Contents

ACKNOWLEDGEMENT........................................................................................................................4
DECLARATION.......................................................................................................................................5
ABSTRACT................................................................................................................................................6
INTRODUCTION.......................................................................................................................................7
PROBLEM STATEMENT..........................................................................................................................8
OBJECTIVES.............................................................................................................................................9
Main Objective........................................................................................................................................9
Specific Objectives..................................................................................................................................9
METHODOLOGY....................................................................................................................................10
BOOKS.................................................................................................................................................10
INTERNET...........................................................................................................................................10
LECTURES NOTES.............................................................................................................................10
CONSULTATIONS..............................................................................................................................10
AutoCAD..............................................................................................................................................10
LITERATURE REVIEW..........................................................................................................................11
Overview of the wood turning lathe machine........................................................................................11
DRIVING MECHANISM.....................................................................................................................11
MAIN COMPONENTS........................................................................................................................11
PEDAL POWERED WOOD TURNING LATHE MACHINE.............................................................11
ELECTRICAL POWERED WOOD TURNING MACHINE...............................................................13
TREADLE LATHE...............................................................................................................................14
PRODUCT DESIGN SPECIFICATION...................................................................................................16
CONCEPTS..............................................................................................................................................18
Concept 1: Pedal driven wood turning lathe machine............................................................................18
Concept 2: Treadle powered wood turning lathe machine.....................................................................20
Concept 3: Sprocket wheel wood turning lathe machine.......................................................................22
EVALAUTION MATRIX........................................................................................................................24
DESIGN CALCULATION.......................................................................................................................25
BELT SELECTION..............................................................................................................................29
MASS OF THE BIG STEPPED PULLEY............................................................................................31
MASS OF SMALL STEPPED PULLEY..............................................................................................32

1
 BENDING MOMENTS CALCULATIONS.........................................................................................32
Bending moment at driver.....................................................................................................................33
Bending moment at driven.....................................................................................................................34
DESIGN OF SHAFTS...........................................................................................................................34
Bending moment...................................................................................................................................36
Axial stress............................................................................................................................................36
Stress due to torsion...............................................................................................................................37
ASME design Code...............................................................................................................................37
TABLE OF FORMULA............................................................................................................................39
DETAILED DRAWINGS.........................................................................................................................41
GHANT CHART......................................................................................................................................43
BUDGET...................................................................................................................................................44
RECOMMENDATIONS...........................................................................................................................45
CONCLUSION.........................................................................................................................................46
REFERENCES..........................................................................................................................................47

2
LIST OF FIGURES

Figure 1: Pedal drive wood turning lathe machine....................................................................................12

Figure 2: Electrical powered wood turning lathe machine.........................................................................13
Figure 3: Treadle wood turning lathe machine..........................................................................................14
Figure 4:Pedal wood turning lathe machine...............................................................................................18
Figure 5: Treadle powered wood turning lathe machine............................................................................20
Figure 6: Sprocket wheel wood turning lathe machine..............................................................................22
Figure 7: driver dimension pulley..............................................................................................................31
Figure 8: pulley connection.......................................................................................................................31
Figure 9: Driver pulley...............................................................................................................................41
Figure 10: Driven pulley.............................................................................................................................42
Figure 11: Connecting system of pulleys and belt.....................................................................................42

LIST OF TABLES

Table 1: Evaluation matrix........................................................................................................................24

Table 2: Table of formulas.........................................................................................................................39
Table 2: Ghant chart..................................................................................................................................43
Table 3: Budget.........................................................................................................................................44

3
ACKNOWLEDGEMENT
We would like to thank Almighty God for the grace, love and good health throughout our time
we have been relentlessly working on this project.
We also thank our project supervisor, Mr. W. Mia for being with us all the time of the project.
He was available at any time we needed him for assistance.
Special thanks goes to our coordinator, Mr. T. Banda for his assistance in everything which we
were doing. We also thank our classmates (DME3) for their support and suggestions pertaining
to engineering technicalities. We appreciate Mr. G. Kunyungwi for his support in providing
needful information.
Lastly, we thank all lecturers for their support.

4
DECLARATION
This final year project report is a partial fulfilment for diploma in Mechanical Engineering for
the authors, Venencio Msundwe (DME/16/PE/019) and David M. Chikuse (DME/16/PE/003).
We hereby sincerely declare that this project report is genuine. The work is absolutely of
students’.

