DEPARTMENT OF MECHANICAL ENGINEERING , UCEK

AUTOMATION IN LATHE BY PNEUMATICS PROJECT WORK BY G. SIVASANKARAMALAN PROJECT GUIDE Mr. P. K. SHYAM SHANKAR. M.E. (Ph.D.) Faculty, UCEK INTERNAL GUIDE Mr. WILFRED VIJAY ANAND. M.Tech, TEF ,BOSCH LTDPROJECT SECTOR : Manufacturing and DesignPLACE OF PROJECT WORK : BOSCH Limited, Bangalore

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PROJECT TITTLE

DESIGN AND DEVELOPMENT OF PNEUMATIC COLLET CHUCK

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Need To reduce the human error, effort and the

difficulties of jaw type chucks in normal lathe

Provide Simple working mechanism in lathe to the operator

Reduce the machining time cycle

The objective of this project is to “Design and development of pneumatic collet chuck” to reduce the manual effort to complete the operation effectively in a short period of time.

OBJECTIVE

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To do the machining operation in normal lathe, the components need to be clamped and unclamped manually by the operator. Since its manual process, the effort estimation will be maximized and the productivity will be less.

The automation on the lathe work head will eliminate the manual effort while machining the component. Since it uses the pneumatic system the proper control for the entire operation will be simple and efficient. If the proper control is obtained the time consumption will be less. So the production ratio will be maximum.

ABSTRACT

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“COLLET CHUCK OPERATING MECHANISM” Theodore E. Williams, Culver City, California. Application January 26, 1953Concept: To provide its working mechanism, it is air

operated and arranged to be mounted at the outboard end of a lathe headstock for operative engagement with the draw tube of a conventional collet chuck

It uses torsional springs in machining operations for clamping and unclamping the operation. During the operation the whole work center will move along with the collet to hold the job

LITERATURE REVIEW

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COLLET CHUCK OPERATING MECHANISM By Theodore E. Williams

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A bar feeding mechanism for a lathe comprising a pair of bar feed devices spaced lengthwise of the feed path of bar stock in the lathe.

Literature survey- Bar feeding mechanism

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Based on the above collet operating mechanism that is given by the Theodore E Williams on the journal of Collet Operating Mechanism by air operated is taken as a base of my project “Pneumatic Collet Chuck”. Here the arrangement of collet in the existing work head is rearranged for the implementation of pneumatics.

The pneumatic systems are used to actuate the collet in the work head when the collet machine tends to operate. Here the arrangement of work head is simplified by installing the small rotating components. The arrangement of this mechanism is based on the existing collet mechanism powered by clutch operation.

Inference from the literature survey

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Work head

cylinder

FRL

5/2Solenoid valve

Air

colletSpring Actuator

Lever

Disc spring

Holder

JobCover Draw

Bar

Spindle

Sensor

Check

valve

Conceptual Modelling

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Methodology

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The fabrication of this “Pneumatic Collet Chuck” is completed under three stages. 1 Modification of lathe headstockThe arrangement of the lathe work head was modified thoroughly. The main part of the work head 3-jaw chuck was replaced by collet chuck.2 Pneumatic systemThe control of the entire operation of the lath was monitored and controlled by this pneumatic system3 Actuation of motor using relay switchWhen the contactor receives the signal from the sensor mounted in the cylinder it starts the main motor

ℓ Spindleℓ Colletℓ Draw barℓ Flange or Sleeveℓ Bearing balls ℓ Actuatorℓ Holderℓ Disk spring

Work Head Components

List of Machine Components

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Disk Springs, also known as Belleville Washers and Belleville Springs, are disks with a slight cone shape that deform to a shorter height when subjected to a load along their axis of symmetry. This elastic deformation characterizes the spring action.

In this project the disk spring plays an important role to operate the whole mechanism. Here it is used to clamp and unclamp the work materials in the collet adapter by means of actuating the pneumatic sequences

The holding of the collet while machining operation is achieved by disk spring

Disk spring

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ℓ FRL Unit ( Filter, Regulator, Lubricator)

ℓ Pneumatic valveℓ Pneumatic cylinderℓ Pressure gaugeℓ U clamp ( Clevis rod)ℓ Sensor

ℓ Pneumatic tubes

ℓ Pneumatic connectors

ℓ Electrical Switch ℓ Silencers &

Check valveℓ Relay switchℓ Electrical

contactors

List of components from Pneumatic system

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Spindle

Draw bar

ColletWork piece

Arrangement of collect and drawbar

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Modelling

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Modelling

The exploded 2D view of “Pneumatic collet chuck”.

