40:1 ratio; that is 40 turns of the hand
crank generates 1 revolution of the spindle or work piece. In other words, 1 turn
of the hand crank rotates the spindle by 9 degrees. Because the operator of the
machine may want to rotate the part to an arbitrary angle indexing plates are
used to ensure the part is accurately positioned.
Direct indexing plate: Most dividing heads have an indexing plate
permanently attached to the spindle. This plate is located at the end of the
spindle, very close to where the work would be mounted. It is fixed to the
spindle and rotates with it. This plate is usually equipped with a series of holes
that enables rapid indexing to common angles, such as 30, 45, or 90 degrees. A
pin in the base of the dividing head can be extended into the direct indexing
plate to lock the head quickly into one of these angles. The advantage of the
direct indexing plate is that it is fast and simple and no calculations are required
to use it. The disadvantage is that it can only be used for a limited number of
angles.
Interchangeable indexing plates are used when the work must be rotated
to an angle not available on the direct indexing plate. Because the hand crank is
fixed to the spindle at a known ratio (commonly 40:1) the dividing plates
mounted at the hand wheel can be used to create finer divisions for precise
orientation at arbitrary angles. These dividing plates are provided in sets of
several plates. Each plate has rings of holes with different divisions. For
example, an indexing plate might have three rows of holes with 24, 30, and 36
holes in each row. A pin on the hand crank engages these holes. Index plates
with up to 400 holes are available.[2] Only one such plate can be mounted to the
dividing head at a time. The plate is selected by the machinist based on exactly
what angle he wishes to index to.
For example, if a machinist wanted to index (rotate) his work piece by
22.5 degrees then he would turn the hand crank two full revolutions plus one-
half of a turn. Since each full revolution is 9 degrees and a half-revolution is 4.5

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degrees, the total is 22.5 (9 + 9 + 4.5 = 22.5). The one-half turn can easily be
done precisely using any indexing plate with an even number of holes and
rotating to the halfway point (Hole #8 on the 16-hole ring).
Brown and Sharpe indexing heads include a set of 3 indexing plates. The plates
are marked #1, #2 and #3, or "A", "B" and "C". Each plate contains 6 rows of
holes. Plate #1 or "A" has 15, 16, 17, 18, 19, and 20 holes. Plate #2 or "B" has
21, 23, 27, 29, 31, and 33 holes. Plate #3 or "C" has 37, 39, 41, 43, 47, and 49
holes. Universal Dividing heads: some manual indexing heads are equipped
with a power drive provision. This allows the rotation of the dividing head to be
connected to the table feed of the milling machine instead of using a hand
crank. A set of change gears is provided to select the ratio between the table
feed and rotation. This setup allows the machining of spiral or helical features
such as spiral gears, worms, or screw type parts because the part is
simultaneously rotated at the same time it is moved in the horizontal direction.
This setup is called a "PTO dividing head".
CNC indexing heads:
CNC indexing heads are similar in design to the manual variety except
that they have a servo motor coupled to the spindle instead of a hand crank and
indexing plates. The servo motor is electronically controlled to index the work
to the required position. The control can either be a simple keypad for the
operator or it may be fully CNC controlled.

CNC indexing heads may be controlled in two different modes. The most
basic method of operation uses simple control functions built into the dividing
head. It does not require a CNC machine. The operator enters the desired angle
into a control box attached to the indexing head and it automatically rotates to
the desired position and locks into place for machining. Changing angles is as
simple as typing a new angle value onto the control pad.

