DESIGN AND FABRICATION ON MINI LATHE MACHINE

Project report submitted in partial fulfillment of

the requirement for the award of the Degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted by
K.BHANU PRASAD 17525A0335

S UDYA SANDEEP 17525A0370

S DURGA PRASAD 17525A0374

Y ANANDA REDDY 17525A0392

Under the Guidance of

Mr. N.S.SASIDHAR
Assistant professor

Department of Mechanical Engineering

VISWANADHA INSTITUTE OF TECHNOLOGY &MANAGEMENT
Mindhivanipalem[v],Anandapuram[M],Visakhapatnam [D]
Approved by A.I.C.T.E., Affiliated to J.N.T.U.K
Ph No;08933-202046 (O) Grams;VITAM
E-mail;vitam _coe@yahoo.co.in
2019-20
 DECLARATION

We Hereby Declare That We Are Student Of Mechanical Engineering,

Viswanadha Institute of Technology & Management, Mindhivanipalem. We
Are Working On Project Under The Guidance Of Mr. N.S.SASIDHAR Further,
This Work Has Been Submitted In Full To Obtained Degree Of The Bachelor Of
Technology That The Studies Described In This Report Entitled “DESIGN AND
FABRICATION ON MINI LATHE MACHINE” In Subject Mechanical
Engineering Is Carried Out By Us.

K. BHANU PRASAD 17525A0335

S. UDYA SANDEEP 17525A0370

S. DURGA PRASAD 17525A0374

Y. ANANDA REDDY 17525A0392

 CERTIFICATE
This is to certify that the project report entitled DESIGN AND FABRICATION
ON MINI LATHE MACHINE is being submitted by

K.BHANU PRASD 17525A0335

S.UDAY SANDEEP 17525A0370

S.DURGA PRASAD 17525A0374

Y.ANANDA REDDY 17525A0392

In partial fulfillment for the award of the Degree of Bachelor of Technology

in Mechanical Engineering to the Jawaharlal Nehru Technological University,
Kakinada is a record of bonafied work carried out under my guidance and
supervision.
The results embodied in this project report have not been submitted to
any other University or Institute for the award of any Degree or Diploma.

Mr.N.S.SASIDHAR Mr.M.Rambabu
Assistant Professor Associate Professor
Project guide Head of department

External Examiner
 ACKNOWLEDGEMENT

The success in this project has been possible by timely help and guidance by
many people. I wish to express our sincere gratitude to all thosewho have
helped and guided us for the completion of the project.

We deeply indebted to our project guide, Mr .N.S.SASIDHAR, Assistant

professor for his constant support, guidance in completion of our project work
and we wish to express our deepest gratitude for his valuable advice, personal.

We express our deep sense of gratitude and respect to our beloved Head of the
department Mr .M.RAMBABU, Department of Mechanical Engineering,
Viswanadha institute of Engineering and Technology JNTUKKakinada
University for his valuable guidance and cooperation throughout our project
work.

We express our sincere gratitude to DR.M.GOVINDA RAJU, principal of VITAM

Visakhapatnam for his grate support and providing facilities to accomplish to
our project successfully.

We express our thanks to all the teaching and nonteaching staff of Department
of Mechanical Engineering for providing a great assistance in accomplishment
of our project.

Last but not least thanks must go out to my friends and family members for
their tireless support and encouragement and we thank one and all that who
supported us directly or in direct in competing this project successfully.
 CONTENTS

