Design and Fabrication of Hexagonal Cutting Lathe Machine

Abstract

The concept of a new product includes product requirement functions, possible behavior form/structure and associated properties. Properties include material assembly-level tolerance, critical surface roughness and hardness, parameter and critical dimension. We are making the Hexagonal cutting lathe machine in which hexagonal cutting should be introduced in a new way, this pattern should be make first with proper allowances and
tolerances after that casting of the pattern, aluminum is used for the casting so that weight can be reduced and so as cost. After casting machining should be done in a proper manner, operations to do so are turning, shaping, drilling, and boring so that rough
surfaces will be extracted. To making hexagonal cutting into reality a live tool is used (The tool which we are using is single point cutting tool). With the live tool other things are also needed which are bearings, spur gears one of 26 teeth and two of 13 teeth and some nuts and bolts for holding the assembly.

Introduction

The principal of lathe machine is that it holds the work between two strong supports called as centers or chuck which revolves. The chuck is mounted on the main spindle of the machine. The cutting tool is rigidly supported in the tool post and it is fed against the rotating job. The job rotates in the axis and the tool moved either parallel or to an inclination with the axis as such a cylindrical, taper, square and spherical surface is produced. Now we are introducing a hexagonal cutting on lathe machine. The machine we are talking about is 14” prototype lathe machine, which produces hexagonal cutting from feeding of round pipes with the help of three single point cutting tools. The cutting
tools revolve around its own axis. The mechanism we used in this is a gear mechanism which helps the chuck to revolve and the cutting tools, a motor which helps to give the power to run this whole machine. This whole product is made by casting and pattern making and machining process.
A lathe may or may not have a stand (or legs), which sits on the floor and elevates the lathe bed to a working height. Some lathes are small and sit on a workbench or table, and do not have a stand.

Almost all lathes have a bed, which is (always) a horizontal beam (although CNC lathes commonly have an inclined or vertical beam for a bed to ensure that chips, falls free of the bed). Woodturning lathes specialized for turning large bowls often have no bed or tail stock, merely a free-standing headstock and a cantilevered tool rest.

hexagonal cutting lathe machine
hexagonal cutting lathe machine

At one end of the bed (almost always the left, as the operator faces the lathe) is a headstock. The headstock contains high-precision spinning bearings. Rotating within the bearings is a horizontal axle, with an axis parallel to the bed, called the spindle. Spindles are often hollow, and have exterior threads and/or an interior Morse taper on the “inboard” (i.e. facing to the right / towards the bed) by which work-holding accessories may be mounted to the spindle. Spindles may also have exterior threads and/or an
interior taper at their “outboard” (i.e. facing away from the bed) end, and/or may have a hand-wheel or other accessory mechanism on their outboard end. Spindles are powered, and impart motion to the work piece. The spindle is driven, either by foot power from a flywheel or by a belt or gear drive to a power source. In most modern lathes this power source is an integral electric motor, often either in the headstock, to the left of the headstock, or beneath the headstock, concealed in the stand.

Principle
The principle of this machine is similar to the ordinary lathe machine because it is the prototype of lathe machine although it is a Hexagonal cutting lathe machine. It’s construction or design is based on lathe machine it has spindle which act as a center
and spur gears which rotate the centers and the tool. Tool is fixed parallel to the center where job has to be fixed the name of this machine is given so because of its special cutting purpose i.e. hexagonal cutting it is achieve because of synchronization of speed of tool and the job or work piece. Synchronization is done by revolving two gears in a same direction and one gear in a opposite direction two gears are of small size and one is of large size the tool we used for special cutting is single point cutting tool with front round shapes. It is a revolutionary step in the history of a mankind so far because of this cutting cannot be achieved on any ordinary lathe machine. That’s why it is Hexagonal cutting lathe machine.

Procedure to Perform Hexagonal Turning On lathe
1. Take the job of 12 mm external diameter which can fit into the spindle.
2. Note that the material is of aluminum.
3. Fit it into the spindle tightly so that the vibration negligible.
4. The cutters we used are single point cutting tool which are 3 in number and fixed at 1200 angle.
5. Now motor revolves the pulley at 8000 rpm, pulley revolves the idle gear at 4000 rpm and the idle gear revolves the major gear at 2000 rpm which are in the ratio of 2:1.
6. Major gear revolves one full rotation and in the meantime small gears makes twice the rotation.
7. The ratio 2:1 helps us in achieving the hexagonal cutting.
8. The pieces which have six sides is called hexagonal piece.

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