The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with D

IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 10, 2015 | ISSN (online): 2321-0613

The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters Dilip M Patel1 DR. Ashwin D patel2 1 PhD. Scholar 2Principal 1,2 Department of Mechanical Engineering 1 Rai University, India 2Ipcowala Institute of Engg and Technology, Anand, India Abstract— Now a day manufacture has to think for most economical, less time consuming, accurate and perfect sequence of production process for manufacturing the product. He has to adopt the various parameters focusing on the above stated facts. The researcher has find out to control the different parameters for optimum process based on economical point of view by which the manufacturer can save round above 30 % cost of product.

The Traditional lathe machine is used as machine tool instead of (SPM) special purpose milling machine. He has made three alterations.

1) Parameter – using milling attachment.

2) Parameter – using special profiled milling cutter.

3) Parameter – using indexing attachment with main spindle.

For the above aspect the researcher has done number of experiments to decide the optimal process and then by doing the same process on SPM & lathe. He has concluded the level of efficiency, economical & optimal process control.

Key words: Barrel Screw, Traditional Lathe machine different parameter

attached equipments is also sharply taken in to consideration.

The working condition of screw inside the barrels and other effecting parameters is taken into account wear & tear, heating condition, temperature, speed of screw, the screw feeder effected portion is harden by diametallic deposition.

A. Barrel Screw: A Screw to be shaped like an Archimedean spiral square threaded profiled on shaft. It works in a closed chambered Jacket known as Barrel Screw rotate according to required speed in barrel and it feed plastic material from one side located Hopper where the raw material is allowed to fall in a Barrel on other side die consist of male & female to piece receives the raw plastic material in a liquid form and it shape the plastic material into required form.

I. INTRODUCTION Barrel Screws are devices suitable for handling a wide variety of materials that have good flow ability characteristics. The screw feeder has a helicoidally surface fitted on a shaft that rotates inside a fixed tube. The material which comes out of the silo is pushed by the helicoids flight along the base of the tube in the direction of transport. The advantages of the screw feeder include the possibility of having different openings, each with its own shut-off organ for unloading the material.

A number of years ago Rexnord proposed a set of selection guidelines, one for conveyors and the other for elevators that are useful for an indicative choice of conveyors on the basis of loading and unloading methods, the course of transport and the features of the material (flow ability, composition granulometry, temperature, friability, abrasiveness and corrosivity.)

Manufacture screw on traditional lathe machine by changing its different – drive viewing on the reduction of cost process utility and easy methoding. When the screw feeder, we are talking it’s use is wide and the profile is somewhat complex on one shaft the pitch of screw may very as well as start may be single, double or triple. The working of screw feeder is in a hollow cylindrical cavity known as barrel.

The simply target is generate the thread profile on lathe machine and to harden it by biometric layer depletion during the process profile different effecting parameters are control and on one layer the optimal parameters are achieved. The cutter to shape the screw profile is specially designed the speed, depth of cut, the lost criteria and the

Fig. 1: Plastic Injection Molding Machine In fact the screw work as a material conveyor to be feed in a barrel from one side to another side outside the barrel surface the heater are installed which maintain the required heat for plastic raw material easily to flow in the barrel and get to be shaped in a Die Cavity as per required shape and size.

Barrel Screw is used for: (1) (2) (3)

Extrusion Plastic Machinery – Injection Moulding Machine Blow Moulding Machinery

The above three plastic plants are used for producing different plastic parts they are generally used for Industrial and Domestic purpose.

1) Use of Barrel Screw for Different Plastic Machinery Plants: - Injection Moulding - Extrusion Moulding - Laminatic Plant - Blow Moulding - Calendaring - Vacuum Forming - Plastics as Engineering Material

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

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2) Different Types of Screw: - Single Screw - Barrier Screw - Twin Screw and Barrel - Parallel Twin Screw and Barrel - Single Screw and Barrel - Grooved Feed Barrel - Barrier Screw - Maddoc Barrier Screw - Single Barrel - Twin Hole Barrel Rear Barrel - Twin Barrels - Grooved Feed Bush

-

3) Removal process (Machining) - accomplished by various cutting tools in different machine tools like lathes, milling machines, drilling machines (with tapping attachment) etc.

- widely used for high accuracy and finish - Employed for wide ranges of threads and volume of production; from piece to mass production.

II. SCREW BARREL UTILITY A. Pipe Plant: -

large threads are hot rolled followed by finishing and smaller threads are straight cold rolled to desired finish cold rolling attributes more strength and toughness to the threaded parts Widely used for mass production of fasteners like bolts, screws etc.