DECLERATION i
CERTIFICATE ii
ACKNOWLEDGMENT iii
ABSTRACT iv
NOMENCLATURE v
LIST OF CONTENTS vi
LIST OF FIGURE vii

CHAPTER 1 INTRODUCTION 1-3

1.1 THEORY 1-2
1.2 OBJECTIVES 3
CHAPTER 2 LITERATURE REVIEW 4-5
CHAPTER 3 DESIGN AND CONSTRUCTION 6-25
3.1 DESIGN CONSIDERATION 6-9
3.2DESIGN PROCEDURE 10-16
3.3 CONSIDERATIONS OF DESIGN 16-17
3.4 AESTHETIC CONSIDERATIONS OF DESIGN 17-18
3.4.1 ASPECTS OF ASTHETIC DESIGN 18
3.5 ERGONOMICS CONSIDERATIONS OF DESIGN 18-19
3.6 MANUFACTURING CONSIDERATIONS IN DESIGN 19-20
3.7 STANDARDIZATION 20-21
3.7.1 OBJECTIVES OF STANDARDIZATION 20-21
3.8 OUR DESIGN 22-25
3.8.1 MATERIAL USED 22-23
3.8.2 TOOTHED BELT 23-25
CHAPTER 4 FABRICATION PROCESS 26-29
4.1 LASERBEAN MACHINING 26-28
4.1.1 ADVATAGES OF CBM 28-29
CHAPTER 5 LATHE MACHING OPERATIONS 29-43
5.1 FACING 29-30
5.2 TURNING 30-37
5.2.1 STRAIGHT TURNING 30-31
5.2.2 STEP TURNING 31
5.2.3 ECENTRIC TURNING 31-32
5.2.3 TAPER TURNING 32-37
5.2.3.1 TAPER 32
5.2.3.2 TAPER TURNING MEDHODS 32-37
5.2.3.2.1 FORM TOOL MEDHOD 33-34
5.2.3.2.2 COMPOUND VEST MEDHOD 34
5.2.3.2.3 TAILSTOCK SET OVER 35
5.2.3.2.4 TAPER ATTACHMENT 36
5.2.3.2.5 COMBINED FEED METHOD 36-37
5.3 DRILLING OPERITION 37
5.4 REAMING 37-38
5.5 BORING 38-39
5.6 KNURLING 39
5.7 THREAD CUTTING 39-41
5.8 CHAMFERING 41-42
5.9 GROOING 42
5.10 FORMING 42-43
5.11 PROJECT DEVELOPMENT STATGES 44
5.12 FINALIZAING MECHANISMS 45
5.13 PARTS FABRICATION 46
5.14 PROJECT DESIGN 47
5.15 MOTORS AND SHAFT /AXLE 48
5.16 FASTENER 49

CHAPTER 6 WORKING 50

CHAPTER 7 CONCLUSION 51
 LIST OF FIGURES

FIG NO. FIGURE NAME PAGE NO

1.1 LATHE 2
3.2 MANI LATHE BASE 11
3.2 FRONT VIEW 12
3.2 BACK SIDE VIEW 13
3.2 LEFT SIDE VIEW 14
3.2 RIGHT SIDE VIEW 15
3.8 DESIGN 22
3.8.2 TOOTHED BELT 23
4.1 L.B.M 27
5.1 FACING 30
5.2 TURNING 31
5.2.2 STEP TURNING 31
5.3.3 ECENTRIC TURNING 32
5.2.3.2.1 FORMING TOOL METHOD 34
5.2.3.2.3 TAILSTOCK SET OVER 35
5.2.3.2.4 TAPER ATTACHMENT 36
5.3 DRILLING 37
5.4 REAMING 38
5.5 BORING 39
5.6 KNURLING 39
5.7 THREAD CUTTING 41
5.8 CHAMFERING 41
5.9 GROOVING 42
5.10 FORMING 43
 ABSTRACT

A lathe machine is used for rotating a workpiece in order to perform sanding,

cutting, drilling, knurling and turning operations on the workpiece. Lathes have
been used on woodworking, metal parts and also on plastic nylon parts for a long
time in the industry. So here we study the design and fabrication of a mini lathe
machine. Our machine consists of a motor with belt arrangement used to drive the
lathe chuck. The machine consists of a bed with a movable arrangement. We use a
chuck attached to the spindle shaft in order to run the motor. Our motor once
powered transmits this power to the spindle through a belt mechanism, which is
then used to rotate the chuck. This rotates the workpeice in chuck. The machine is
built to hold and rotate the workpeice and move the tool in a sliding mechanism, so
as to achieve the desired operations. The machine outer frame is designed to hold
the workpeice firmly with tool in place so as to achieve desired operations with
ease. Thus we successfully study the design and fabrication.
 INTRODUCTION
A mini lathe (also styled mini-lathe or minilathe) is a machine tool used for the
complex shaping of metal and other solid materials. Mini lathes are related to (full-
sized) lathes but are distinguished by their small size and differing capabilities,
application, use, and locations. Sometimes referred to as desktop lathes or table-
top lathes, mini lathes can be comfortably used in areas where a full-sized lathe
would be impractical.

