International Journal for Research in Engineering Application & Management (IJREAM)

ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

Design Analysis, Simulation and Fabrication of

Spur Gear Cutting Attachment for
Lathe Machine
1
Gunturu Mohan, 2C. Vijayabhaskar Reddy
1
UG Student, 2Professor, Sri Venkateswara College of Engineering Technology (Autonomous)
R V S Nagar, Chittoor, Andhra Pradesh, India.
1
[email protected], [email protected]

Abstract—Lathe is a very important manufacturing subsystem in many sectors. Even though it is a versatile machine, it
has some limitations while performing certain operations like a spline, gear cutting. The use of milling machines in the
production of gear cutting is well recognized. This paper aims at the design and development of an attachment that can
help lathe operations to machine spur gear product effectively. Attachment is designed as able to cut spur gear
accurately and flexible to use. Milling machine cutting load and thrust loads is applied while doing the analysis. The
results are studied and analyzed whether the attachment is able to withstand the load with the help of ANSYS tool.
Finally, from the results obtained attachment is fabricated.

Keywords— Design, analysis, motion simulation, fabrication. Attachment assembly and machining.

I. INTRODUCTION modified as holding and indexing device but this attachment

is heavy and complex.
Job shops and small-scale industries are heavily constrained
to use general purpose machines due to financial limitations. 1.1 Gears
Machines such as Lathes and Milling machines are versatile Assume that two plain wheels mounted bolt to two parallel
with these groups as they required minimum funding and are shafts and pressed tightly connected with one another. If one
easy to maintain. Researchers always attempt to help these wheel is rotated regarding its axis, the opposite wheel
industries through innovative methods to enlarge the ambit conjointly can rotate due to the friction between them as
their production using these general purpose machines [1]. shown in Fig 1. The rotation is thus transmitted from one
A variety of attachments are already in use by these shaft to another.
industries. As so far the literature reviews collected based on
some lathe machine attachments like the keyways, slotting,
internal keyway, and grinding wheel attachments for lathe
machine. These papers are helping lathe machine to obtain
maximum efficiency and utilization. literature collected on
gear cutting related journal explained about the parameters
to be considered while doing the design of an attachment
and required instructions to be considered while doing gear
cutting attachment for lathe machine.
J.C.Harbison (1994), [2] presented a milling attachment for
lathes. He modified the attachment that cutting tool fitted to
the arbor and that is supported by chuck and tailstock. He
modified direct indexing to compound indexing.
J.W.Bracus (1942), [3] presented a gear cutting attachment.
He was studied and modified smith’s attachment and he
tried to initiated indexing in the attachment.
T.E.Smith(1940), [4] presented a keyway and gear cutting
attachment for lathes. He is the initiator for this concept he
Fig.1. Gears
builds a gear and keyway cutting attachment for lathe by
adding another motor to the cutting tools and chuck The surfaces of the two wheels will move at constant speed
if there is no slipping. it's obvious that with the increase in

56 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

Load to be transmitted, the wheels will begin to slide on one the tooth form with shaped cutters or generating the form
another. to stop slipping slots is additionally cut on the with a rack cutter, a shaping cutter or a hob cutter Despite its
cylindrical surfaces of the wheels and projections added name, the roughing processes truly manufacture a sleek and
between them. These slots and projections form the teeth accurate gear tooth. just for high exactness and quiet
and wheels with such teeth area unit known as toothed running,
wheels or gears
1.4 Requirement of gear cutting attachment in lathe:
1.2 Spur gear
Lathe is a very important manufacturing subsystem in many
Spur gears have their teeth parallel to the axis and are used sectors. Even though it is a versatile machine, it has some
for transferring power between two parallel shafts. they're limitations while performing certain operations like a spline,
simple in construction as shown in Fig 1, simple to gear cutting. The use of milling machines in the production
manufacture and low cost. They need the most effective of the spline and gear cutting is well recognized. If an
potency and smart accuracy rating. they are used in high attachment on general purpose lathe is made available, the
speed and high load application altogether varieties of trains cost of production of a product could be reduced. A CNC
and an honest sort of velocity ratios. Hence, they perceive machine can perform the said operations more effectively
wide applications right from clocks, organization gadgets, since the human involvement is limited. However, due to
motorcycles, vehicles, and railways to aircrafts. increase in the cost of a CNC machine and the indirect costs
associated with these machines, they are considered as white
1.3 Gear manufacturing methods:
elephants in a certain class of manufacturing units.
Gear producing is divided into two classes particularly
forming and machining. Forming consists of direct casting, II. METHODOLOGY
molding, drawing, or extrusion of tooth forms in liquid, In this chapter, the methodology is covered to create gear
powdered, or heat softened materials and machining involve cutting attachment for a lathe to perform the gear cutting
roughing and finishing operations [5] as shown in Fig 2. operation in it. Initially, a Flow chart is shown in Fig 3. It
consists of methods of making gear cutting attachment,
Selection of a method, Basic drawings, designing and
modifications, Design and analysis, material selection as per
requirement, Fabrication, Assembly and Testing [6].

