A

Project Report

On

“DESIGN AND FABRICATION OF GEAR CUTTING ATTACHMENT FOR LATHE

MACHINE”

Submitted to

CHHATTISGARH SWAMI VIVEKANAND TECHNICAL UNIVERSITY, BHILAI (C.G.)

in Partial fulfillment for the award of degree

of

BACHELOR OF TECHNOLOGY

IN

MECHANICAL ENGINEERING

By

Rohan Bansiyar
Harsh Dhawale
Ashvin Godhe
Aayush Pandey

Under the Guidance of

Mr S.K SAO
Associate Professor

DEPARTMENT OF MECHANICAL ENGINEERING

BHILAI INSTITUTE OF TECHNOLOGY, DURG (C.G.) 491001
Session: 2021-2022

i
 DECLARATION

We the undersigned solemnly declare that the report of the project work entitled “Design and
fabrication of gear cutting attachment for lathe machine” is based on our own work carried
out during the course of our study under the supervision of “Mr S.K SAO”.

We assert that the statements made and conclusions drawn are an outcome of the project work. I
further declare that to the best of my knowledge and belief that the report does not contain any
part of any work which has been submitted for the award of any other degree/diploma/certificate
in this University or other university.

Rohan Bansiyar Harsh Dhawale

300103719308 300103718001
BA90071 BG0676

Ashvin Godhe Aayush Pandey

300103719301 300103718083
BB36611 BG0646

i
 CERTIFICATE

This is to certificate that report of the project submitted is an outcome of the project work
entitled “Design and fabrication of gear cutting attachment for lathe machine” carried out
by

Rohan Bansiyar University Roll No. 300103719308

Harsh Dhawale University Roll No.300103718001

Ashvin Godhe University Roll No.300103719301

Aayush Pandey University Roll No.300103718083

Carried out under my guidance and supervision for the award of degree in Bachelor of
Engineering in Mechanical Engineering at Chhattisgarh Swami Vivekanand Technical
University, Bhilai (C.G.), India.

To best of my knowledge the report is

• Embodied the work candidates themselves.
• Has duty been completed.
• Fulfills the requirement of ordinance relating to the Bachelor of Engineering degree of
the University.
• Is up to the desired standard for the purpose of which is submitted.

---------------------- …....….....................
Project Guide Project Coordinator
Mr S.K SAO Dr (Mrs.) Shubhrata Nagpal

Dr. (Mrs.) Sheina Shekher

Head of Department
(Mechanical Engineering Department)

ii
 CERTIFICATE BY THE EXAMINERS

This is to certify that the project entitled

“Design and fabrication of gear cutting attachment for lathe machine”

Submitted by

Rohan Bansiyar University Roll No.300103719308 Enrollment No.BA90071

Harsh Dhawale University Roll No.300103718001 Enrollment No.BG0676

Ashvin Godhe University Roll No.300103719301 Enrollment No.BB36611

Aayush Pandey University Roll No.300103718083 Enrollment No.BG0646

has been examined by the undersigned as a part of the examination for the award of Bachelor of
Engineering degree in Mechanical Engineering of Chhattisgarh Swami Vivekanand Technical
University, Bhilai (C.G.)

---------------------- ----------------------

Internal Examiner External Examiner

Date: Date:

iii
 ACKNOWLEDGEMENT

We would like to express our special thanks of gratitude to our teacher Mr S.K.SAO as well as
our principal Mr. M.K.Gupta Who gave us this golden opportunity to do this wonderful project
on the Topic "Design and Fabrication of gear cutting attachment for Lathe Machine”; which
also helped us in doing a lot of Research and we came to know about so many new things we are
really thankful to them. Secondly, we would also like to thank our parents and friends who
helped us a lot in finishing this project within the limited time. We are making this project not
only for marks but also to increase our knowledge.