Mini lathes are well suited for use in restricted spaces where heavy machining or
high accuracy are not requirements. Mini lathes find a place in homes, basements,
and garages. As they are a popular tool for hobbyists, they are commonly sold
through hobby catalogs and hobby websites. Mini lathes are preferred over larger
lathes by some professionals, commonly locksmiths, jewelers, designers,
and engineers for prototyping or fabrication work.

Despite a more available price point and lower rigidity than their larger
counterparts, mini lathes still operate within the required tolerances of many tasks.
This makes them particularly useful in applications where small precision pieces
are needed for projects like miniature engines that require fine detail and
mechanical accuracy.

Small ultra-precision and diamond turning lathes exist, but have little in common
with a desktop-style mini lathe other than form factor. The smallest CNC mini
lathe was made by researchers at the Mechanical Engineering Laboratory
of Japan’s Ministry of Economy, Trade and Industry and Olympus Optical Co. It is
32 mm long, 25 mm wide, and 30.5 mm high, the lathe weighs just 100 grams. In
test runs, the tiny lathe produced a brass needle 0.05 mm wide and 0.6 mm long
and screws that are 0.05 mm thick.
Mini lathes are commonly used to cut wood. Accessories for woodcutting are
available, a reduced work envelope limits the machine to small projects and
increases difficulty. A majority of mini lathes utilize a variable speed electric
motor and are usually employed to turn soft metals or wood. Delrin and other free-
machining plastics can be effectively cut, but others (such as Acetate and PVC)
require experience and specialized knowledge of machining, and are commonly
found to be difficult to machine by mini lathe users who are not professional
machinists.
 OBJECTIVES

The main objectives of this project are to:

(a) Use available local materials in fabrication
(b) Achieve a reduction in the cost of production of the machine

(c) Reduce the labour cost and time spent on using hand tools for wood
dressing
(d) Create awareness for, and encouragement of indigenous technology
(e) Increase Productivity and creativity
The vital need for the fabrication of wood lathe is significant in the much
delay and time as well as energy wasted in using simple hand tools to carry out
jobs moreover, the cost of importation of a lathe machine is tool high for an
average war. Similar to the use of other machine tools, the wood lathe machine
will help to reduce the cost and consequently increase the rate of production and
craftsmen skill. It is also important to explore the design of machines to improve
on the ones already in existence.
 LITERATURE REVIEW

This covers a brief but concise history of the lathe machine, and other
works relevant to this project, which had been done earlier.

1.3 TREAD IN LATHE MACHINE FABRICATION

The emergence of the lathe machine date back to an unknown period,
but it gained popularity between the sixteenth and seventeenth centuries. Then
opticians used it for cutting lenses used in the construction of astronomical
telescope. They modified the relatively rough technique for special purposes.
Artisans and furniture makers used the larger lathes in turning frame works
though the frames were made of wood and had one or two headstocks
depending on the work being done. The wooden frame made it inaccurate.

Discussed below are some related lathe machines:

A. CENTER LATHE MACHINE

A center lathe is used to machine metals, by rotating the work fierce
mounted between centers against a cutting tool. The tool can be fed both
transversely and longitudinally with respect to the turning axis of the job. The
tool can be operated manually or automatically and many shapes as well as
different works can be done on the center lathe. Such work as cylindrically,
eccentric or conical shape can be machined. Also done on the center lathe are
threading turning and boring operations.
B. CERAMIC LATHE MACHINE
The ceramic – lathe is used for ceramic machining along, though the
operation is similar to that of the center lathe.