27
 This is simpler than setting up a manual indexing head because there is
no need to interchange indexing plates or to calculate which hole positions to
use. It is also faster for repetitive operations because the work can be indexed
by simply pressing a button, eliminating the need to count rotations of the hand
crank or specific hole positions on the indexing plate. A CNC dividing head
may be used in this manner on either manual or CNC machinery.
Most CNC dividing heads are also able to function as a full CNC axis
and may be wired into the control of a CNC machine. This enables the
machine's main CNC controller to control the indexing head just like it would
control the other axes of the machine. This can be used to machine complex 3D
shapes, helices with a non-constant pitch, and similar exotic parts. This mode of
operation cannot be used on a manual machine tool because it requires a full
CNC controller to operate.
The first lathe machine that was ever developed was the two-person lathe
machine which was designed by the Egyptians in about 1300 BC. Primarily,
there are two things that are achieved in this lathe machine set-up. The first is
the turning of the wood working piece manually by a rope; and the second is the
cutting of shapes in the wood by the use of a sharp tool. As civilizations
progressed, there have been constant modifications and improvements over the
original two-person lathe machine, most importantly on the production of the
rotary motion.

28
Induction plates
WORK HOLDING DEVICE:
A fixture is a work-holding or support device used in
the manufacturing industry.  Fixtures are used to securely locate (position in a

29
specific location or orientation) and support the work, ensuring that all parts
produced using the fixture will maintain conformity and interchangeability.
Using a fixture improves the economy of production by allowing smooth
operation and quick transition from part to part, reducing the requirement for
skilled labor by simplifying how work pieces are mounted, and increasing
conformity across a production run.
A fixture differs from a jig in that when a fixture is used, the tool must move
relative to the work piece; a jig moves the piece while the tool remains
stationary.

A fixture's primary purpose is to create a secure mounting point for a work

piece, allowing for support during operation and increased accuracy, precision,
reliability, and interchangeability in the finished parts. It also serves to reduce
working time by allowing quick set-up, and by smoothing the transition from
part to part.[3] It frequently reduces the complexity of a process, allowing for

30
unskilled workers to perform it and effectively transferring the skill of the tool
maker to the unskilled worker. Fixtures also allow for a higher degree of
operator safety by reducing the concentration and effort required to hold a piece
steady.
Economically speaking the most valuable function of a fixture is to reduce labor
costs. Without a fixture, operating a machine or process may require two or
more operators; using a fixture can eliminate one of the operators by securing
the work piece.
Work holding devices on a lathe:

As we know the lathe is one of the oldest and highly important machine
tool. There is vast number of applications of this machine tool. So for
facilitating the easy machining of the work piece it should be held tightly and
securely. For this purpose many types of accessories are being used for
facilitating easy holding of the work piece. 
Some of the work holding devices are 
1) Carriers and catch plates
2) Face plates
3) Angle plates
4) Mandrels
5) Rests

Carriers and catch plates:

These are in general used for driving the work piece when it is held in
between two centers namely head stock and tail stock. Carriers are also called as
the driving dogs. These are attached to the work piece by the help of setscrews.
Whereas the catch plates are pinned to the headstock.
Face plates:

31
 Faceplates are used for holding those work pieces, which cannot be held
both by centers and by chucks. The construction of the faceplates is very
simple. It consists of a center bore and plain and radial slots through the plate
for facilitating the holding of the work piece. The central bore has a radius equal
to that of the radius of the spindle of the lathe. And the plain and radial slots
provide a healthy platform for holding the work piecrs by using T-bolts and
clamps.

FACE PLATE
Angle plates
These are used along with faceplates for maintaining the given work
piece horizontal i.e. perpendicular to the tool used. Angle plates consist of two
faces, which are highly machined, and these also have the provision of holes for
the easy clamping of the work piece to it. 

32
 Angle plate
Mandrels:

This type of work holding devices are employed for holding previously
drilled or bored hole so as to facilitate effective outer surface machining. The
work is loaded over the mandrels between the centers. The ends of the mandrels
are made slightly smaller than the original diameter. This is done for effective
gripping of the mandrel in the chuck or any other holding device. In general the
material used for the manufacturing of the mandrels is plain carbon steel.
Various types of mandrels are in usage. Various types of mandrels are 
1) Plain mandrels
2) Step mandrels
3) Collar mandrels
4) Screwed mandrels
5) Cone mandrels

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6) Gang mandrels
7) Expansion mandrels

Plain mandrels:
This type of mandrels finds a numerous number of applications in shops
where identical pieces are to be generated. The body of these mandrels has
generally a tapered shape. The difference in the tapped diameter is of 1 to 2 mm
and the length varies between 55mm to 430mm. the tapper is provided for
facilitating high end gripping for holding the work piece. 