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Design of Components

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Design of Components

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Flow Chart

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Design of Belleville Spring

Design Calculations

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Design of Disk spring or Belleville SpringOD = Maximum outside

diameter (upper surface)ID = Minimum inside diameter (bottom surface)H =Conical disk height (cone height)OH = Overall height = t + hT =Actual thickness of diskβ = Cone angle of diskR =Radius from centre line to load bearing circle (bottom surface)M =Ratio factor

The axial force of the Belleville springs are calculated by,

𝑃=𝐸 𝛿

(1−𝛿2 )𝑀 (𝑑02

)2 ¿=100461 N

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Design of sleeve or spindle or muff couplingConsidering Hollow shaft, The relation

between shearing and crushing stresses are given by

T= l * w * Ʈ * d/2 = 0.600 N/

Design of Draw Bar :

Estimation critical speed of drawbar

= 7114.71 ≡ 8000 rpm

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Design of Collet

Design of Clevis Rod

Design Calculations

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Design of Collet actuator

Design of Spacer taper

Design Calculations

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5

Design of Pneumatics System

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PROCUREMENT / MANUFACTURING OF COMPONENTS

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PROCUREMENT / MANUFACTURING OF COMPONENTS

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PROCUREMENT / MANUFACTURING OF COMPONENTS

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Pro-E The tool that is used for represent the layout of the work centre. All the component that is related to the work centre is drawn by this tool in 2D & 3D manner Fluid Draw This is the tool by FESTO that is mainly used to draw the pneumatic and hydraulic circuit and used to show its actuation SMC draw This is also a pneumatic based tool, used to represent the pneumatic layout of this project. Disk Spring solver This tool used to analysis the all the aspects that is related to the disk spring.

Software Used

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Load analysis of Belleville Spring by Disk spring Solver

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26

Spring rate and Spring work 

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FRL

Switch Pneumatic cylinderCollet

Pneumatic pipe

Sensor

Pneumatic Valve

Assembly of PCC

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Manufacturing of glow plug

The PCC was tested for its performance in manufacturing a Glow Plug component. A glow plug is a heating device used to aid starting diesel engines. The glow plug is a pencil shaped piece of metal with a heating element at the tip.

The lathe contain pneumatic collet chuck is tested by cutting and chamfering of the glow plug. The rate of cutting and chamfering operation in PCC is two times faster than the old chuck operated lathe. The detailed analysis of this test is tabulated below.

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TailHead

Plug type Thickness in mm facing & Chamfer length in mm

No of Glow plug / Shift (8 hours)

Dime-

nsions

T t (need to cut in lathe) Jaw chuck (existing) PCC (new)

1 5 3.2 2+0.5 1200 2000

2 5 3 2.5+0.5 1100 1900

3 4 2 1.5+0.2 1350 2200

4 6 3.5 2+0.7 1200 1950

5 3.8 2.1 3.5+0.2 800 1800

6 3.2 2 3.5+0.2 800 1800

Testing and Results

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S.no Dimensions In mm Material Old Chuck In Mins Air operated collet in Mins

1 20 Aluminium rod 10 5

2 20 Mild Steel rod 18 9

3 10 Brass rod 12 6

4 5 Copper rod 3 8

5 20 Stainless steel 15 9

Testing - Jaw Chuck Vs Pneumatic Collet chuck

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The design and development of

“Pneumatic Collect chuck” for a Lathe Machine was successfully done and implemented in a lathe machine. The performance of the lathe machine after replacing pneumatic chuck was tested and found that the PCC was working properly. It is observed that the production rate have been increased unanimously after implementing this project.

In this project a detailed study about the processes involved in BOSCH was carried out, design and development of a new component in a lathe machine was completed with various design techniques like pneumatic system, Cad modelling and Analysis of a component have also done.

CONCLUSION

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 1.T.E.WILLIAMS 2,726,090 “Collet chuck operating

mechanism” Filed Jan. 26. 1953 INVENTOR. 2. Dr.Heeresh Mistry, “Fundamentals of Pneumatic

Engineering”, 3. Hoffman, Edward G. (2004), “

Jig and fixture design” (5th ed.), Cengage Learning, ISBN 978-1-4018-1107-5.

4.Brown, Chris (2011-04-25), "A close look at index able chucks", Production Machining.

5.R.S.khurmi, J.K.Gupta , “A Text Book Of Machine Design” (1890),

REFRENCES

Bibliography and References

http://books.google.com/books?id=-2ev3yYwvq0C&pg=PA53 Hoffman 2004, http://www.rego-fix.com/collets/

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