C. WOOD LATHE
The wood lather, just like other types of lather, it can be used to carry
out a wide range of machining operations, it saves time and does not wed much
ski //s as in the use of hand tools.
 Design Consideration
Several structural design considerations should be taken into account for
economical and efficient manufacturing. Many of these apply to other joining
methods, and all apply to both subassemblies and the complete structure.
1. The device should be suitable for local manufacturing capabilities.
2. The attachment should employ low-cost materials and manufacturing methods.
3. It should be accessible and affordable by low-income groups, and should fulfill
their basic need for mechanical power
4. It should be simple to manufacture, operate, maintain and repair.
5. It should be as multi-purpose as possible, providing power for various
agricultural implements and for small machines used in rural industry.
6. It should employ locally available materials and skills. Standard steel pieces
such as steel plates, iron rods, angle iron, and flat stock that are locally available
should be used. Standard tools used in machine shop such as hack saw, files,
punches, taps & dies; medium duty welder; drill press; small lathe and milling
machine should be adequate to fabricate the parts needed for the dual-purpose
bicycle.
7. It should make use of standard bicycle parts wherever possible.
8. The device should adapt easily to as many different bicycles as possible. No
permanent structural modification should be made to the bicycle.
9. Though the device should be easy to take off the bicycle, it is assumed that it
would usually remain attached to facilitate readiness and ease of transport from site
to site. The device, therefore, should not interfere with the bicycle's transportation
mode.
10. The broad stand, which provides stability during power production mode, can
be flipped upward during the transport mode. This stand/carrier would be a
permanent fixture of the dual-purpose bicycle.
11. The power take-off mechanism should be as efficient as possible, and should
develop relatively high r.p.m. (close to 200) for versatility of application. We had
seen designs for devices that take power from the rear tire by means of a friction
roller pressed against it, but we had doubts about the efficiency of this
arrangement. In order to improve efficiency we used hard bearing surfaces such as
roller chains, sprockets and ball bearings. We decided that the most appropriate
location for this power take-off mechanism would be at the front of the bike near
the fork tube (see photographs).
12. Care must be exercised to insure that the power take-off assembly is far enough
forward so as not to interfere with pedaling. Most standard adult bicycle frames
have plenty of room for the power take-off mechanism and pulley. Power is
supplied to the shaft by means of a chain from the bike's chain wheel (crank) to a
ratcheted sprocket on the shaft. During the prime-mover mode, the bike's regular
chain is slipped off of the chain-wheel, and the specially sized chain to the power
take-off mechanism is slipped on.
13. The device should be able to transmit power to a variety of machines, and
changing drive ratios should be as simple as possible. We decided that a V-belt and
pulley arrangement would be most appropriate for this. Belts do not require the
precise alignment that chains do. Belts can even accommodate pulleys that are
slightly skewed with respect to each other. Changing drive ratios is as easy as
changing pulleys. Also, belts are reasonably efficient.
14. The device should contain a ratcheting mechanism that would let the operator
"coast” periodically to rest and conserve energy. A free wheel from any bicycle
can be easily adapted for this purpose.
15. Excessive weight should be avoided, as durability is a prime consideration.
 DESIGN PROCEDURE

1. Definition of problem
2. Synthesis
3. Analysis of forces
4. Selection of material
5. Determination of mode of failure
6. Selection of factor of safety
7. Determination of dimensions
8. Modification of dimensions
9. Preparation of drawings
10. Preparation of design report
 DESIGN CONSIDERATIONS
 Strength
 Rigidity
 Reliability
 Safety
 Cost
 Weight
 Ergonomics
 Aesthetics
 Manufacturing considerations
 Assembly considerations
 Conformance to standards
 Friction and wear
 Life
 Vibrations
 Thermal considerations
 Lubrication
 Maintenance
 Flexibility
 Size and shape
 Stiffness
 Corrosion
 Noise
 Environmental considerations
 AESTHETIC CONSIDERATIONS IN DESIGN
• Appearance is an outward expression of quality of the product and is the first
communication of product with the user.
• Aesthetics is defined as the set of principles of appreciation of beauty. It deals
with the appearance of the product.