Step mandrel:
A special type of mandrel, which facilitates faster processing’s by
holding various sized workpiecrs without replacing the mandrel. This type of
mandrels finds applications in repair shops and generally used for turning
collars, washers and odd sized workpiecrs.

Collar mandrel:
A collar mandrel has a collar arrangement, which is fixed and may have
size larger than that of the 100mm. this type of construction is a type of
optimizing the material being used. 
Screwed mandrels:
These mandrels have a thread cut engraved on one side along with a
collar. Such type of mandrels is called as screwed mandrels. Screwed mandrels
are used when work pieces having internal threads are to be machined. The size
of the threads to be engraved on the screwed mandrels depends on the type of
work piece, which is going to fit over it.
Cone mandrel:

34
 Cone mandrels have a cone shaped piece attached at one of the mandrel.
This type of arrangement allows the mandrel to handle a variety of work pieces
having a varying internal crossectional diameter. The work piece is held tightly
by fixing a nut at the other end of fixing the work piece to the mandrel. Too
tight fitting of the work piece over the cone may damage the internal surface
finish of the work piece along with the damage to the cone shape of the
mandrel.
Milling fixtures:
See also: Milling machine
Milling operations tend to involve large, straight cuts that produce lots of
chips and involve varying force. Locating and supporting areas must usually be
large and very sturdy in order to accommodate milling operations; strong
clamps are also a requirement. Due to the vibration of the machine, positive
stops are preferred over friction for securing the work piece. For high-volume
automated processes, milling fixtures usually
involve hydraulic or pneumatic clamps.

Drilling fixtures:
See also: Drill

35
 Drilling fixtures cover a wider range of different designs and procedures
than milling fixtures. Though work holding for drills is more often provided
by jigs, fixtures are also used for drilling operations.
Two common elements of drilling fixtures are the hole and bushing.
Holes are often designed into drilling fixtures, to allow space for the drill bit
itself to continue through the work piece without damaging the fixture or drill,
or to guide the drill bit to the appropriate point on the work piece. Bushings are
simple bearing sleeves inserted into these holes to protect them and guide the
drill bit.
Because drills tend to apply force in only one direction, support
components for drilling fixtures may be simpler. If the drill is aligned pointing
down, the same support components may compensate for the forces of both the
drill and gravity at once. However, though monodirectional, the force applied
by drills tends to be concentrated on a very small area. Drilling fixtures must be
designed carefully to prevent the work piece from bending under the force of
the drill.
Jigs and Fixtures:
Some machining operation is so simple’ which are done quite easily, such
as turning, the workpiecr is held in position in the chuck and turning operation
is done easily. No other device is required to hold the workpiecr or to guide the
tool on the machine in such an operation. But some operations are such type in
which the tool is required to be guided by means of another device and also
some workpiecrs are of such forms which are required to be held in position on
the machine by means of another device.
The device which guides the tool is called jig and the device which holds
the workpiecr in position is called fixture.
Jigs and fixtures are special purpose tool which are used to facilitate
production (machining, assembling and inspection operations), when work
piece is based on the concept of interchangeability according to which every

36
part will be produced within an established tolerance. Jigs and fixtures provide
on means of manufacturing interchangeable parts since they establish a relation
with predetermined to tolerance between the work and cutting tool. They
eliminate the necessity of a special set up for each individual park. So’ A jig is
may be de-fined as a device which hold and position the work; locate or guides
the outing tool relative to the work piece and usually not fixed to the m/c table.