VENENCIO MSUNDWE DAVID M. CHIKUSE

Signature …………………. Signature ……………………..

Date ……………………… Date ………………………….

5
ABSTRACT
Most of the wood industries in Malawi use the lathe machine that are run manually by two
operators. These machine increase the cost of labour and occupying a large space in the
workshop. The lathes that are solely driven requires a lot of human power to run the machine in
order to turn the work piece into desired shape and size.
This project is aimed at re-designing and manufacturing a single operated manually wood lathe
machine. This lathe machine will solve the problems of higher labour costs. Its economic design
allows an operator to input cheap manual power with ease at the same time achieving the
maximum power required to rotate the work piece. The machine can handle approximately as
much as 100mm by 100mm square wood of maximum length of 1000mm. the market price of
the machine should be less than MK150, 000.00

6
INTRODUCTION
The wood lathe machine is introduced to lessen the human suffering and to improve economic
and technological standard, and for years now Malawi recognized that she was economically and
technologically poor and has been economically dependent on the western world for survival in
terms of technology. To discourage this importation of technological equipment placed enlarge
on the importation of certain goods and this inspired the students from University of Malawi, the
Polytechnic to recognize indigenous technology through our fore fathers who used axe, cutlass
and some other sharp tools for designing woods. But, as time goes on, technologist introduced
mini wood lathe machine, which comes in various designs and models as technology improves.
That’s why; the importance of wood lathe cannot be over emphasized. It is the
acknowledgement of this fact that led to the re-design of single manually operated wood lathe
machine. Even though this project of re-designing and manufacturing of single manually
operated wood lathe machine is a copied design, we will try to improve more on this machine so
that it can be re-designed with little or no stress, utilizing the available materials in order for the
machine to be in operation and also to reduced cost for production purposes and durability being
of utmost important.

7
PROBLEM STATEMENT
Woodturning is a process of shaping a piece of wood by turning it against sharp tool on a
machine (woodturning lathe machine) and it is usually in cylindrical shape.
Some of these machines are electrically powered and others are manually operated. Most of
these machines are found in urban areas, expensive and labour intensive. Due to these
limitations, it essential to re-design, manufacture and improve manually single person operated
woodturning machine to suit the currently condition.

8
OBJECTIVES

Main Objective
The main objective of this project is to re-design, manufacture and improve single person
operated wood lathe.
Specific Objectives
1. Develop drive mechanism design
2. Manufacture individual components
3. Assembly
4. Testing

9
METHODOLOGY
The following are the methods we used to come up with successful project. Through these
methods three concepts were generated.
BOOKS
The books were used to know the right components of materials to be used in designing the
project. In the book, different wood turning lathe machines were observed which helped us to
select the right mechanism and types of materials to use.
INTERNET
On the internet the information were gathered which helped us in coming up with the
components to be used. The information gathered on the internet was also used to analyze the
existing design which provides an insight on how best we can design manually operated wood
turning lathe machine.
LECTURES NOTES
These provides a background information regarding factors that were considered when coming
up with a design. Through the notes the product specification was developed as well as the
evaluation of matrix.
CONSULTATIONS
Fellow students and some academicians were consulted. In order to come up with this project
required knowledge from different people, so a lot of information was gathered from these
people.
AutoCAD
AutoCAD software has been used in detailed and calculation drawing.

10
LITERATURE REVIEW
Overview of the wood turning lathe machine
The wood turning lathe machine is used for turning wood to form cylinders, cones, and discs, or
any combination of these shapes. Such items include breadboards, teapot stands, fruit bowls,
eggcups, and tool handles, table lamps, and table legs. There is poor precision since the cutting
tool is moved by hand not by machine. A steady hand and good skill is needed to control the
cutting tool to accurately turn smooth curves and complex contours on the work piece (Ernie
Conover, 2001).
DRIVING MECHANISM
Drive mechanisms are means used as a source of power to drive the machine. Below are some of
mechanisms that wood turning machine uses as its driving mechanism.
MAIN COMPONENTS
The following the main parts of lathe machine,
1. Bed
It is the main body of the machine on which all the components are bolted.
2. Headstock
This part is used to connect the drive mechanism of the machine from the pedal to the spindle. It
is also used for holding work holding accessories.
3. Tailstock
This is the part that helps to support the work-piece to be held between centers.