ASPECTS OF AESTHETIC DESIGN

 Form(shape)
 Symmetry and shape
 Color
 Continuity
 Variety
 Proportion
 Noise
 Contrast
 Impression and purpose
 Style
 Material and surface finish
 Tolerance

ERGONOMICS CONSIDERATIONS IN DESIGN

• Ergonomics is defined as the study of the man - machine - working environment
relationship
• It aims at decreasing the physical and mental stresses to the user
• Areas covered under ergonomics
• Communication between man (user) and machine
• Working environment
• Human anatomy and posture while using the machine
• Energy expenditure in hand and foot operations

MANUFACTURING CONSIDERATIONS IN DESIGN

 Minimum total number of parts in a product
 Minimum variety of parts
 Use standard parts
 Use modular design
 Design parts to be multifunctional
 Design parts for multiple use
 Select least costly material
 Design parts for ease of manufacture
 Shape the parts for minimizing the operations

STANDARDIZATION
• It is the process of establishing the set of norms to which a specified set of
characteristics of a component or a product should conform
• Example: Standardizing the shaft consists of specifying the set of shaft diameters
and material
 OBJECTIVES OF STANDARDIZATION
• To make the interchangeability of the components possible
• To make the mass production of components easier
MECHANICAL PROPERTIES OF MATERIALS
 Strength
 Stiffness/Rigidity
 Elasticity
 Plasticity
 Ductility
 Brittleness
 Malleability
 Toughness
 Machinability
 Resilience
 Creep
 Fatigue
 Hardness
 OUR DESIGN

Material Used
Bed – Wood
Chuck and spindle – Mild steel
Tail stock – wood
Dead centre – Mild steel
Tool support – wood
 Toothed belt

A toothed belt; timing belt; cogged belt; cog belt; or synchronous

belt is a flexible belt with teeth moulded onto its inner surface. It is
designed to run over matching toothed pulleys or sprockets. Toothed belts
are used in a wide array of in mechanical devices, where high-power
transmission is desired.

Timing belts,toothed belts, cogged or cog belts, and synchronous

belts[4] are non-slipping mechanical drive belts. They are made as flexible
belts with teeth moulded onto their inner surface. The belts run over
matching toothed pulleys or sprockets.[5][6][7] When correctly tensioned,
these type of belts have no slippage, and are often used to transfer motion
for indexing or timing purposes (hence their name). They are often used in
lieu of chains or gears, so there is less noise and a lubrication bath is not
necessary.

Toothed belts are used widely in mechanical devices, including sewing

machines, photocopiers and many others. A major use of toothed belts is
as the timing belt used to drive the camshafts within an automobile or
motorcycle engine.
As toothed belts can deliver more power than a friction-drive belt, they are
used for high-power transmissions. These include the primary drive of
some motorcycles, notably later Harley-Davidsons; and
the supercharger used for dragsters.

Microlight aircraft driven by high-speed two-stroke engines such as

the Rotax 532 use toothed belt reduction drives to allow the use of a
quieter and more efficient slower-speed propeller. Some amateur-built
airplanes powered by automotive engines use cog belt reduction drive
units.

Toothed belts are made of a flexible polymer over a fabric reinforcement.

Originally this was rubber over a natural textile, but developments in
material science have had a substantial effect in increasing the lifetime of
these belts. This included changes from natural to synthetic
rubber and polyurethane and also the adoption of nylon, Kevlar, or
other aramid fibres and carbon fibres in their reinforcement.

Toothed belts have two failure modes, one gradual and one catastrophic.
There is an increased risk of either over the lifetime of the belt, so it is
common for highly-stressed belts to be given a service lifetime and to be
replaced before this failure can occur.

One failure mode is gradual wear to the tooth shape, which may eventually
lead to slippage over rounded teeth. The belt often continues to work, but
the relative timing between shafts changes.

The catastrophic failure mode is caused by delamination between the belt

and its fabric reinforcement. Although this may be caused by age and wear,
it is often accelerated by mistreatment of the belt, often during initial
installation. Overloading the belt by bending it to a narrow radius is a
common cause of damage, either by bending out of the belt's designed
axis, twisting, levering it into place with tools, bending in the correct axis but
to too small a radius, or even knotting a belt in storage. Another cause,
particularly with natural rubber belts, is contamination by oil, especially to
the edges where the reinforcing fabric is exposed and can cause a wick
effect.

It is extremely rare for a timing belt to break. More common is for the belt to
delaminate, disconnecting the fabric strength member from the teeth that
ride on the pulleys. The belt is then often thrown from the pulleys and may
be further damaged, cut, or break. Although worn teeth may be detectable
by careful inspection, internal deterioration is not considered to be reliably
detectable and so the observance of service lifetimes is important.
 FABRICATION PROCESSES USED

Laser Beam Machining (LBM)

Lasers are used for many purposes. One way they are used is for cutting metal
plates. On mild steel, stainless steel, and aluminum plate, the laser cutting process
is highly accurate, yields excellent cut quality, has a very small kerf width and
small heat affect zone, and makes it possible to cut very intricate shapes and small
holes.
Most people already know that the word “LASER” is actually an acronym for
Light Amplification by Stimulated Emission of Radiation.