THANKS AGAIN TO ALL WHO HELPED US.

iv
 ABSTRACT

This paper aims at designing and fabrication of gear cutting attachment to lathe. In present work.
We made an attempt to design and fabricate an attachment for a gear cutting for a medium duty
lathe. This attempt will reduce the investment for medium and small industries, subsequently
reducing the manufacturing cost of gears. The attachment to the lathe can be perform an indexing
mechanism like milling machine and carriage function, to and fro movement and sliding on a
bed. The attachment was mounted on carriage, where we fixed the work piece and a mandrel was
designed the cutting tool. This mandrel was attached to the head stock spindle which is the main
source for rotation of the cutting tool. The attachment was carefully designed after studying the
proper mechanisms and power requirement and force analysis on work material and a cutting
tool.

v
 INDEX

• INTRODUCTION 1-3

• LITERATURE REVIEW 4-6

• PROBLEM IDENTIFICATION 7

• METHODOLOGY 8-16

• WORKING 17

• CALCULATION 18-19

• CONCLUSION 20

• FUTURE SCOPE 21

• BIBLIOGRAPHY 22

vi
 CHAPTER-1
INTRODUCTION

Workshops and small-scale industries are heavily constrained to use general purpose machine
due to financial limitation. Lathes and milling machines are popular with these groups since
they need little capital and are simple to maintain. Researchers are always attempting to assist
these businesses through innovative ideas and new ways to expand the scope of their output
utilizing these general-purpose machines.

A wide range of accessories are already in use in these industries. Although various attachments
are already in use in these industries like keyways, slotting, internal keyway, grinding wheel
and eccentric turning for lathe machine. Still it’s facing many difficulties like machining of gear
cutting and splines on the shaft. These papers are helping lathe machine to obtain maximum
efficiency and utilization. To overcome this difficulty, it is necessary to design an attachment
for the lathe. Which is able to overcome these difficulties and flexible to use it in standard
lathes.

Gears are used for transmitting power from one part of a machine to another part. Assume
that two plain wheels mounted bolt to two parallel shafts and pressed tightly connected
with one another. If one wheel rotated regarding its axis, the opposite wheel conjointly can
rotate due to the friction between them as shown in Fig 1. The rotation is thus transmitted
from one shaft to another. The surfaces of the two wheels will move at constant speed if
there is no slipping. it's obvious that with the increase in Load to be transmitted, the

1
wheels will begin to slide on one another. to stop slipping slots is additionally cut on the
cylindrical surfaces of the wheels and projections added between them. These slots and
projections form the teeth and wheels with such teeth area unit known as toothed wheels or
gears.

SPUR GEAR
Spur gears have their teeth parallel to the axis and are used for transferring power between
two parallel shafts. they're simple in construction as shown in Fig 1, simple to manufacture
and low cost. They need the most effective potency and smart accuracy rating. they are used
in high speed and high load application altogether varieties of trains and an honest sort of
velocity ratios.
Hence, they perceive wide applications right from clocks, organization gadgets, motorcycles,
vehicles, and railways to aircrafts.

GEAR MANUFACTURING METHODS: -

2
Gear manufacturing is basically divided into two parts particularly forming and machining.
Forming consists of direct casting, molding, drawing, or extrusion of tooth forms in liquid,
powdered, or heat softened materials and machining involve roughing and finishing
operations as shown in Fig 2.
MACHINING

Machining is outlined as a controlled method that takes the material and transforms it into a
desired final form and size. This may embrace material removal as seen with such actions as
cutting, drilling, boring, or material addition. Although machining is most ordinarily used
with the metal product, machining can even be through with materials like wood, ceramic,
plastic, and composite materials.

REQUIREMENT OF GEAR CUTTING

ATTACHMENT IN LATHE

Lathe is a very important manufacturing system in many sectors and industries.

Although it’s a very versatile machine, it has some limitations and drawbacks while
performing certain operations like a spline, gear cutting. The use of milling machines in
the production of the spline and gear cutting is well recognized in the industries. If an
attachment on general purpose lathe is made available, the cost of production of a
product could be reduced. A CNC machine can perform the said operations more
effectively since the human involvement is limited.
However, the CNC machine is very expensive and is required skilled workers to
operate the machine

3
 CHAPTER-2

LITERATURE
REVIEW

Gadak Ramesh., Londhe Pradip G., Shaikh Bilal A., Shaikh Firoj S.,
(2016)”.[1]

The author 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. The results are studied and analyzed whether the
attachment is able to withstand the load with the help of ANSYS tool. It is found out that
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.