JIGS AND FIXTURE:

A fixture is a work holding device and position the work; but doesn’t
guide ‘locate or position the cutting tool’ the setting of the tool is done by
machine adjustment and a setting blocker using slip gauges. A fixture is hold or
clamp-ed to the machine table. It is usually heavy in construction. Jigs are used
on drilling , reaming , tapping and counter boring operations , while fixtures are
used in connection with turning , milling , grinding , shaping , planning and
boring operations.
The use of jig and fixture makes possible more rapid and more accurate
manufacturing at a reduction of cost.
Uses of Jigs and Fixtures:
1. Jigs and fixtures are used to reduce the cost of production as there use
elimination being out work and setting up of tools.
2. To increase the production.
3. To assure the high accuracy of the parts.
4. To provide for interchangeability.
5. To enables heavy and complex shaped parts to be machined by holding
rigidly to a machine.
6. To control quality control expenses.
7. Less skilled labor.
8. Saving labor.
9. There use partially automates the machine tool.

37
 10.Improve the safety at work, thereby lowering the rate of accidents
JIGS:
The most-common jigs are drill and boring jigs. These tools are
fundamentally the same. The difference lies in the size, type, and placement of
the drill bushings. Boring jigs usually have larger bushings. These bushings
may also have internal oil grooves to keep the boring bar lubricated. Often,
boring jigs use more than one bushing to support the boring bar throughout the
machining cycle.

In the shop, drill jigs are the most-widely used form of jig. Drill jigs are
used for drilling, tapping, reaming, chamfering, counter boring, countersinking,
and similar operations. Occasionally, drill jigs are used to perform assembly
work also. In these situations, the bushings guide pins, dowels, or other
assembly elements.
Jigs are further identified by their basic construction. The two common
forms of jigs are open and closed. Open jigs carry out operations on only one, or
sometimes two, sides of a work piece. Closed jigs, on the other hand, operate on
two or more sides. The most-common open jigs are template jigs, plate jigs,
table jigs, sandwich jigs, and angle plate jigs. Typical examples of closed jigs
include box jigs, channel jigs, and leaf jigs. Other forms of jigs rely more on the
application of the tool than on their construction for their identity. These include
indexing jigs, grunion jigs, and multi-station jigs.

38
 Specialized industry applications have led to the development of
specialized drill jigs. For example, the need to drill precisely located rivet holes
in aircraft fuselages and wings led to the design of large jigs, with bushings and
liners installed, contoured to the surface of the aircraft. A portable air-feed drill
with a bushing attached to its nose is inserted through the liner in the jig and
drilling is accomplished in each location.
Fixtures have a much-wider scope of application than jigs. These work
holders are designed for applications where the cutting tools cannot be guided
as easily as a drill. With fixtures, an edge finder, center finder, or gage blocks
position the cutter. Examples of the more-common fixtures include milling
fixtures, lathe fixtures, sawing fixtures, and grinding fixtures. Moreover, a
fixture can be used in almost any operation that requires a precise relationship
in the position of a tool to a work piece.

Fixtures have a much-wider scope of application than jigs. These work

holders are designed for applications where the cutting tools cannot be guided
as easily as a drill. With fixtures, an edge finder, center finder, or gage blocks
position the cutter. Examples of the more-common fixtures include milling
fixtures, lathe fixtures, sawing fixtures, and grinding fixtures. Moreover, a
fixture can be used in almost any operation that requires a precise relationship
in the position of a tool to a work piece.

39
 Fixtures are most often identified by the machine tool where they are
used. Examples include mill fixtures or lathe fixtures. But the function of the
fixture can also identify a fixture type. So can the basic construction of the tool.
Thus, although a tool can be called simply a mill fixture, it could also be further
defined as a straddle-milling, plate-type mill fixture. Moreover, a lathe fixture
could also be defined as a radius-turning, angle-plate lathe fixture. The tool
designer usually decides the specific identification of these tools.
STRUCTURE:
Structural steel is a category of steel used as a construction material for
making structural steel shapes. A structural steel shape is a profile, formed with
a specific cross section and following certain standards for chemical
imposition and mechanical properties. Structural steel shapes, sizes,
composition, strengths, storage practices, etc., are regulated by standards in
most industrialized countries.
Structural steel members, such as I-beams, have high second moments of
area, which allow them to be very stiff in respect to their cross-sectional area.