The laser beam is a column of very high intensity light, of a single wavelength, or
color. In the case of a typical CO2 laser, that wavelength is in the Infra-Red part of
the light spectrum, so it is invisible to the human eye. The beam is only about 3/4
of an inch in diameter as it travels from the laser resonator, which creates the
beam, through the machine’s beam path. It may be bounced in different directions
by a number of mirrors, or “beam benders”, before it is finally focused onto the
plate. The focused laser beam goes through the bore of a nozzle right before it hits
the plate. Also flowing through that nozzle bore is a compressed gas, such as
Oxygen or Nitrogen.
Focusing the laser beam can be done by a special lens, or by a curved mirror, and
this takes place in the laser cutting head. The beam has to be precisely focused so
that the shape of the focus spot and the density of the energy in that spot are
perfectly round and consistent, and centered in the nozzle. By focusing the large
beam down to a single pinpoint, the heat density at that spot is extreme. Think
about using a magnifying glass to focus the sun’s rays onto a leaf, and how that can
start a fire. Now think about focusing 6 KWatts of energy into a single spot, and
you can imagine how hot that spot will get.
The high power density results in rapid heating, melting and partial or complete
vaporizing of the material. When cutting mild steel, the heat of the laser beam is
enough to start a typical “oxy-fuel” burning process, and the laser cutting gas will
be pure oxygen, just like an oxy-fuel torch. When cutting stainless steel or
aluminum, the laser beam simply melts the material, and high pressure nitrogen is
used to blow the molten metal out of the kerf.
On a CNC laser cutter, the laser cutting head is moved over the metal plate in the
shape of the desired part, thus cutting the part out of the plate. A capacitive height
control system maintains a very accurate distance between the end of the nozzle
and the plate that is being cut. This distance is important, because it determines
where the focal point is relative to the surface of the plate. Cut quality can be
affected by raising or lowering the focal point from just above the surface of the
plate, at the surface, or just below the surface.
There are many, many other parameters that affect cut quality as well, but when all
are controlled properly, laser cutting is a stable, reliable, and very accurate cutting
process.
Advantages of LBM:
 Tool wear and breakage are not encountered.
 Very small holes with large aspect ratio can be achieved.
 A wide variety of hard and difficult-to-machine materials can be tackled.
 Machining is extremely rapid and the setup times is economical.
 Holes can be located accurately by using an optical laser system for
alignment.
 The operating cost is low.
Lathe Machine Operations:
Facing
Facing is the operation of machining the ends of a piece of work to produce flat
surface square with the axis. The operation involves feeding the tool
perpendicular to the axis of rotation of the work.

Turning
Turning in a lathe is to remove excess material from the workpiece to produce a
cylindrical surface of required shape and size.
 Straight turning:The work is turned straight when it is made to rotate
about the lathe axis and the tool is fed parallel to the lathe axis. The
straight turning produces a cylindrical surface by removing excess metal
from the workpieces.
  Step turning: Step turning is the process of turning different surfaces
having different diameters. The work is held between centres and the tool
is moved parallel to the axis of the lathe. It is also called shoulder turning.

Eccentric turning
If a cylindrical workpiece has two separate axes of rotating, one being out of
centre to the other, the workpiece is termed as eccentric and turning of different
surfaces of the workpiece is known as eccentric turning. The distance between
the axes is known as offset. Eccentric turning may also be done on some special
machines. If the offset distance is more, the work is held by means of special
centres. If the offset between the centres is small, two sets of centres are marked
on the faces of the work. The work is held and rotated between each set of
centres to machine the eccentric surfaces.

Taper turning
Taper
A taper may be defined as a uniform increase or decrease in diameter of a piece
of work measured along its length.

