7/31/2019 Puneet Final Semester Project

1/50

1

SSTTAATTIICC SSTTRREESSSS AANNAALLYYSSIISS OOFF AA LLAATTHHEE FFOORRMM TTOOOOLL

UUSSIINNGG AANNSSYYSS

Submitted in

Partial fulfillment for the award of the degree of

BACHELOR OF TECHNOLOGY

In

MECHANICAL ENGINEERING

Submitted by-

Puneet Mehra (MT-1935-2K7)

Shubhra Kacker (MT-1947-2K7)

Shelly Tirlok (MT-1946-2K7)

Under the guidance of-

Mr. Mukesh Gupta

YMCA UNIVERSITY OF SCIENCE AND TECHNOLOGY FARIDABAD

SESSION 2007-2011

7/31/2019 Puneet Final Semester Project

2/50

2

CANDIDATES DECLARATION

I hereby certify that the work which is being presented in this project, entitled Static Stress

Analysis of a Lathe Form Tool using ANSYS, in partial fulfillment of the requirement for final

semester project and submitted in the Mechanical Engineering department is the authentic

record of our own work carried out during a period from January, 2011 to April, 2011 under the

supervision ofMr. Mukesh Gupta.

Puneet Mehra

Shubhra Kacker

Shelly Tirlok

7/31/2019 Puneet Final Semester Project

3/50

3

SUPERVISORS DECLARATION

This is to certify that the above statement made by the candidate is correct to the best of my

knowledge. All the four students were dedicated and sincere to their project work.

Mukesh Gupta

(Supervisor)

The Viva-Voice Examination of all the three Students has been held on..

Mukesh Gupta

(Supervisor)

7/31/2019 Puneet Final Semester Project

4/50

4

ABSTRACT

Simulation is now-a-days the best implemented method for the testing of materials and

products without actual prototyping which involves a lot of money and time which both are

very precious in the field of production.

On the other hand lathe is a very important tool used in day to day production which

uses various tools for different operations.

We have done a steady state stress analysis of a form tool used on lathe used for

making fillets and semicircular grooves for different stresses produced in it and also the strain

produced. For this purpose a HSS radius tool is used. All the values of the stresses and the

material properties were fed to a CAE package ANSYS v13 which implements FEM.

The results obtained were validated by the criteria of convergence and have been

produced in this report. The stress levels and the strain levels were very much within the

permissible limit and hence the tool is safe from the various forces acting on it

7/31/2019 Puneet Final Semester Project

5/50

5

ACKNOWLEDGEMENT

I am awed and overwhelmed as I bow to Dr. Sandeep Grover, Professor and Head, Department

of Mechanical Engineering Y.M.C.A. University of Science and Technology. I wish to express

my sincere gratitude to my project guide Mr. Mukesh Gupta, for providing me an opportunity

to do my project work Static Stress Analysis of a Lathe Form Tool using ANSYS. This project

bears on imprint of many people. It is an eternal honor to have word as his student for such a

long spell. His support, personal guidance, thought provoking discussions and encouragement

helped me guide through the upheavals. I wish God Almighty bestowed upon me the blessings

that I never falter in my duties as a true student.

Last but not the least I wish to avail myself of this opportunity, express a sense of gratitude and

love to my friends and my beloved parents for their manual support, strength and help for

everything.

Puneet Mehra

Shubhra Kacker

Shelly Tirlok

7/31/2019 Puneet Final Semester Project

6/50

6

CONTENTS

S.No. Description Page No.

Chapter 1: Introduction

1.1 What is Lathe? 9

1.2 Lathe History 9

1.3 Metal Working Lathe 11

1.4 Lathe Tools 13

1.5 Tool Materials 14

1.6 Tool Geometry 17

1.7 Metal Cutting 19

1.8 Forces in Two-Dimensional Cutting 20

1.9 ANSYS 22

Chapter 2: Literature Review

2.1 Previous studies in Stress Analysis of Tools 24

Chapter 3: Present Work

3.1 Tool Selection 27

7/31/2019 Puneet Final Semester Project

7/50

7

3.2 Selection of Tool Material 28

3.3 Structural Loads and Constraints 29

3.4 ANSYS Generated Project Report 30

Chapter 4: Results & Discussions

4.1 Results 44

4.2 Validation of Results 47

Chapter 5: Future Scope

5.1 Transient Structural 485.2 Thermal 485.3 Analytical Validation 49REFERENCES 50

7/31/2019 Puneet Final Semester Project

8/50

8

LIST OF FIGURES

S.No. Description Page No.