Fig.2. Gear manufacturing processes

1.3.1 Forming gear teeth

Altogether tooth-forming operations, the teeth on the gear
area unit formed all right away from a mold or die into that
the tooth shapes are machined. The accuracy of the teeth is
entirely hooked into the quality of the die or mold and
commonly is far but that will be obtained from roughing or
finishing ways in which. Most of these ways that have high
tooling costs making them appropriately only for high
production quantities
Fig.3. Methodology flow chart
1.3.2 Machining
2.1 Previous Methods
The bulk of power transmission metal gears of machinery
Two concepts are being attempted in the design and
area unit made by machining process from the cast, forged,
development of the attachment. One is to provision the
or hot rolled blanks. Refer Fig 2 for classification of
headstock with the workpiece while tool post is loaded with
machining processes. Roughing processes embrace milling
a tool and is guided by a special purpose motor. The second

57 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

method is that the headstock containing the tool is going to Outside Diameter (D) = (N+2)/P
rotate at various speeds while the tool post or tailstock Cordial Thickness (T) = D1sin(90/N)
contains workpiece for holding, cutting angle and changing
direction to perform gearing and slotting operations.
2.2 Selection of A Method
This project, therefore, aims at the design and development
of an attachment that can help lathe operations to produce
splines and gears of a product effectively and also realize
cost reduction. It is essential that the product quality should
be made comparable with that of milling operation or even
better. Ways and means will be found to incorporate features
both at design stage and production stage to achieve this
goal. Such an attachment will increase the flexibility of the Fig.4. Spur gear nomenclature
lathe.
Work piece diameter 50 mm
After analyzing the methods, In the end, choose the method For this work piece if the number of teeth 18 then the gear
based on some consideration like work piece holding parameters will be
tendency external bodies to be attached in lathe machine 1) Outside Diameter D = (N+2)/P
regarding complete setup it should be strong, safety, Outside Diameter = 50 mm
flexible, low cost and also it should be easy to attach and Teeth number = 18
remove. 50 = (18+2)/P
By considering all these things thefirst method was chosen. P = 20/50
= 0.4 mm
2.3 Design of Indexing and Spur Gear
2) Pitch Diameter D1 = N/P
2.3.1 Indexing [8] P = 0.4
In general, direct indexing plate has 24 holes in a circle D1 = 18/0.4
The workpiece is divided by using the formula = 45 mm
Holes by which pin is to be moved = 24/n 3) Addendum a = 1/P
n = no divisions in work piece = 1/0.4
by this direct indexing plate, these many slots can be cut = 2.5 mm
2 divisions in work piece = 24/2 = 12 holes 4) Dedendumd = w-A
3 divisions in work piece = 24/3 = 8 holes
4 divisions in work piece = 24/4 = 6 holes 5) Whole Depth W = 2.157/P
6 divisions in work piece = 24/6 = 4 holes = 2.157/0.4
8 divisions in work piece = 24/8 = 3 holes = 5.3925
12 divisions in work piece = 24/12 = 2 holes D = 5.3925 – 2.5
24 divisions in work piece = 24/24 = 1holes = 2.8925 mm
2, 3, 4, 6, 8, 12, 24. 6) Circular Pitch CP = 3.1416/P
To get other divisions I have taken 18 holes in the same = 3.1416/0.4
plate = 7.854 mm
2 divisions in work piece = 18/2 = 9 holes 7) Tooth Radius R = ¾(CP)
3 divisions in work piece = 18/3 = 6 holes = ¾ (7.854)
6 divisions in work piece = 18/6 = 3 holes = 2.94 mm
9 divisions in work piece = 18/9 = 2 holes 8) Module m = D1/N
18 divisions in work piece = 18/18 = 1 holes = 45/18
2, 3, 6, 9, 18 = 2.5
2.3.2 Spur gear creation [7] 9) Chordal thickness T = D1 sin(90/N)
= 45 sin (90/18)
Whole Depth (W) = 2.157/P = 3.922 mm
Addendum (a) = 1/P Workpiece diameter 50 mm
Tooth Radius (R) = ¾(CP)
Pitch Diameter (D1) = N/P For this workpiece, if the number of teeth 24 then the gear
Circular Pitch (CP) = 3.1416/P parameters will be
Diametral Pitch (P) = N/D1 1) Outside Diameter OD = (N+2)/P
Teeth number (N) = D1xD Outside Diameter = 50 mm
Teeth number = 24
Dedendum (d) = W-a