Taper turning methods

1. Form tool method
2. Compound rest method
3. Tailstock set over method
4. Taper turning attachment method
5. Combined feed method
 1. Form tool method
A broad nose tool is ground to the required length and angle. It is set on the work
by providing feed to the cross-slide. When the tool is fed into the work at right
angles to the lathe axis, a tapered surface is generated.
This method is limited to turn short lengths of taper only. The length of the taper
is shorter than the length of the cutting edge. Less feed is given as the entire
cutting edge will be in contact with the work.

2. Compound rest method

The compound rest of the lathe is attached to a circular base graduated
in degrees, which may be swiveled and clamped at any desired angle.
The angle of taper is calculated using the formula
𝐷1 − 𝐷2
tan 𝛼 =
2𝑙
Where,
D1 &D2 = large and small dia. respectively
𝑙 = length of taper
α = taper angle or the angle about which compound rest is swiveled
The compound rest is swiveled to the angle calculated as above and clamped.
Feed is given to the compound slide to generate the required taper.
 3. Tailstock set over method
Turning taper by the setover method is done by shifting the axis of rotation of the
workpiece at an angle to the lathe axis and feeding the tool parallel to the lathe
axis. The construction of tailstock is designed to have two parts namely the base
and the body. The base is fitted on the bed guideways and the body having the
dead centre can be moved at cross to shift the lathe axis.
The amount of setover – S, can be calculated as follows
𝐷1 − 𝐷2
𝑆=𝐿×
2𝑙
The dead centre is suitably shifted from its original position to the calculated
distance. The work is held between centres and longitudinal feed is given by the
carriage to generate the taper.
The advantage of this method is that the taper can be turned to the entire length
of the work. Taper threads can also be cut by this method.
The amount of setover being limited, this method is suitable for turning small
tapers (approx. upto 8°). Internal tapers cannot be done by this method.

4. Taper attachment method

The taper attachment consists of a bracket which is attached to the rear end of
the lathe bed. It supports a guide bar pivoted at the centre. The bar having
graduation in degrees may be swiveled on either side of the zero graduation and
set at the desired angle to the lathe axis. A guide block is mounted on the guide
bar and slides on it. The cross slide is made free from its screw by removing the
binder screw. The rear end of the cross slide is tightened with the guide block by
means of a bolt. When the longitudinal feed is engaged, the tool mounted on the
cross slide will follow the angular path as the guide block will slide on the guide
bar set at an angle of the lathe axis. The depth of cut is provided by the
compound slide which is set parallel to the cross-slide.
The advantage of this method is that long tapers can be machined. As power feed
can be employed, the work is completed at a shorter time. The disadvantage of
this method is that internal tapers cannot be machined.

5. Combined feed method

Feed is given to the tool by the carriage and the cross-slide at the same time to
move the tool at resultant direction to turn tapers.

Drilling operation:
It is the process of producing cylindrical hole in the workpiece. In this operation,
Workpiece is held in a chuck or a suitable device and the drill is held in the
tailstock. During operation, the drill is fed by rotating the handwheel of the
tailstockin clockwise direction. First a shorter length is drilled by using a smaller
and shorter drill, followed by producing the required diameter with the help of
correct drill size.
Reaming Operation
It is a finishing operation because a very small amount of material is removed
during the operation. For performing reaming a multi-teeth tool is used, which is
called as reamer. During the operation, the workpiece is held in a chuck or face
plate and the reamer shank is fitted in a sleeve or inserted in the tapered hole of
the tailstock spindle.