1.3 A Metal Working Lathe 12

1.4 Projections of a Lathe Tool 13

1.4 Types of Lathe Tools 14

1.6 Tool Bit Geometry 17

1.7 Machining Terminology 19

1.8 Forces in Metal Cutting 20

3.4 Tool Used 30

4.1 Maximum Principal Stress 44

4.1 Maximum Principal Elastic Strain 45

4.1 Total Deformation 46

7/31/2019 Puneet Final Semester Project

9/50

9

Chapter 1

INTRODUCTION

1.1What is Lathe?

A lathe is a machine tool which rotates the workpiece on its axis to perform various operations

such as cutting, sanding, knurling, drilling, or deformation with tools that are applied to the

workpiece to create an object which has symmetry about an axis of rotation.

Lathes are used in woodturning, metalworking, metal spinning, and glassworking. Lathes can be

used to shape pottery, the best-known design being the potter's wheel. Most suitably equipped

metalworking lathes can also be used to produce most solids of revolution, plane surfaces and

screw threads or helices. Ornamental lathes can produce three-dimensional solids of incredible

complexity. The material can be held in place by either one or two centers, at least one of which

can be moved horizontally to accommodate varying material lengths. Other workholding

methods include clamping the work about the axis of rotation using a chuck or collet, or to a

faceplate, using clamps or dogs.

1.2 Lathe History

The lathe is an ancient tool, dating at least to ancient Egypt and known and used in Assyria,

ancient Greece, and the Roman and Byzantine Empires.

The origin of turning dates to around 1300 BC when the Egyptians first developed a two-person

lathe. One person would turn the wood work piece with a rope while the other used a sharp

7/31/2019 Puneet Final Semester Project

10/50

10

tool to cut shapes in the wood. The Romans improved the Egyptian design with the addition of

a turning bow. Early bow lathes were also developed and used in Germany, France and Britain.

In the Middle Ages a pedal replaced hand-operated turning, freeing both the craftsman's hands

to hold the woodturning tools. The pedal was usually connected to a pole, often a straight-

grained sapling. The system today is called the "spring pole" lathe (see Pole lathe). Spring pole

lathes were in common use into the early 20th century. A two-person lathe, called a "great

lathe", allowed a piece to turn continuously (like today's power lathes). A master would cut the

wood while an apprentice turned the crank.

During the Industrial Revolution, mechanized power generated by water wheels or steam

engines was transmitted to the lathe via line shafting, allowing faster and easier work. The

design of lathes diverged between woodworking and metalworking to a greater extent than in

previous centuries. Metalworking lathes evolved into heavier machines with thicker, more rigid

parts. The application of lead screws, slide rests, and gearing produced commercially practical

screw-cutting lathes. Between the late 19th and mid-20th centuries, individual electric motors

at each lathe replaced line shafting as the power source. Beginning in the 1950s,

servomechanisms were applied to the control of lathes and other machine tools via numerical

control (NC), which often was coupled with computers to yield computerized numerical control

(CNC). Today manually controlled and CNC lathes coexist in the manufacturing industries.

7/31/2019 Puneet Final Semester Project

11/50

11

1.3 Metal Working Lathe

In a metalworking lathe, metal is removed from the workpiece using a hardened cutting tool,

which is usually fixed to a solid moveable mounting, either a toolpost or a turret, which is then

moved against the workpiece using handwheels and/or computer controlled motors. These

(cutting) tools come in a wide range of sizes and shapes depending upon their application.

Some common styles are diamond, round, square and triangular.

The toolpost is operated by leadscrews that can accurately position the tool in a variety of

planes. The toolpost may be driven manually or automatically to produce the roughing and

finishing cuts required to turn the workpiece to the desired shape and dimensions, or for

cutting threads, worm gears, etc. Cutting fluid may also be pumped to the cutting site to

provide cooling, lubrication and clearing of swarf from the workpiece. Some lathes may be

operated under control of a computer for mass production of parts (see "Computer Numerical

Control").

Manually controlled metalworking lathes are commonly provided with a variable ratio gear

train to drive the main leadscrew. This enables different thread pitches