PEDAL POWERED WOOD TURNING LATHE MACHINE

Pedal driven wood lathe machine is a manually pedal operated system which is used for wood
cutting and wood turning. The pedal driven setup has a simple mechanism operated with pedal
and wheel arrangement. It operates on the principle of rotating work piece and a feeding cutting
tool. It is different from normal (electrical powered) lathe machine as the machine are given the
power to run the machine manually.

11
 Headstock
Tailstock Tool
post
Chair
Pedal

Bed

Pulley

Figure 1: Pedal drive wood turning lathe machine.

BASIC OPERATION
According to William Fairham and Gray Roberts, 1922, the drive mechanism of pedal wood
turning machine is generated from the principle of pedals. As one operator is pedaling, the
potential energy is converted to the kinetic energy in the pedal which is transmitted to the pulley
using the chain. The pulley drives the spindle that is connected to the smaller pulley by means of
another belt which is connected to spindle. A work piece is mounted on a suitable work holding
device (e.g. chucks). A single point cutting tool is held by the operator and rested on the tool
post. The work piece is rotated continuously by pedaling operation and 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.

ADVANTAGES
 No electrical energy is required.
 Cost of machine is less and hence more number of people can afford.
DISADVANTAGES
 No hard metals can be turned.
 The machine is operated by two operators.
 Time consuming since the machine run at low speed.

12
ELECTRICAL POWERED WOOD TURNING MACHINE
According to Richard Raffan, 1985, the design of lathe machine was improved by ancient
Romans who added a turning bow which eased the wood work. In 1772, a horsed
powered boring machine was installed which was used for making canons. During the
industrial revolution steam engine, electrical engine, and water wheels were attached to
the lathe to turn the work piece at higher speeds which make the work faster and easier.
After 1950, many new designs were made which improved the precision of the work.

Motor
switch
Figure 2: Electrical powered wood turning lathe machine

BASIC OPERATION
The drive mechanism of this wood turning machine comprises spindle, motor, pulleys and belts.
When switched on, the motor converts electrical energy to kinetic energy. This kinetic energy is
then transmitted to a pulley which is connected to a spindle by belt. The cutting tool is held by
hand against a revolving work piece while being supported by a tool rest. The tool rest is
adjustable, and usually clamped to the bed at a position that best suits the operation at hand.

ADVANTAGES
 No time consuming since it is run at higher speed.
 Little labour involved, since it is run by electricity.

13
DISADVANTAGES
 Costly, since it is electrical powered.
 Limited range of use, since it is electrical powered of which it cannot be used in area
where there is no source of electricity.
 It has more weight due to the presence of motor and all parts are made of metals.

TREADLE LATHE
Treadle wood turning machine is a lathe machine which is operated by a single operator. This
machine was developed by Davie Chifodya and Gabriel Kalilombe, year 3 students from
University of Malawi, the Polytechnic, in 2018. The main reason of the project was to reduce
cost and also labour. The project was given to them by a client Mr. Mphande.

Figure 3: Treadle wood turning lathe machine

14
BASIC OPERATION
According to Davie and Gabriel 2018, the machine operates in the way the treadle sowing
machine operates. By applying the driving force on the treadle which is connected to the driving
wheel by an iron bar, rotates the driving pulley which in turn rotates the driver (small pulley). It
is this small pulley is in direct contact with a spindle and the spindle is connected to chuck that
provide the rotation of work piece during operation.
The treadle rotates the driver pulley by the up and downward movement of the treadle.
Advantages
1. Provide a clear working area during operation
2. It provides the operator with the chance to either operate while seated or standing.
Disadvantages
1. There is not selection of speed.

15
PRODUCT DESIGN SPECIFICATION
In order to come up with the best solution to the problem, the following parameters were
considered:
A. Materials
The type of materials has been used to suit the people who are in rural and urban area where
even during blackout can be used.
 Locally available materials, for example, wood
 Resistance to corrosion
B. Weight
The intended machine weighs at least 50 kilograms
C. Durability
The machine will be in good condition for at least 5 years in operation.
D. Operation
The machine would be easy to operate, for example;
 Single operator
 Easy to operate even semi-skilled and unskilled can operate
 Easy to maintain the machine
E. Performance
The machine performance should at least have a capacity of 1000mm by 100mm, whereby
1000mm is length of work and 100mm is work diameter.
F. Safety
The machine should not have sharp edges.
Guards should be provided where necessary e.g. on pulleys
G. Cost
The estimated production cost of the machine is not more than K170, 000.00
H. Speed
The machine should able to revolving at 750rev/min
I. Portability
Should be able to be transferred from one place to another