M. Sagar Kumar, (2016). [2]

The author studied that the gear cutting arrangement in lathe machine reduce the initial
investment of small-scale industries for milling which can use their lathe machine for gear
cutting operations. This also helps in reducing the space covered by the machines and the
remaining space can be used for other productive work output. It is been observed that a
country GDP is largely affected by many small-scale industries. By selecting and
incorporating such small but useful ideas a small-scale industrialist can save huge amount of
time, energy, and money hence forth increasing the overall productivity of a firm and hence
contributing more efficiently in countries GDP.

P. Sivasankaran, IJENR, ISSN: 2277. (2017). [3]

Here the author studied about the importance of designing and manufacturing the gears. Gear
is a very important element of mechanical transmission. It is manufactured by different
process like casting, milling, Hobbing and shaping. It is found out that among all these
manufacturing process milling is preferred the most, as the cost of milling machine is costly,
we are making a new attachment which make gear when installed 5 on lathe carriage. This
cheap device hence avoids dependency on costly milling machine for job production. It also
helps save money and space

4
S. Shinde, R. Tathe, S. Bolkuntwar, S. Gite, IJSRD, ISSN: 2321-0613.
(2017).[4]

The author studied the proper fabrication attachment and working on lathe to perform gear
cutting operation. As it will reduce the investment as well as space for small scale industry.
In the indexing mechanism is used which is also used in milling machine. The attachment is
mounted on carriage of lathe. We fixed the work piece and tool is rotating perpendicular to
work piece mounted on carriage and the mandrel is design to hold the cutting tool

Vinayak Dalvi, Avinash Jayswal, Pruthviraj Mistry, Bibin Thomas. IJARIIE

ISSN(O) – 2395-4396. (2017). [5]

The author studied the manufacturing of gear on lathe by understanding the working of the
project model. The attachment is mounted on carriage. Work piece is fixed and tool is rotating
perpendicular to work piece. Mandrel is design to hold the tool. Manufacturing cost of gear can
be reduced by this method also reduce the cost of milling machine. This is multipurpose tool for
lathe machine. Time and cost for machining is reduce hence it increase the efficiency of lathe
machine.

Pullagura Pushpalata, G. Suresh, K. Balaji, P. Kumar Babu. IJRASET:

ISSN2349-4395. (2018). [6]
Here the author used the general and simple lathe attachment to carry out the manufacturing
operation of the splines and gear cutting which wasn’t doable in a normal lathe, so by fabrication
and general attachments limitations will be overcome by it, thereby reducing the floor space,
increasing productivity and flexibility.

Chetan R. Patil, Swapnil Sagar, Swapnil Gavhane, Dipak Bachhav, Abishek

Naik. IJRASET, ISSN: 23219653. (2018). [7]
This paper aims at designing and fabrication of gear cutting attachment to a medium duty lathe,
which will reduce the investment for medium and small-scale industries by reducing the
manufacturing cost of gears. The attachment will perform an indexing mechanism like milling
machine and carriage function to and fro movement and sliding on bed, The attachment was
mounted on carriage, where we fixed the work piece and mandrel was designed to hold the
cutting tool.

“Gunturu Mohan, C. Vijiya Bhaskar Reddy. IJREAM, ISSN- 24549150.

(2018). [8]

Here The main objective of the author was to design and fabricate a spur gear cutting attachment
for lathe machine for the purpose of gear cutting. Due to the certain constraints in lathe and high
initial cost in milling machine gear cutting operation is not economical for small scale industries,
So the author has made and attachment which will reduce the initial investment cost. This will

5
also reduce the space cover by the different type of machines and the remaining space can be
used for other productive work output.

“Dushyant Singh, (IJEIR) ISSN-2334-2356. (2019). [9]

The author basically discusses about the design and fabrication of slotting/milling attachment to
lathe. Here attachment is designed and fabricated to add the capability of horizontal milling
machine in lathe, A cutter is mounted in a cutting Arbour, which in turn is mounted between the
headstock and the tailstock. With this arrangement, it is possible to do keyway cutting in a shaft
or milling a plane surface on a workpiece.

“R. Bharatwaaj, A. Hari Prasath, S. Hari Patisath, J. Jony Anderson.