58 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

50 = (24+2)/P Attachment modeling deals with necessary parts required to

P = 26/50 hold and guide the work piece to perform the operation.
= 0.52 mm Parts modeled for attachment is given below.
2) Pitch Diameter D1 = N/DP  Main base with guides.
P = 0.52  Supporting base with guides.
D1 = 24/0.52  Cap.
= 46.15 mm  Main guide center.
3) Addendum a = 1/DP  Supporting guide center
= 1/0.52  Shaft with thread.
= 1.92 mm
3.3 Work holding design
4) Dedendum d = w-A
5) Whole Depth W = 2.157/P Work holding modeling is nothing but modeling required
= 2.157/0.52 parts to hold the work piece between centers.
= 4.15 mm
3.4 Tool holding design
d = 4.15 – 1.92
= 2.23 mm To accomplish machining it is necessary to insert toll
6) Circular Pitch CP = 3.1416/P between headstock and tailstock. Required models are made
= 3.1416/0.52 to insert tool.
= 6.04 mm 3.5 Assembly
7) Tooth Radius R = ¾(CP)
= ¾ (6.04)
= 4.53 mm
8) Module m = D1/N
= 46.15/24
= 1.922
9) Chordal thickness T = D1 sin(90/N)
= 46.15 sin (90/24)
= 26.38 mm

III. MODELLING
All CAD models are modeled with help of CATIA V5 tool.
Modeling of parts is divided into 5 steps
 Basic lathe.
 Attachment design.
 Work holding design.
 Tool holding design.
 Assembly.
3.1 Basic lathe
Modeling basic lathe deals with basic lathe parts. These Fig.5. Detail view
parts specifications are taken from general purpose standard
In assembly stage, Bottom to top approach was selected to
lathe and few are assumed measurements. Modeled parts
perform assembly in assembly workbench. Each part
names are given below.
dragged in to assembly workbench and accomplished
 Lathe bed
assembly. The detail view is shown in Fig 5 Initially,
 Headstock
themain base and supporting base with guides are fitted to
 Tailstock
the cross slide with base nuts and bolts. Threaded shafts are
 Carriage
fitted to centers of main and support. This subassembly is
 Chuck
fitted to the main base and supporting bases. Now caps are
 Cross slide
fitted to base and shaft with help of rows. As shown in Fig 6
 Carriage wheel
 Cross slide wheel This sub assembly is attached the cross slide. Now work
 Power shaft piece is aligned in between two bases with help of work
holding the device. pulleys aligned to the threaded shaft.
3.2 Attachment model
Belt arranged in-between two pulleys. Indexing plate
attached to work holder which is fitted to the center of the

59 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

main guide, both ends are tightened by hexagonal nuts as IV. MOTION SIMULATION AND
shown in Fig 6. ANALYSIS
4.1 Motion simulation
To perform motion simulation we chosen solid works
motion simulator so all Catia v5 parts are converted from
‘.catpart and .catproduct’ in to ‘.igs’ format. All required
motions are applied to the assembly parts and the final
animated video was saved. Motions applied to the assembly
parts are illustrated in Table 1

X X Y Y Z Z
S.NO PARTS linear rotation linear rotation linear rotation
(mm) (RPM) (mm) (RPM) (mm) (RPM)
1 Carriage -200 0 0 0 0 0
2 Centers 0 0 0 0 -100 0
3 Cross 0 0 150 0 0 0
Fig.6. Details of assembly
slide
.5.1 Final assembly 4 chuck 0 600 0 0 0 0
Detailed view of final assembly is shown in Fig 7 5 other 0 0 0 0 0 0
Table.1. Motion simulation details