16
 J. Standards and Specification
The specifications of the machine are based on British Standards.

17
CONCEPTS
Concept 1: Pedal driven wood turning lathe machine

Figure 4:Pedal wood turning lathe machine

18
Main components
1. Headstock
2. Tailstock
3. Bed
Drive mechanism
This machine will be using the same mechanism used in cycling the bicycle. The machine will
have a single operator, as he/she pedaling the cranks which transmit its motion to sprocket by
means of chain, the sprocket drives a shaft that is connected to the flywheel and flywheel
transmit its motion to small pulley through a belt. Due to direct contact between small pulley and
spindle, this makes spindle also to rotate. The operator finishes the process of wood turning by
feeding a single pointed cutting tool against a rotating work with the support of tool rest, which
is mounted between headstock and tailstock. Until the desired diameter and shape is obtained,
then the operator stops pedaling.
Advantages
1. High life span since all revolving parts are made of metal
2. Health to the operator, since the pedaling force will be equally shared
Disadvantages
1. Operating while seating is not safe
2. Poor gripping work piece
3. Difficult to maintenance

19
Concept 2: Treadle powered wood turning lathe machine

Figure 5: Treadle powered wood turning lathe machine

20
Main components
1. Treadle
2. Flywheel
3. Headstock
4. Tailstock
5. Bed
Drive mechanism
The machine will be generating its power from person foot, pedaling the pedal. The pedal will
drive a big stepped pulley and the big stepped pulley will transmit the motion to the small
stepped pulley by a means of belt. The spindle starts rotating because of direct contact with a
small stepped pulley (there is positive relationship). As the spindle rotate, the work piece which
is mounted between centers also rotate because of rotation of spindle. The operator feeds a single
pointed cutting tool against a rotating work. Unwanted materials are removed until the desired
diameter and shape is obtained.
Advantages
1. Easy to maintenance
2. No need for lubrication
3. Good gripping of work piece
4. There is variation of speed
Disadvantages
1. Low life span because most of revolving parts are not made of metal
2. No health to the operator since there is no equal distribution of pedaling force

21
Concept 3: Sprocket wheel wood turning lathe machine

Figure 6: Sprocket wheel wood turning lathe machine

22
Main components
1. Rim
2. Headstock
3. Tailstock
4. Bed
Drive mechanism
The machine will be working on a principle of applying force on treadle which is connected to
the driving rim by a chain joined to an elastic rubber at its ends and also attached to the base on
the other end. When downward force applies on a treadle which will turn pulls the chain down
hence causing forward rotation of the wheel (rim). The drive mechanism will be in one direction,
upon releasing the treadle stretched the rubber pulls back the chain and sprocket by obeying its
elastic property and this will not affect the rotation of wheel. The driving wheel drives a small
pulley at the headstock through the belt which will be connected to the bigger pulley to the small
pulley with flywheel. This makes the spindle to also start rotating due to direct contact with a
small pulley. The operator feeds a cutting tool against rotating work piece mounted between
centers. The machine stops until the desired diameter or shape is obtained.
Advantages
1. Easy to operate since it requires less force to drive the rim due to the elastic rubber which
increases force
2. High safe due to inclusion of elastic rubber which gives one direction of the rotation
Disadvantages
1. Poor gripping efficiency
2. It requires large space due to protrusion of the rim
3. Expensive due rubber which will require frequently change

23
EVALAUTION MATRIX

Table 1: Evaluation matrix

Concepts Concept 1 Concept 2 Concept 3

Criteria

Durability D + + - D + - - D

Cost of A - + + A + - - A
Materials
T T T

Performance U - - + U - + + U
(efficiency)
M M M
Weight 0 + 0 - + +

Safety - - + 0 + 0

Swing of the 0 - 0 - + +
machine

Easy to - - + 0 + 0
Operate

Easy to - + + + - -
Maintain

Easy to 0 + 0 + - -
Manufacture

TOTAL 0 = 3, - = 9, +=6 0 = 5, - = 4, +=9 0 = 2, - = 8, +=8

24
DESIGN CALCULATION
Power transmitted

 According to Craft Supplies, Determining the safe speed for wood lathe, U.S.A, 19th
August, 2012, it stated that the safe speed for turning wood is 750rpm but it can be
increased to 1100rpm but not exceed 1200rpm.
 According to Rurthie Matthes, Sport Science, Drivers and Gears page 3, 2012, a standard
number of turns that a person can make per minute is 125rpm.

speed of driver
Therefor the speed ratio =
speed of driven

 The speed of first step pulley is 750rpm.

