Lathe Chuck Research Articles

Analisis Perawatan Mesin Bubut Menggunakan Metode Reliability Centered Maintenance (RCM) Pada CV. Sumber Jaya Makassar

The aim of this research is to analyze the determination of the maintenance system and component replacement time intervals using the Reliability Centered Maintenance (RCM) method. This research was carried out at CV. Sumber Jaya Makassar which is located on Jl. Pioneers of Independence, Biringkanaya District, Makassar City. The data obtained shows that there is one lathe machine component that has a very high level of damage, namely the lathe machine electrical system component. From the results of the Mean Time Between Maintenance (MTBM) calculation, it is found that the maintenance interval for the lathe machine electrical system components is every 223.1111 hours, the lathe machine is every 401.6 hours, the lathe machine's fixed head is every 508 hours, the lathe's removable head is every 669.3333 hours. clock and lathe chuck every 1004 hours. To obtain the performance of a lathe that can operate according to its performance, planned or periodic care or maintenance is needed or what is often called preventive maintenance, namely by carrying out daily, weekly and monthly maintenance.

Using Six Sigma DMAIC Cycle to Improve Workplace Safety in the Company from Automotive Branch: A Case Study

The article presents the results of the use Six Sigma DMAIC cycle to improve workplace safety and decrease the cost associated with work accidents in the company from the automotive branch. Selected tools of the DMAIC cycle were used at each stage: the project card and the Pareto-Lorenz diagram at the define (D) stage, the matrix diagram at the measure (M) stage, the Ishikawa diagram with the verification of causes at the analysis (A) stage, the 5WHY method at the improve (I) stage and the c control chart at the control (C) stage. Each of the successive stages was based on the results of the previous one in order to achieve a lasting solution for the analysed problem by the implementation of remedial measures. Because of the implementation of remedial measures, the level of work safety in the examined company was improved. The DMAIC analysis made it possible to identify the main causes (Xn) of accidents at work and to objectively evaluate them in order to discover the root cause (Xn!) of the problem. The root cause turned out to be inadequate protection of the lathe due to the protective cover installed too far away from the lathe chuck, which resulted in the catching of protective sleeves or gloves of the lathe operators and accident events in the form of upper limb damage. The solution to this problem was to reduce the gap between the guard and the lathe chuck by adjusting the guard so that no more items of workers' clothing were caught while the machine was running. The article proves the effectiveness of using the Six Sigma DMAIC cycle in analyzing and improving the state of occupational safety and is an incentive to use this cycle and a specific set of tools to analyze similar problems.

Failure of hydraulic lathe chuck assembly

Present work provides a detailed failure investigation of a hydraulic lathe chuck assembly that comprises a plunger, three jaws, and three jaw-carriers that are made of carburized, tempered and sub-zero treated EN36C steel. The chuck assembly suffered premature failure of the plunger and one of the jaw carriers during the service in a CNC lathe. The investigation comprises a detailed metallurgical failure analysis involving: visual inspection, fractography, metallography, and hardness measurements. The analysis concludes that plunger failed first by fatigue fracture that is originated at a sharp corner of a T-slot. The mating jaw-carrier failed in the next event due to instant misalignment and overstressing during the lathe operation. The investigation concludes that design flaw and improper heat treatment cycle as the reasons for the premature failure of the assembly. Through experimental simulation of the heat-treatment cycles using EN36C specimens, the work suggests that carburizing, cryogenic treatment and then tempering is the proper sequence for achieving the best combination of mechanical properties that should extend the service life of the chuck-assembly.

High-temperature 3D printing of polyetheretherketone products: Perspective on industrial manufacturing applications of super engineering plastics

A refined additive manufacturing system of material extrusion type was developed considering the high-temperature conditions of extruder and chamber. With this setup, a super engineering plastic material, named polyetheretherketone (PEEK), could be printed into three-dimensional (3D) parts without any delamination or warpage. To obtain maximum performance in terms of mechanical strength, experimental studies were conducted considering the thermal process parameters such as nozzle and chamber temperatures. These optimal process settings and carefully controlled heating conditions, incorporated with post-processing of additional heat treatment, could provide a high degree of crystallinity and high tensile strength (i.e., more than 90% compared to original material properties). To demonstrate the feasibility of industrial applications, we fabricated and tested several product prototypes, such as a wafer jig, a lathe chuck part, and plastic injection molds, all of which confirmed the excellent performance of PEEK for chemical resistance, high strength, and heat resistance, respectively.