Initially, motion applied to the carriage to position the work

with respect to cutting tool as carriage -200 mm linear
motion in x-direction after moving the carriage in x negative
direction check weather tool and work are properly arranged
or not if it is arranged then give linear motion to the shaft by
applying screw joint in between center and shaft. Center
linear motion in z negative direction i.e., -100 mm by this
motion depth of cut applied.
Next motion is given to the cross slide in y positive direction
150 mm this is like guiding workpiece towards cutting tool
for machining. Before doing all these things rotary motion
given to the cutting tool i.e., chuck 600 rpm. Now align the
timer in a sequence to perform motion simulation. Checked
Fig.7.Final modified assembly all motions given to the parts and result video were saved.
Sample video frame was shown in Fig 9
3.5.2 Rendered image
Rendering is nothing but converting 2D or 3D models in to
realistic images. Rendered image of lathe machine with
attachment is shown in Fig 8

Fig.9. Simulation frame image

Fig.8. Rendered image

60 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

4.2 Analysis Relevance 0

In analysis stage, we have considered two forces which exist Element Order Program
in milling machine operation Controlled
I. Cutting force Sizing
II. Thrust force Size Function Adaptive
I. Cutting force Relevance Center Fine
Power (P) = 1 kw Element Size 5.0 mm
Cutter diameter(D) = 45 mm
Initial Size Seed Assembly
Speed of chuck (N) = 600 rpm Transition Fast
Span Angle Center Coarse
Velocity (V) = πDN / 60
= (π*0.045*600)/60 Automatic Mesh Based Defeaturing On
V = 1.88 m/s Defeature Size Default
Power (P) = F. V Minimum Edge Length 2.50 mm
Cutting force (F) = P / V Table.3. Meshing
= 1000/1.88
 Equivalent elastic stress (von- mises):
F1 =796 N
Equivalent elastic stress i.e., von- mises stresses is show
F2 =7960 N Taken for test attachment strength.
in Fig 10
II. Thrust force
Cutter diameter (D) = 45 mm
Speed of chuck (N) = 600 rpm
Thrust force constant (K) = 42.35
Feed rate (f) = 1.5 mm/min
Thrust force (th) = K*N*D*f^0.7
=
42.35*600*0.045*1.5^0.7
= 1200 N
All parameters are taken from general purpose lathe and
Fig.10. Equivalent elastic stress in MPa
milling machine Now these values will be applying on the
modeled assembly structure and analyzed by using ansys  Equivalent stress (von- mises)
software ‘static structural analysis’ Equivalent stress is shown in Fig 11
Terms are going to find with this analysis:
 Equivalent elastic stress (von- mises)
 Equivalent stress (von- mises)
 Max shear stress
 Maximum principal elastic strain
 Units:
Units considered while doing analysis stage are shown in
Table 5.2
Unit system Metric (mm, kg, mv) Degree
red/s Fig.11. Equivalent stress
Angle Degree  Max shear stress:
Rotational velocity red/s Max shear stress is shown in Fig 12
Table.2. Units
 Meshing:
Meshing details are given in Table 3
Object Name Mesh
State Solved
Display
Display Style Body Color
Defaults
Physics Preference Mechanical
Fig.12. Max shear stress in MPa

61 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

 Maximum principal elastic strain

The maximum principal elastic strain is shown in Fig
13

Fig.14. main base assembly

5.3 Attaching the attachment to the lathe:

Fig.13.Maximum principal elastic strain In general, lathe consists of tool post mounts on the cross
slide but to attach this attachment to the lathe tool post is
Simulation calculations:
removed as shown in Fig 15
Hence stress concentration factor F1 (α˳) =
=31.8