125
speed ratio=
750

1
speed ratio=
6

 To calculate speed for the second step of pulley.

Diameter of second driver step

Therefore, the speed of second step =
Diameter of second driven step

460
Second step speed = , let the speed of second step be x,
100

480
But =750 rpm , first step speed
80

480=60000 … … … … … .. ( i )

460=100 x … … … … … . ( i )

480 60000
To find x, =
460 100 x

48000 x=27600000

25
 27600000
x=
48900

x=575 rpm

Therefore, speed for the second step is 575rev per minute.

 To calculate speed of the third step of pulley.

diameter of driver
speed=
diameter of driven

440
Let speed of third step of pulley be x, therefore x=
120

480
But we know that =750
80

480=60000 … … … … … … ( i )

440=120 x … … … … … … …. ( i )

480 × 120 x=440 ×60000

26400000
x=
57600

x=458.33rpm

 The speed range of the machine is from 750rpm to 458.33rpm.

 According to Bhakti Satalkar, Proper Weight for Height and Age, 3rd June, 2018, He
stated that a person of age 18 to 30 years have a weight of 155lb.

In kilogram, 1lb = 0.45359237Kg

155lb = 70.2Kg.

1
 But when a person is applying force while seating down, the weight applied is of
4
his/her weight, according to Bradley Wiggins, Cycling Power, 2012, France.

1
Therefore, of 70.2Kg = 17.55Kg.
4

26
To calculate force, force = weight × gravitational force

= 17.55 × 9.81

= 172.17N

Power required to rotate the work piece,

P=T ×ω 2

ω2 r 1 ω1
But = , ω 2=r 1 ×
ω1 r 2 r2

Speed of the driven pulley N=750rpm, where, N is number of turns in rev per minute.

r 1=radius of drive ,r 2=radius of driven , ω1=¿

ω 1=2 πN

750
ω 1=2 π ×
60

ω 1=78.54 rad / s

0.24 ×78.54
ω 2=
0.04

ω 2=471.24 rad /s

Torque of driver pulley, T =F l × R l

Where F l=force on drive , Rl=radius of drive pulley

 During a General Cycling Discussion, Minimum Haman Torque –Bike Forums, 12 June,
2006, they stated that the minimum human torque that can be applied on a pedal is 75Nm.

2 πNT
Therefore, power¿ , P= power
60

P=981.25W

27
Therefore, power required to rotate the work piece is 981.25W.

 According to engineering catalogue, the diameter of driven pulley having a speed of

750rpm is 80mm and its power rating is 0.80kW.

diameter of driven pulley

Therefore, diameter of driver pulley, = speed ratio =
diameter of drive pulley

Since the speed ratio is 1:6 therefore, the diameter of driver pulley is x.

x=6 × 80

x=480 mm

Diameter of driver pulley = 480mm

Diameter of driven pulley = 80mm

To find force on driven pulley, we are going to use mechanical advantage (M.A).

Sdriver pulley F driven pulley

M.A = =
S driven pulley F driver pulley

Let speed of driver pulley be Sl , speed of driven be Ss , force of driver pulley side be F l, force of
driven pulley side be F s.

F l × Sl
F s=
Ss

172.17 ×1
F s=
6

F s=28.695 N

Therefore, the length of offsetting rod is, torque divide by force applied. Let length of offset rod
be Lrod .

75
Lrod =
172.17

Lrod =0.4356 m

28
 Lrod =44 mm

Torque of driver pulley is the same as torque on the driven pulley, because all of them has the
same force being applied on them and rotate at the same speed.

To calculate torque on driven pulley,

P × 60
T=
2 πN

981.25 ×60
T=
2 π × 750

T =12.49 Nm

According to Marija Gradimir Darnon, University of Belgrade, June 2006, He stated that the
cutting force is mean cutting power divide by cutting speed.

Let cutting power beC p, cutting speed beC s, and cutting force be F c.

Cp
F c=
Cs

172.17
F c=
750

F c =0.22956 N

BELT SELECTION
To calculate belt tension and other parameters, the center between the two pulleys must be
known.

The overall height of the lathe is chosen to be 1500mm.

 Calculation of speed of the large stepped pulley.