PVC Pipe Manufacturer (U PVC, R PVC, CPVC) HDPE Pipe Manufacturer PVC Braided Pipe Plant PVC Suction Hose Pipe PVC Soft Tubing Plant

4) Semi finishing and finishing (Grinding) characteristics - usually done for finishing (accuracy and surface) after performing by machining or hot rolling but are often employed for direct threading on rods - precision threads on hard or surface hardened components are finished or directly produced by grinding onlyemployed for wide ranges of type and size of threads and volume of production

B. Sheet Plant: -

III.

Air Bubble Sheet Plant PP Sheet Plant HIPS Sheet Plant PVC Sheet Plant Thermo Forming

Now a day plastic & relative product is hugely used in Industries as well as domestic purposes. The process mainly used to manufacture plastic is injection molding, blow molding plastic, film making etc.

The raw materials are continuously feed in to the barrel and long working life by certain heat treatment process of metal deposition

C. Film Plant: -

PVC Film Plant Lamination Film Plant Blown Film Plant Tape Plant Multi-Layer Film Plant Cable Manufacturer (Any Type of Materials) Compounding Plant Injection Moulding Machinery Blow Moulding Machinery Any type of Plastic Pallet Manufacturing

IV.

D. Barrier Screw (Double Thread): -

Single Thread Screw

E. Screw Manufacturing Classification & Screw -

Different

Method,

SIGNIFICANCE OF PROPOSED RESEARCH

Screw

Application Production of Screw Threads – Possible Methods And Their Characteristics: The various methods, which are more or less widely employed for producing screw threads, are: 1) Casting characteristics - only a few threads over short length - less accuracy and poor finish - Example – threads at the mouth of glass bottles, spun cast iron pipes etc.

2) Forming (Rolling) characteristics - blanks of strong ductile metals like steels are rolled between threaded dies

RESEARCH METHODOLOGY

This Project is based on an experimental research. It is commonly used in sciences and engineering the number of experiments are carried out considering different parameters and how the parameters changes and causes to change other are verified.

The Experimental method is a systematic and scientific approach to researcher in which the researcher manipulates one or more variables, controls and measures any change in other variable.

The experiment has been carried out on conventional lathe machine and CNC Thread Milling Machine. In order to perform different machining operations on a lathe and CNC Thread Milling Machine. The raw material of barrel screw that is EN41B Round Bar of ∅110 mm is taken and it is to be holding on lathe chuck and it is machined by HSS Single Point cutting tool and milling cutter. The number of machining operation is performed considering the following parameters.

- Job Speed - Feed - Depth of Cut The six machining operation is carried out on EN41B material round bar on lathe machine and CNC Thread Milling Machine in order to manufacture barrel screw with the same parameters and by changing some of parameters.

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

The three machined barrel screws are Screw No. 1 manufactured on lathe machine and Screw No. 2 manufactured on CNC Thread Milling Machine with same feed and job speed and Screw No. 3 is manufactured on CNC Thread Milling Machine with varying job speed and Feed.

Screw No. 1, Screw No. 2 and Screw No. 3 are tested in laboratory and considering the following tests.

- Dimension Check – Up - Surface Finish - Hardness - Micro Structure - Chemical Analysis And also comparison in terms of manufacturing cost.

VI. PARAMETRIC CHANGES A. Milling Attachment: Milling attachment as shown in figure is developed for threading the barrel screw. A separate AC variable drive motor is installed via V. Pulley block a central shaft with taper shank sleeve and collect chuck is fixed with box type fabricated structure both end of shaft is supported by Ball Bearing. The attachment is installed on cross slide of lathe machine with front support live rest.

V. EXPERIMENTAL SET-UP & DESCRIPTION A. Lathe Machine specification: The length between centers =10’’ = 3048 MM The overall length of machine =14’’ = 4267 MM The centre weight of measured =14’ = 355.6 MM the swing diameter over bed =16’ = 406.4 MM The length of bed = 12’’ = 3662 MM

Fig. 3: Milling Attachment End mill cutter ∅ 25 mm and specially profiled taper round nose cutter is installed in collect chuck.