COMMON STRUCTURE
The shapes available are described in many published standards worldwide,
and a number of specialist and proprietary cross sections are also available.

40
 Fig: No: 4.17 LAYOUT OF STRUCTURE
A steel I-beam, in this case used to support timber joists in a house.
 I-beam (I-shaped cross-section - in Britain these include Universal
Beams (UB) and Universal Columns (UC); in Europe it includes the
IPE, HE, HL, HD and other sections; in the US it includes Wide
Flange (WF or W-Shape) and H sections)
 Z-Shape (half a flange in opposite directions)
 HSS-Shape (Hollow structural section also known as SHS (structural
hollow section) and including square, rectangular, circular (pipe)
and elliptical cross sections)
 Angle (L-shaped cross-section)
 Structural channel, or C-beam, or C cross-section
 Tee (T-shaped cross-section)
 Rail profile (asymmetrical I-beam)
While many sections are made by hot or cold rolling, others are made
by welding together flat or bent plates (for example, the largest circular hollow
sections are made from flat plate bent into a circle and seam-welded).

41
Base frame attachment

42
 CHAPTER - 5
WORKING PRINCIPLE

WORKING PRINCIPLE:
 Very easy method to gear cutting process in this project.
 Basically we are attached the workpiecr in lathe chuck, but this project
work piece was fixed in tool post.
 Gear cutting tool attached in lathe so chuck it is continuously rotate.
 This gear cutter makes a cut to the work piece.
 So chuck forcedly gradually gives the feed of cut in the work piece, this
case shaft get a shape of gear.
 Here indexing plate attached, it’s use to give the angle of cut .

43
 CHAPTER 6
ADVANTAGES AND APPLICATION

ADVANTAGE:
 Very Easy Method
 Maintain easy
 Less cost
 Easily available

APPLICATION:
 Small, medium scale industries
 Work shops

44
 CHAPTER - 7
CONCLUSION
We know that Country’s GDP is largely affected by many small scale
industries. Also, we saw that in this fast moving world a micro industries are
facing very tough competition from large scale industries and it’s almost very
difficult for them to survive and earn their share of bread and butter as they
have an only choice of selecting one or two machine at a time due which there
is a rise of a serious problem called as either sub contraction or renting of
machines which further decreases the overall efficiency of whole machine and
industry. By selecting and incorporating such small but useful ideas a small
scale industrialist can save huge amount of time, energy, and money hence forth
increasing the overall productivity of a firm and hence contributing more
efficiently in countries GDP

45
 REFERENCES

1.Designing and Fabrication of Multipurpose Tool Post for Lathe Machine

(IJSRD/Vol. 2/Issue 03/2014/033).
2.IMPROVEMENT IN GEAR-CUTTING ATTACHMENTS FOR LATHES.
(Specification forming part of Letters Patent No. 208,491, dated October 1,
1878 ;application filed March 1l, 1878).
3.MILLING ATTACHMENT FonLÀfrHEsJoseph C. Harbison, Eldorado, Ill.,
assignor of forty-three and onefthird per cent to .Obe Roberts, Eldorado.
(Application January 17, 1946, Serial No. 641,783)
4.THOMAS O. MILLS, OF ROGKFOItI), ASSIGNOR OF ONE-HALF ÍHIS
RIGHT TOWILLIAM H. MILLS, OF FREEPORT, ILLINOIS.
(IMPROVEMENT IN GEAR-CUTTING ATTACHMENTS ) (Patent No.
144,214, dated November 4, 1873)
5.Richard A. Maker (1993) “Milling machine lathe attachment” Application
number : US 08/002,967.
6.Production technology by R.K.Jain & Workshop technology by Hajariya
Chaudhry.
7. Wikipedia and GOOGLE SCHOLAR

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