 As stated in previous report that the spindle will be run at a speed of 750 rpm

Given

Small stepped pulley speed (driven) = 750 rpm

29
Big stepped pulley speed (driver) =125rpm

Speed ratio = 6:1

To calculate center distance (C)

b+ √ b −8(De−de)
2 2
C=
8

Given, De=480mm, de=80mm

b=2Le-π (De+de)

π (De+ de) ( De−de)2

Where ¿=2C + +
2 4C

Le is effective length

¿=2694.84 mm

Therefore, b = 2(2694.84)-π (480+80)

b = 3630.4mm

3590.8+ √ 3630.4 2−8 (400)2

C=
8

C = 885mm

Therefore coefficient of friction µ between a wood and belt

µ=0.3

Angle of the groove, α=380 /2

α=190

 Then tension in the belt=Ttension=Tt

T 1 µθ
=e
T2

¿ e 0.3 ×2.8

30
 T1
=2.316
T2

T1=2.316T2

But force, F=T1-T2

172.17 = 2.316T2-T2

172.17 = 1.316T2

T2 = 172.17/ 1.316

T2 = 130.82N

T1 = 2.316 × 130.82

s T1 =302.98N

MASS OF THE BIG STEPPED PULLEY

Mass = Volume × Density

Mass = V× ρ

Figure 7: driver dimension pulley

31
 480mm
80mm

885mm
Figure 8: pulley connection

Taking the density of aluminium to be 2700Kg/m3

M =[π (D 2−d 2)/ 4 ×W ]× ρ

M =[π (0.482−0.32 )/4 × 0.015]×2700

M =5.96 Kg

MASS OF SMALL STEPPED PULLEY

Mass = Volume × Density

Mass = V× ρ

Mass=[π (d 2)/4 ×W ]× ρ

2
Mass=[π (0.14 )/ 4 × 0.015]×2700

M =0.83 Kg

BENDING MOMENTS CALCULATIONS

a) Reaction at driver side

R1 R2
32
 W

Let R1 and R2 be reaction force acting upward on bearings, w weight of pulley.

R1 ×a=( M × F g )× c , where M = 5.96Kg

Where “a” is the whole length of shaft, c is distance from R1 to W and fg is force of gravitate.

R1 ×175=(5.96 ×9.81) ×87.5

175 R1=58.47 × 87.5

5116.125
R 1=
175

R1=29.23 N

Since the load is loaded at the centre and distance from R1 to c and R2 to c.

Therefore, R2=29.23N

b) Reactions at driven side

R1 W R2

Let R1 and R2 be reaction force acting upward on bearings, w weight of pulley.

R1 ×a=( M × F g )× c , where M= 0.83Kg

Where a is the whole length of shaft, c is distance from R1 to W and fg is force of gravity.

R1 ×175=(0.83 × 9.81)×87.5

175 R1=8.1423 ×87.5

712.45125
R1=
175

33
 R1=4.07 N

Since the load is loaded at the centre and distance from R1 to c and R2 to c.

Therefore, R2=4.07N

Bending moment at driver

Let bending moment at R1 be a, at c be c and at R2 be x. we are going to denote bending moment
as BM.

BM at a = R1 × distance

BM at a = 29.23 × 0

BM at a = 0Nmm

BM at c = R1 × distance

BM at c = 29.23 × 87.5

BM at c = 2557.63Nmm

BM at x = R2 × distance

BM at x = (29.23 ×175) – (29.23 × 175)

BM at x = 0Nmm

Bending moment at driven

Let bending moment at R1 be a, at c be c and at R2 be x. we are going to denote bending moment
as BM.

BM at a = R1 × distance

BM at a = 4.07× 0

BM at a = 0Nmm

BM at c = R1 × distance

BM at c = 4.07 × 87.5

BM at c = 356.125Nmm

34
 BM at x = R2 × distance

BM at x = (356.125 ×175) – (356.125 × 175)

BM at x = 0Nmm

DESIGN OF SHAFTS
We are going to use alloy steel material for our shafts, since alloy steel has fewer tendencies to
crack, wrap or distort in heat treatment. In addition to that, alloy steel has great strength and
residual stresses are less compare with carbon.

 Design a shaft based on strength

In this case shaft is design so that stress at any location should not exceed the material yield
stress. Therefore, no consideration of deflection and twist of a shaft.

Since the shaft or spindle will be rotating, therefore the shaft we will be experiencing both
bending moment and axial stress.