Boring Operation:
It is an operation which is employed for machining internal surfaces, hence also
called as internal turning. Boring is done to enlarge the already drilled hole and
bring them to the exact required size. Generally, a single point cutting tool is used
for this purpose.
Knurling
Knurling is the process of embossing a diamond shaped pattern on the surface of
the workpiece. The knurling tool holder has one or two hardened steel rollers
with edges of required pattern. The tool holder is pressed against the rotating
work. The rollers emboss the required pattern. The tool holder is fed
automatically to the required length. Knurls are available in coarse, medium and
fine pitches. The patterns may be straight, inclined or diamond shaped.
Thread cutting
Thread cutting is one of the most important operations performed in a lathe. The
process of thread cutting is to produce a helical groove on a cylindrical surface by
feeding the tool longitudinally.
1. The job is revolved between centres or by a The longitudinal feed should be
equal to the pitch of the thread to be cut per revolution of the work piece.
2. The carriage should be moved longitudinally obtaining feed through the
leadscrew of the
3. A definite ratio between the longitudinal feed and rotation of the
headstock spindle should be found Suitable gears with required number of
teeth should be mounted on the spindle and the leadscrew.
4. A proper thread cutting tool is selected according to the shape of the It is
mounted on the toolpost with its cutting edge at the lathe axis and
perpendicular to the axis of the work.
5. The position of the tumbler gears are adjusted according to the type of the
thread (right hand or left hand).
6. Suitable spindle speed is selected and it is obtained through back
7. Half nut lever is engaged at the right point as indicated by the thread
chasing
8. Depth of cut is set suitably to allow the tool to make a light cut on the
9. When the cut is made for the required length, the half nut lever is The
carriage is brought back to its original position and the above procedure is
repeated until the required depth of the thread is achieved.
10.After the process of thread cutting is over, the thread is checked by
suitable gauges.
Chamfering
Chamfering is the operation of bevelling the extreme end of the workpiece. The
form tool used for taper turning may be used for this purpose. Chamfering is an
essential operation after thread cutting so that the nut may pass freely on the
threaded workpiece.
Grooving
Grooving is the process of cutting a narrow goove on the cylindrical surface of the
workpiece. It is often done at end of a thread or adjacent to a shoulder to leave a
small margin. The groove may be square, radial or bevelled in shape.

Forming
Forming is a process of turning a convex, concave or any irregular shape. For
turning a small length formed surface, a forming tool having cutting edges
conforming to the shape required is fed straight into the work.
 MOTORS
A DC motor is any of a class of rotary electrical machines that converts direct
current electrical energy into mechanical energy. The most common types rely on
the forces produced by magnetic fields. Nearly all types of DC motors have some
internal mechanism, either electromechanical or electronic, to periodically change
the direction of current flow in part of the motor.

DC motors were the first type widely used, since they could be powered from
existing direct-current lighting power distribution systems. A DC motor's speed
can be controlled over a wide range, using either a variable supply voltage or by
changing the strength of current in its field windings

SHAFTS / AXLE
An axle is a central shaft for a rotating wheel or gear. On wheeled vehicles, the
axle may be fixed to the wheels, rotating with them, or fixed to the vehicle, with
the wheels rotating around the axle.[1] In the former case, bearings or bushings are
provided at the mounting points where the axle is supported. In the latter case, a
bearing or bushing sits inside a central hole in the wheel to allow the wheel or gear
to rotate around the axle. Sometimes, especially on bicycles, the latter type axle is
referred to as a spindle.
 FASTENER

A fastener (US English) or fastening (UK English) is a hardware device that

mechanically joins or affixes two or more objects together. In general, fasteners are
used to create non-permanent joints; that is, joints that can be removed or
dismantled without damaging the joining components. Welding is an example of
creating permanent joints. Steel fasteners are usually made of stainless
steel, carbon steel, or alloy steel.
 WORKING

The machine contains of a bed on which the entire assembly of the machine is
done. The chuck and spindle are made from a single rod on the lathe. And it is
mounted on the headstock made of wood with two roller bearing for smooth
rotation. A high rpm motor is used to rotate the chuck with the help of timing
pulley and timing belt. The tail stock is made up of wood on the lathe and dead
centre is mounted inside it with roller bearing arrangement. A guide way is given
on the bed to allow the tail stock to have linear motion on the bed. A tool support
is provided so that tool can be rested on it horizontally and cuts can be given to
theworkpiece as required. When the motor is given 12 volt DC supply it starts
rotating so the pulley attached to it also rotates and with the help of belt spindle
and chuck rotates. As timing pulley and timing belt is used there is no slippage of
belt and hence 100 percent efficiency is achieved. As most of the parts are made of
wood it is very light in weight and easy to handle.
 CONCLUSION

So in this way we studied how to design and manufacture mini lathe for wood
machining. And it is made very compact in size and light in weight hence easy to
carry it anywhere. Variety of wood machining can be done on this lathe and it is
easy to use. As it is compact in size we can keep it anywhere and it occupies less
space.