Experimental Investigation and Analysis of Tensile Strength of Dissimilar Friction Welded Joints of Aluminium 6061 and Mild Steel

Nowadays, the joining process plays a vital role in every field of engineering application. Various similar and dissimilar materials are joined by many joining processes to a formed complex component. In all joining processes, welding is a very popular and effective joining process that gives permanent joint. In this process material to be joined is under influence of heat which is produced with aid of external (flame) and internal (friction) mediums. Further, there are types of welding process called friction welding which is solid-state welding, in that process friction had developed between materials having relative motion thus sufficient heat also produced, and welding is performed in solid-state. In recent time’s friction welding is widely used in automobile, aeronautical, structural, marine, etc areas due to its flexibility demand for various materials. In this research work, the aluminium 6061 and mild steel are joined by friction welding by varying the rotating speed of lathe chuck, friction time, burn-off length, and the joint is examined by a tensile test to check its strength. Taguchi’s orthogonal array was used to design the experiment and at the end, the ANOVA test is carried out for the optimization of process parameters.

A Critical Review on Fume Extraction System for Pipe and Plate Welding

In general, for both pipe and plate welding fixtures plays a crucial role. The current study investigates exposure among welders employed in the shop floor area. This welding fumes extractor has a exhaust ventilation setup to track sensitivity to welding fumes using glass fiber filter paper. The trick to acquiring the most effective system fitted to the closed atmosphere so that the gases do not disperse beyond the welding chamber is by learning the fundamentals of ventilation and airborne contaminant extraction. In previous tests, fixtures outside the fumigation hood were installed for both pipe and platform welding. By using a lathe chuck with 4 jaws fixed at both ends that keep the pipe up to 30 mm in diameter, a basic concept of the fixture is constructed. A horizontal rotating stand that is movable only in the y-axis can be set according to the area to be welded without any deflections. This device will be rotated with minimum speed, where the welding can be done effectively without press and dislocations. The main vision is to control the welding fumes in a closed chamber and to fabricate a lightweight fume extraction hood with pipe and plate welding fixtures. This research comes up with good social benefits to reduce blowout of fumes in industries and visibility during welding.

Reducing the effect of centrifugal forces on the clamping force in the new design of a three-jaw lathe chuck

The article considers a simple and reliable design of a new three-jaw lathe chuck, characterized by high operational characteristics: high rotation speed, durability, calibrated clamping of products and a number of others. The abandonment of classical methods of construction enabled us to create a new effective design. In addition, this design only due to its principle, enables you to compensate for centrifugal forces at any rotational speed, and at the same time the lathe chuck has a standard size for installation on machines.

Development of a Specialized Lathe Chuck for Turning Operations of Cast Iron Rope Wheels

The use of lathe chucks in machine building companies is the result of a great deal of work and the develop-ment of technical thought. Due to the progress and the possibility of increasing efficiency and at the same time relieving people from work that requires a lot of effort, especially physical effort, the use of better and more efficient production methods is a target that should be pursued nowadays. In the manufacturing pro-cess, these objectives can be achieved with the use of dedicated equipment. The following work will present an example of a lathe chuck specialized in turning operations. The aim of the work was to use a universal chuck as a base for designing and manufacturing a specialized chuck so that it is possible to mount rope wheels with diameters from 240 to 580 mm. This would eliminate the necessity of time-consuming changeo-vers. In addition, it is assumed that the handle must meet the conditions imposed by the limited number of tools and the working dimensions of the machine. The machining process itself was also important, where the most advantageous solution was to perform most of the operations in one clamping.