But before, let’s calculate allowable stress and allowable shear stress, since we know that the
shaft is solid shaft but having allowance key way for mounting the pulleys.

Therefore, ultimate stress is 84MPa and ultimate shear stress is 42MPa.

 To calculate allowable stress,

δ ult
δ allowable=
F.S

Where F.S is factor of safe which is 2.

84
δ allowable=
2

δ allowable=42 MPa

 To calculate allowable shear stress,

τ ult
τ allowable=
F.S

35
 42
τ allowable=
2

τ allowable=21 MPa

 To calculate diameter of the shaft,

π 3
P= ×τ × d
16

π 6 3
12.49= ×(21×10 )×d
16

3 12.49
d=
4123340.358

d = √ 3.029097507 ×10
3 3 −6

d=0.014468974 m

d=14.5mm

Therefore shaft diameter is 20mm, the standard size of shaft and also to increase factor of safe.

Bending moment
 To calculate stress due to bending moments at driver,

32 M
σ b= 3 4
π d (1−K )
0

Where K=0, M=2557.63Nmm and d=20mm

32× 2557.63
σ b= 3 4
π 200 (1−0 )

81844.16
σ b=
25132.74123

2
σ b=3.26 N / mm

Where, M : Bending moment at the point of interest

36
 do : Outer diameter of the shaft

K : Ratio of inner to outer diameter of the shaft (K=0 for a solid shaft because inner
diameter is zero)

Axial stress
4 αF
σ a= 2 2
π d (1−K )
0

Where, F : Axial force (tensile or compressive)

α : Column-action factor (=1.0 for tensile load), where F is force applied = 172.17N

4 × 1× 172.17
σ a=
π 2020 (1−02)

688.68
σ a=
1256.637061

σ a=0.548034131 N /mm2

Stress due to torsion

16 T
τ xy =
π d (1−K 4)
3
0

Where T : Torque on the shaft

τxy : Shear stress due to torsion

16 ×12.49
τ xy =
π 2030 (1−0 4 )

199.84
τ xy =
25132.74123

−3 2
τ xy =7.95 ×10 N /mm

37
ASME design Code
The shaft are normally acted upon by gradual and sudden loads, hence ASME code by suitable
load factor.

16
4 √
τ allowable= 3
{C bm M +αF d 0 ¿ ¿ ¿ ¿
π d (1−K )
0

Therefore the ASME design code is 40MPa since the shaft has a keyway which provide locking
position for pulleys.

For stationary shaft Cbm Ct

Load gradually applied 1.0 1.0
Load suddenly applied 1.5-2.0 1.5-2.0
For rotating shaft
Load gradually applied 1.5 1.0
Load suddenly applied (minor shock) 1.5-2.0 1.0-1.5
Load suddenly applied (heavy shock) 2.0-3.0 1.5-3.0

PARAMETER FORMULA ANSWER

Speed of driver According to Rurthie Matthes, sport science 125rpm

Speed of driven According to Craft Suppliers, safe speed to turn a 750rpm

wood
Speed ratio speed of driver 1:6
speed of driven
Force applied F s=W × F g 172.17N

Torque of driver T l=F l × R l , but according to General cycling 75Nm

pulley discussions on 12 June, 2006
Torque of driven P × 60 12.49Nm
T=
2 πN
pulley

38
Power transmitted 2 πNT 981.25W
P=
60
Diameter of Engineering catalogue using speed 750rpm 80mm
driven pulley
Diameter of Using speed ratio (6 × 80) 480mm
driver pulley
Force on driven Fl × Sl 28.695N
F s=
pulley Ss

Offsetting rod Ts 44≈45mm

L=
length Fl

Effective length π (De+ de) ( De−de)2 2694.84mm

¿=2C + +
2 4C
Center distance b+ √ b −8(De−de) 885mm
2 2
C=
8
Cutting force (Fc) Cp 0.22956N
F c=
Cp
Mass of pulleys M s=v × ρ , M l =v × ρ M s=0.83 Kg
M l=5.96 Kg
Shaft diameter π 3 d= 20mm
P= ×τ × d
16
Allowable stress π 3 δ all =42 MPa
P= ×τ × d
16
Allowable shear τ ult τ all=21 MPa
τ allowable=
stress F.S