IJRESM ISSN: 25815792. (2020). [10]
This paper aims at the designing and development of an attachment that can help lathe operations
to machine spur gear product effectively. Attachment is designed to as to be able to cut spur gear
accurately and flexible to use, Here the result is 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.

6
 CHAPTER-3
PROBLEM IDENTIFICATION
• Few most commonly used gear manufacturing processes in industries are as follow: -

1. Form Milling – for simple and job-shop production.

2. Hobbing - for mass production.
3. Shaping – for mass production and internal gear manufacturing.

• All processes mention above required costly machine tools and equipment's, which may
not be affordable for all the small-scale industries and workshops. Whereas in some
processes we don’t get the desired gear suitable for our requirement. Then our problem
is that we have to find out such method or technique which can be used to manufacture
teeth on gear without using such a costly machine tool. Hence our need is that we have
to find out a cheap alternative method for gear production.

7
 CHAPTER-4
METHODOLOGY

Chapter 4 is the methodology that has been used to make the gear cutting attachment in lathe.
The concept and design for the product was gathered from the brainstorming and research
process. During the research process, observation on current skill was made. The milling
attachment need to be attached on the lathe machine. In this chapter the information that included
is Basic drawing and design, Design of component, Selection of component as per suitability,
Working and calculation. It also allows others to replicate our study and run new and different
studies that are based on our methodology

Software used
Fusin360: Fusion360 is a CAD, CAM, and CAE software. It starts straight in a 3D environment which
is good for visual. Sculpting is probably the most fun part of using fusion where free-form organic models
can be sculpted. Because of its cloud connectivity, your designs will stay safe. Also features like cloud
rendering and cloud simulations will give you an edge because complex simulations will be done quickly.
This software can easily be learned online as there are a lot of resources available.

BASIC DRAWING AND DESIGN CONCEPTS

The main objective of this project is to design the gear cutting attachment in lathe machine.
The aim of this project is to make gear without bought extra machine in workshop and
reduce the overall cost to done this process. So, the new product and design should have a
mechanism which available to gear cutting and hold on the carriage of lathe machine so
that it can move on lathe bed easily.
This is the idea concept for new design of gear cutting attachment in lathe.

Proposed Basic Drawing

8
Fig. 1 Base plate

Fig. 2 Side Frames

9
 Fig. 3 Slider with Screw

Fig.4 Shaft with indexing

Design of components

10
Fig. 5 Design of base plate

11
 Fig. 6 Design Left side frame

Fig. 7 Design Right side frame

12
Fig. 8 Design of slider with screw

13
 Fig. 9 Design of shaft with indexing

Fig. 10 Design of locating pin

14
Fig. 11 Design of top plate

15
Fig. 12 Design of assembled attachment

16
17
 WORKING

In this gear cutting attachment, gear milling cutter with arbor is held between two center of
lathe machine and when power given to lathe machine it starts rotating(anticlockwise) which
we want in the cutting tool motion. The work piece is fitted on the Stepped shaft and this shaft
is rotated in metal block when indexing is performed while cutting it remains rest position.
The standard gear mechanism which is important for gear tooth production after equal
interval. The shaft which is in metal block slider can also be moved in vertical direction
according to diameter of work piece and there is nut bolt arrangement is provided for locking
of metal block slider in C channel. Feeding motion for this shaft is provided by the rotating
the carriage wheel against the motion of cutting tool. Hence all motion is available for this
attachment for gear making purposes. And we can also manufacture here Spur as well as
helical gear by using this attachment. For Production of helical gear, we need tilting of bottom
plate (as that of Taper turning) according to helix angle of gear. For Production of next teeth,
we have to disengage the screw and by rotating the shaft in metal block slider up to next hole
of standard gear so that we lock this position for gear cutting by engaging the screw in that
standard gear

18
 CALCULATUION

● Force calculation
● There are two forces relating to the milling cutter, one is cutting force another is thrust.

According to the machine specifications, P Power = 1kw

N = Speed of rotation of the spindle = 560 rpm

D = Diameter of the cutter =approx.50 mm

Therefore, using the formulae for cutting force

V = πDN / 60
P =F. V
Therefore, F=P/V
Putting the above values in this equation, we get cutting force
F =680 N.