Hence stress concentration factor F2 (α˳) =

= =3.17
Hence stress concentration factor for F1 and F2 are in save
zone. The maximum load can apply on the attachment is
7960 N and the load which we have collected from the
milling machine is 796 N stress concentration factor is far
most saver side so that we can consider the attachment can Fig.15. Carriage
accept the load analysis stage successfully completed. All
results are verified and the modeled assembly design is in After fitting main and supporting bases to the carriage,
safe condition now moving into next step i.e., material Pulleys and belt are fitted to threaded shafts to transfer
selection and fabrication. rotary motion from main base shaft to supporting base shaft.
This will help centers to maintain equal vertical motions
V. MATERIAL SELECTION & shown in Fig 16
FABRICARION
5.1 Material Selection
The material what we have to select that should be less
costly and available every ware So that all job shops can use
this attachment easily. That is why we have chosen stainless
steel as the standard for the structure. For few parts like
threaded shaft and center, we have taken another grade of
stainless steel which consists more hardness than existing
one.
5.2 Fabrication Work
Fig.16. Final assembly
In fabrication stage production drawings are produced for
main and supporting bases with supports, a center for the VI. FEATURES, RESULTS, AND
main base and supporting bases, caps, work holding and tool
CONCLUSION
holding shafts, andthreaded shafts. These are fabricated one
by one. In the end, all parts are assembled and attached to 6.1 Advantages
the lathe. One of its Subassembly is shown in Fig 14. It is  Initial cost will be reduced.
main base sub assembly combines with the main base with  Flexible in operation.
guides, cap, threaded shaft, center part, few screws, and  Simple in operation and no need for a skilled
bolts. operator.
 Good accuracy can be achieved.

62 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.

 International Journal for Research in Engineering Application & Management (IJREAM)
ISSN : 2454-9150 Vol-03, Issue-12, Mar 2018

 Simple construction. [4] T.E.Smith“Keyway and Gear Cutting Attachment

 Easy to install. for Lathes”
 Work piece diameter can be extended up to US; No: 2188447., Jan 30, 1940
200mm
[5] GadakhRamesh S, Londhepradip G, Shaikh Bilal A And
6.2 Disadvantages Shaikhfiroj S “Gear Manufacturing By Using
Conventional Lathe Machine”
 Spline gear cutting work piece thickness should
not exceed 150 mm. eissn: 2319-1163 | pissn: 2321-7308
 There is a chance to get vibration during
[6] Sagar, Mr. Neeraj Kumar and Mr. Jagbir Sharma
operation.
“Analysis of Spur Gear Cutting Using Milling
 Hard material like high carbon steel cannot be cut
Machine”
(unless until structure should make up of strong
metal like cast iron etc.). issn: 2347 – 4718., february-2016, issn: 2320-2092.,
aug.-2016
6.3 Area of Application
[7] Dr. Ramachandra C G, Shashank S, Raghavendra M J
 Production of the spur gear, spline shaft, grooves
and Kaushikranganath T “Design and Fabrication of
etc.
Gear Cutting Attachment for Lathe” e-issn: 2454-
 In small workshop where milling machine is not
6135., oct -2017
affordable.
[8] R. K. Jain “Production Technology” Page no: 891 to
VII. RESULTS AND CONCLUSION 894

The attachment is made to cut spur gear which is done by

Modeling and assembly of CAD parts are accomplished by
CATIA V5 software. Motion simulation was done by
SolidWorks motion simulator software and the video was
recorded. The static structural analysis was done by ANSYS
software and results are examined. Fabrication of the
attachment is completed by using raw material as stainless
steel. Final fabricated model is fitted to the lathe machine
and sample gear is produced. Produced samples might
competitive with milling accuracy. A lot of investment is
saved instead of buying a gear cutting machine. Also by
using this attachment production cost of making gear also
reduced.
VIII. FUTURE SCOPE
In this attachment direct indexing chosen as dividing head.
This has particular limitation it is only a few no of divisions
can make by using this attachment. This limitation can
overcome by using compound indexing. If the centeris
combined with bushes, then the shaft wear and tear will be
reduced material like cast iron and stainless steel will be
improving the strength of the attachment and that will allow
us to perform almost all horizontal milling operations

REFERENCES
[1] JahnaviMadireddy“Importance of Lathe Machine in
Engineering Field and Its Usage”ISSN: 2249-4596.,
2014
[2] J.C.Harbison“Milling Attachment for Lathes”
No: 2453315., Nov. 9, 1948
[3] J.W.Bracus“Gear Cutting Attachment”No:2286709.,
June 16, 1942

63 | IJREAMV03I123622 DOI : 10.18231/2454-9150.2018.0051 © 2018, IJREAM All Rights Reserved.