VII. OBSERVATION TABLE AND GRAPHS A. Lathe Machine:

Process :Turning 1 EN41 Φ 110 mm Length: 3360 mm Material:Round Bar Machinin From Φ 110 mm to Φ 100.5 mm g:length:3360 mm Tool: P20 Carbide Tipped Turning tool

Sr. No 1 2 3

Total Depth of cut (mm) 5 3 1.5

Observation Table 5.2.1.1 Feed Cutting cutting of tool speed time (mm / (mm/ (min) min) min) 7 34.54 480 5 33.97 672 3 32.02 1120

Total Depth of cut (mm) 5 3 1.5

Observation Table 5.1.1.2 Feed Cutting cutting of tool speed time (mm / (mm/ (min) min) min) 15 51.81 224 10 49.45 336 5 48.04 672

Total Depth of cut (mm) 5

Observation Table 5.1.1.3 Feed Cutting cutting of tool speed time (mm / (mm/ (min) min) min) 20 69.08 168

Job Speed (R.P.M.) 100 100 100

Fig. 1: Lathe Machine

Sr. No 1 2 3

Sr. No Fig. 2: Lathe Machine

1

Job Speed (R.P.M.) 150 150 150

Job Speed (R.P.M.)

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200

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

3 1.5

15 10

65.94 64.05

224 336

200 200 Sr. No

Process :1

Turning

Tool:

P20 Carbide Tipped Turning tool

Material:-

Sr. No

Total Depth of cut (mm) 5 3 1.5

Cutting Time ( min)

1 2 3

Observation Table 5.2.1.1 Feed Cutting cutting of tool speed time (mm / (mm/ (min) min) min) 7 34.54 480 5 33.97 672 3 32.02 1120

1 2 3

Cutting Time (min)

Machinin g:-

EN41 Φ 110 mm Length : 3360 mm Round Bar From Φ 110 mm to Φ 100.5 mm length:3360 mm

Job Speed (R.P.M.) 100 100 100

672 480

500 0 5

3

Feed of Tool (mm/min)

Ciutting Speed (mm/min)

80 70 60 50 40 30 20 10 0

69.08

65.94

64.05

51.81

49.45

48.04

34.54

33.97

32.02

100 50

150 R.P.M

7

3

35 34.5 34 33.5 33 32.5 32 31.5 31 30.5

Machining :-

33.97

32.02

3

1.5

Fig. 7: Depth of Cut vs. Cutting Speed

Machining :-

Tool:

Fig. 5: Depth of Cut vs. Cutting Speed

Material:-

3

34.54

5

Process :3

1.5

Turning (Spline) EN41 Φ 110 mm Length : 3360 mm Round Bar From Φ 100.5 mm to Φ 89.7 mm length:200 mm

5

Depth of cut (mm)

Depth of Cut (mm)

Process :2

40

Feed of Tool(mm/min)

200 R.P.M 5

66.66 28.57

0

Material:100 R.P.M

100 100 100

Feed of tool vs. Cutting Time

Fig. 4: Feed of tool vs. Cutting Time

Depth of Cut vs. Cutting Speed

Job Speed (R.P.M.)

Depth of cut vs. Cutting Speed

1120

7

Observation Table 5.2.2.1 Feed Cutting cutting of tool speed time (mm / (mm/ (min) min) min) 7 31.55 28.57 5 29.98 40 3 28.73 66.66

Fig. 6: Feed of tool vs. Cutting Time

Feed of tool vs. Cutting Time 1500 1000

Total Depth of cut (mm) 5 4 1.8

Cutting Speed (mm / min)

2 3

Sr. No 1 2 3 4

Spline Milling EN41 Φ 110 mm Length : 3360 mm Round Bar Spline Milling 6 slot size: 89.7 mm to 77.9 mm Width 16 mm, Depth 11.5 mm Slot length 170 mm Hss milling cutter Dia 16 mm 4 flute Initial slot is generate by 16 MM Diameter End Mill Cutter then the taper cut is generated by radius End Mill Form Cutter

Observation Table 5.2.3.1 Total Feed of Cutting Depth of tool (mm speed (mm/ cut (mm) / min) min) 5 10 70.41 4 15 66.48 1.8 20 66.34 1 20 61.93

cutting time (min) 17 11.33 8.5 8.5

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

Feed of tool vs. Cutting Time Cutting TIme (min)

17 20

11.33

8.5

8.5

15

20

20

0 10

Process :- 5 Material :Machini ng:-

Thread Milling EN41 Φ 110 mm Length : 3360 mm Round Bar Helix machining of 100 mm pitch Length: 1350 mm and machining from Φ 92.5 mm to Φ 75.5 mm Parallel core Hss Milling cutter 4 flute Φ 25 mm Cutter Speed: 250 R.P.M.