Thrust calculation

● To calculate the thrust force, following formula was used

Thrust force (th) = K * D * f^0.7 N
D =50mm
f = 0.5mm/min N =560
K = thrust force constant = 42.35

● Putting these values in the above equation, we get Thrust force (th) = 1290 N

INDEXING

In general, direct indexing plate has 24 holes in a circle. The workpiece is divided by using
the formula
Holes by which pin is to be moved = 24/n

19
n = no divisions in work piece by this direct indexing plate,
these many slots can be cut
2 divisions in work piece = 24/2 = 12 holes 3 divisions in
work piece = 24/3 = 8 holes 4 divisions in work piece = 24/4
= 6 holes 6 divisions in work piece = 24/6 = 4 holes 8
divisions in work piece = 24/8 = 3 holes
12 divisions in work piece = 24/12 = 2 holes
24 divisions in work piece = 24/24 = 1holes 2, 3, 4, 6, 8, 12,24.

20
 CONCLUSION

The design and fabrication of this project was successfully handled and every dimension
was calculated by referring to published research on this topic. Thus, this attachment can
provide a cheap and economical alternative for the gear cutting machine for small scale
industries and small workshops.
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.
By selecting and incorporating such small but useful ideas a small-scale industrialist can
save huge amount of time, energy, and money hence forth increasing the overall
productivity of a firm.

21
 FUTURE SCOPE

In this attachment if direct indexing is replaced by compound indexing, then the limitation
of cutting specific number of teeth can be eliminated and we can cut any no of teeth on
gear.
If use of bush come into picture in slider’s hole, then wear and tear of shaft can be minimized up
to a commendable level and so life of shaft as well as Slider will increase. 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.

Another future scope of this project is we can also make gear on drilling machine because it is
present in all workshop and fabrication shop easily, as rotating motion is available on spindle
of drilling machine the only problem is feeding of work piece against the cutter. By improving
drilling table, we can also achieve this one.

22
 BIBLIOGRAPHY
[1] M. Sagar, 2016, “Design and Fabrication of Gear Cutting Attachment to Lathe for
Machining a Spur Gear, International Journal of Innovations in Engineering and Technology,
Special Issue NCRTEEF OSS 2016, pp.217-285.

[2] Shaikh Bilal A et al, 2016, “Gear manufacturing by using conventional lathe machine”,
IJRET: International Journal of Research in Engineering and Technology eISSN: 2319-1163
pISSN: 2321-7308.

[3] P. Sivasankaran, 2017, “Slotting/Milling Attachment to Enhance Features of Lathe”,

International Journal of Engineering Innovation & Research Volume 6, Issue 4, ISSN: 2277 –
5668.

[4] S.Shinde et al, 2017,” Attachment on Lathe Machine to Perform Gear Cutting Operation”,
IJSRD - International Journal for Scientific Research & Development Vol. 5, Issue 01 ISSN:
2321-0613.

[5] Avinash Jayswal et al, 2017,” Lathe attachment for gear manufacturing”, IJARIIE-Vol-3
issue-2 ISSN(O)-2395-4396.

[6] G. Suresh et al, 2018, “Spur Gear Cutting Attachment for Lathe Machine”, International
Journal of Emerging Engineering Research and Technology Volume 6, Issue 7, PP 18-25
ISSN 2349-4395 (Print) & ISSN 2349-4409.

[7] Swapnil Sagar et al, 2018,” Design and Fabrication of Spur Gear Cutting Attachment for
Lathe Machine”, International Journal for Research in Applied Science & Engineering
Technology (IJRASET) ISSN: 2321-9653; IC Value: 45.98; SJ Impact Factor: 6.887 Volume
6 Issue V.

[8] Gunturu Mohan, Vijaya Bhaskar Reddy, 2018,” Design Analysis, Simulation and
Fabrication of Spur Gear Cutting Attachment for Lathe Machine”, International Journal for
Research in Engineering Application & Management (IJREAM) ISSN: 2454-9150 Vol-03,
Issue-12.

[9] J. Jony Anderson et al, 2020,” Gear Cutting Arrangement on Lathe Machine”,
International Journal of Research in Engineering, Science and Management Volume-3, Issue-
6.

[10]. V.B. Bhandari, Design of machine elements, Third edition, Tata McGraw Hill Education
private limited, New Delhi.

23