Bending moment 32 M
σ b=
π d (1−K 4 )
3
0 σ b=3.26 N

Axial stress 4 αF
σ a= 2 2
π d (1−K )
0 σ a=0.5480341 N

Stress due to 16 T
τ xy = 3 4
torsion π d (1−K )
0
−3
τ xy =7.95 ×10 N

39
ASME code of 16
τ allw= √ {C bm M +αF d 0 ¿ ¿ ¿ ¿
shaft π d (1−K 4 )
3
0 40MPa

40
TABLE OF FORMULA
Table 2: Table of formulas

DETAILED DRAWINGS

Figure 9: Driver pulley

41
Figure 10: Driven pulley

Figure 11: Connecting system of pulleys and belt

42
GHANT CHART
Table 3: Ghant chart

                       
ACTIVITY NOV DEC JAN FEB MAR APR MAY JUN JUL AUG SEP
RESEARCH                      
(Literature review )  
CONCEPT                      
GENERATION
CONCEPT                      
EVALUATION
PROPOSAL                      
PRESENTATION
PROPOSAL                      
SUBMISSION
DETAILED DESIGN                      
 
CALCULATIONS                      
&
PRESENTATION
PREPARATION
FINAL                      
PRESENTATION
FINAL REPORT                      
SUBMISSION

43
BUDGET

Material Specification Qty Rate Cost

Bearing FY604 4 7,000.00 28,000.00
Stepped large pulley 400 ×20×45 1 20,000.00 20,000.00
Stepped small pulley 140×20×45 1 10,000.00 10,000.00
Wood 100×50(1500mm) 10 3,000.00 30,000.00

Mild steel shafts 30×1000mm 1 5,000.00 5,000.00

Screw and nut 20×250mm 1 4,000.00 4,000.00

Bots and nuts M8×65mm 20 150.00 3,000.00

M12×75mm 20 200.00 4,000.00

Rod 300mm 1 1,500.00 1,500.00

Belt 5×1135mm 1 6,000.00 6,000.00

Nails 100mm 1 5,000.00 5,000.00

K
2
g
Total 116,500.00

Table 4: Budget

44
RECOMMENDATIONS
The machine has been designed of having different speeds, accommodation of a log of at least
one meter (1 meter) and of with small thickness of the work piece. The future designers should
consider designing the machine that will accommodate a work piece of a lager diameter.

45
CONCLUSION
In this project report we have provided an overview of issues concerning different aspects of
woodturning lathe machine. This project focuses on principle of woodturning lathe, tooling and
machine parameters and process performances. The following major conclusion have been
drawn from this project report;
 Historical development of the woodturning lathe machine from ancient time to modern
time.
 Various parts and components of machine have been explained
 Calculations has been done in order to come up with the recommended sizes of different
components and parameters of the machine.
 Different types of woodturning lathe have been discussed and
 Entire time frame, Gantt chart and estimated budget has been included in this project
proposal report.

46
REFERENCES
1) Fairham William & Roberts Gray, (1922), 1 st edition.; Wood Turning Machine,
Toolemera, United Kingdom.
2) Raffan Richard, (1985), 3rd edition.; Turning Wood, Taunton Press, United States of
America.
3) Conover Ernie, (2001), 2nd edition.; Complete Guide to the Machine and its Accessories,
Taunton Press, United States of America.
4) Rowley Keith; (1991); 2nd edition.; Wood Turning a Fundamental Course, Guild of
Master, Craftsman, United Kingdom.
5) https://blog.sketchup.com/sketchupdate/pedal-powered-lathe-sketchup
6) https://za.pinterest.com/pin/342273640410755306
7) Chifodya Davie & Kalilombe Gabriel, (2018), Designing and Manufacturing a Solo and
Manually Driven Lathe Machine, The Polytechnic, Malawi.
8) Mr. C. Mvula, Lecture at University of Malawi, The Polytechnic, Mechanical
Engineering Department.
9) Mr. T. Banda, Lecture at University of Malawi, The Polytechnic, Mechanical
Engineering sCoordinator.
10) Marija Gradimir Darnon, June 2006, University of Belgrade, Faculty of Forestry, Dept
of Wood Processing, Belgrade, Serbia
11) Bike Forums, Minimum Human Torque –During a General Cycling Discussion, 12 June,
2006
12) Bradley Wiggins, Cycling Power, 2012, France.
13) Bhakti Satalkar, Proper Weight for Height and Age, 3rd June, 2018
14) Rurthie Matthes, Sport Science, Drives and Gears page 3,
15) Craft Supplies, Determining the safe speed for wood lathe, U.S.A, 19th August, 2012,

47