Feed of Tool (mm/min) Fig. 8: Feed of tool vs. Cutting Time

Tool:

75 70 65 60 55

70.41 66.48

61.93

5

4

1.8

1

Depth of cut (mm) Fig. 9: Depth of Cut vs. Cutting Speed

Process :- 4 Material :Machini ng:-

Sr. No

Total Depth of cut (mm)

1 2 3 4

5 5 5 2

66.34

Observation Table 5.2.5.1 Feed of Cutting cutting tool speed time (mm (mm/ (min) / min) min) 6 72.61 225 7 68.68 192.85 8 64.76 168.75 9 60.83 150

Job Speed (Min per Revolution) 16.66 14.28 12.5 11.11

Thread Milling EN41 Φ 110 mm Length : 3360 mm Round Bar Helix machining of 100 mm pitch Length: 2735 mm and machining from Φ 100.5 mm to Φ 92.5 mm Parallel core assuming cutting speed of screw dia considering cutter RPM HSS Milling cutter 4 flute Φ 25 mm Cutter Speed: 250 R.P.M.

Tool:

Sr. No

Total Depth of cut (mm)

1 2 3

4 3 1

Observation Table 5.2.4.1 Feed of Cutting cutting tool speed time (mm (mm/ (min) / min) min) 6 78.89 455.83 8 74.18 341.87 10 71.82 273.5

Job Speed (Min per Revolution) 16.66 12.5 10

Feed of tool vs. Cutting Time Cutting Time ( min)

Cutting Speed (mm / min)

Depth of cut vs. Cutting Speed

Cutting Speed (mm / min)

35

29.98

28.73

5

4

1.8

30

Fig. 9: Depth of Cut vs. Cutting Speed

168.75

150

7

8

9

100 0 6

Feed of tool (mm/min) Fig. 10: Feed of tool vs. Cutting Time

Tool:

Thread Milling EN41 Φ 110 mm Length : 3360 mm Round Bar Helix machining of 100 mm pitch Length: 1000 mm and machining from Φ 92.5 mm to Φ 75.5 mm Tapper core Hss Milling cutter 4 flute Φ 25 mm Cutter Speed: 250 R.P.M.

Sr. No

Total Depth of cut (mm)

1 2 3 4

5 5 5 2

25

Depth of cut (mm)

192.85

200

Process :- 6 Material :Machini ng:-

Depth of cut vs. Cutting Speed 31.55

225

300

Observation Table 5.2.6.1 Feed of Cutting cutting tool speed time (mm (mm/ (min) / min) min) 6 72.61 166.66 7 68.68 142.85 8 64.76 125 9 60.83 111.11

Job Speed (Min per Revolution) 16.66 14.28 12.5 11.11

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

Cutting Time (min)

Feed of tool vs. Cutting Time 200 150 100 50 0

166.66

6

142.85

125

111.11

7

8

9

Feed of Tool (mm/min) Fig. 11: Feed of tool vs. Cutting Time

B. CNC Milling Machine Observation Table with varying feed: Fig. 14: Depth of Cut vs. Cutting Speed

Fig. 15: Feed of tool vs. Cutting Time

Fig. 12: Depth of Cut vs. Cutting Speed

Fig. 16: Depth of Cut vs. Cutting Speed

Fig. 13: Feed of tool vs. Cutting Time

Fig. 17: Feed of tool vs. Cutting Time

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

Fig. 18: Feed of tool vs. Cutting Time Fig. 20: Feed of tool vs. Cutting Time VIII. CONCLUSION The three screws are manufactured on final stage Screw No. 1 on lathe machine with different parameter Screw No. 2 on CNC Milling machine with same3 observation as per Screw No. 1 and Screw No. 3 on CNC Milling by taking the different feed and different job speed.

A. Comparing these three conclusions have been drawn.: -

Fig. 19: Feed of tool vs. Cutting Time

-

screws.

The

following

The manufacturing process sequence is finalised There is no change in machining time for Screw -1 and Screw -2 and the machining time is less for Screw – 3.

The all three screw are inspected dimensionally and find the accuracy is as per drawing.

The cost consideration has been calculated and per hour machining cost is 300 Rs. / hr for lathe and 850 Rs./hr for CNC Milling Machine The initial investment of lathe and different parameter accessories are less than thread milling CNC Machine.

The maintenance is easy for lathe machine with different parameters & accessories.

The manufacturing process is easy and simple in the case of lathe machine.

In CNC Thread Milling Machine the complication of operation may be occurring.

This research work opens new door in the field of manufacturing.

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The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters (IJSRD/Vol. 3/Issue 10/2015/086)

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Productivity is more because the ultimate cost of production is less in case of lathe machine.

The three parameters to be changed on lathe machine is a new trend of manufacturing barrel screw.

B. Limitation: The rate of production on CNC Milling Machine is more than lathe machine with different parameters.

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