Risk assessment of workshops at Iran University of Science and Technology Using Fuzzy FMEA

Introduction: Many safety accidents in various industries are caused by poor safety culture of employees. Therefore, safety training can play an essential role in reducing workplace accidents and any damage to students. According to the importance of university workshops, the purpose of this study was to identify and assess the safety and health risks of the foundry and machinery workshops of Iran University of Science and Technology.
 Methods: This descriptive study was conducted at Iran University of Science and Technology in the 2018. After identifying risks, the Fuzzy Failure Modes and Effect Analysis (FMEA) technique was used to identify and assess the RPN number of risks which is calculated by multiplying of Severity x Occurrence x Detection and all risks were prioritized based on the calculated RPNs. Finally, corrective actions are presented to reduce injury risks.
 Results: The RPN range of 10 potential hazards in the machinery workshop calculated from 5.8 to 230.3, and the RPN range of 19 potential hazards in the foundry workshop calculated from 1.3 to 665.3. The danger of " throwing lathe chuck wrench " with RPN=230/33 in machinery workshop and "melt throwing due to air retention in metal parts " with RPN=665/33 in foundry workshop received the top priorities.
 Conclusion: Based on the calculated results, it is expected that the implementation of proposed corrective actions and the development of educational programs to promote students' safety culture can reduce the level of existing risks significantly.

The Influence of Printing Orientation on Surface Texture Parameters in Powder Bed Fusion Technology with 316L Steel.

Laser technologies for fast prototyping using metal powder-based materials allow for faster production of prototype constructions actually used in the tooling industry. This paper presents the results of measurements on the surface texture of flat samples and the surface texture of a prototype of a reduced-mass lathe chuck, made with the additive technology—powder bed fusion. The paper presents an analysis of the impact of samples’ orientation on the building platform on the surface geometrical texture parameters (two-dimensional roughness profile parameters (Ra, Rz, Rv, and so on) and spatial parameters (Sa, Sz, and so on). The research results showed that the printing orientation has a very large impact on the quality of the surface texture and that it is possible to set digital models on the building platform (parallel—0° to the building platform plane), allowing for manufacturing models with low roughness parameters. This investigation is especially important for the design and 3D printing of microelectromechanical systems (MEMS) models, where surface texture quality and printable resolution are still a large problem.

Study and evaluation of abrasive water jet turning process performance on AA5083

AbstractIn this study, the effect of processing parameters on surface roughness and macro surface characteristics was analyzed during the machining of Ø30 mm and 300 mm aluminum alloy AA5083 abrasive water jets. As the processing parameters (up to 10 mm min−1, 15 mm min−1, 20 mm min−1 and 25 mm min−1), abrasive flow rate (50 g min−1, 150 g min−1, 250 g min−1 and 350 g min−1), the lathe chuck rotational speed (25 min−1, 50 min−1, 75 min−1 and 100 min−1) and the nozzle approach distance (2 mm, 5 mm, 8 mm and 11 mm) were used in experiments. In experimental studies, the pump pressure (360 MPa) was used as a constant, in the form of an abrasive Garnet (100 mesh), and the nozzle diameter as 0.76 mm. According to the findings, the best results in terms of surface roughness were obtained as a result of turning speed and abrasive flow rate. When the macro surface characteristics were examined, it was found that the lathe chuck rotational speed increased, the rate of nozzle progression was low, the rate of abrasive flow was high and the nozzle approach distance was lower and the smoother surfaces were obtained.

Modernization of the technique for rotary shape-formation of outer profiled surfaces

We have proposed a technique for obtaining outer profiled surfaces, which is characterized by affordability and low cost of equipment used. The technique is based on that a regular rotating center is fixed in a lathe’s tool holder in a special way. A basic socket head of the required profile is applied as a profile-forming matrix. A tool holder’s rotation angle ensures a fracture angle of the rotating center’s axis relative to the axis of a workpiece rotation. A value for the fracture angle reaches 1.5°. The end surface edge of the matrix executes a reciprocating motion per every rotation of the lathe chuck along the surface of a workpiece. In this case, the end surface of the matrix and a workpiece are in contact at a single point, going deeper by the magnitude of feed per every rotation of the chuck. Application of a given technique is an alternative to existing technique of rotational shape-formation of outer profiled surfaces, whose implementation requires specialized equipment and specialized cutting tools, the price for which is quite high (UAH 57,000 and UAH 6,000, respectively). In addition, changing the size or shape of the required profile necessitates installing a new cutting tool, replacing which requires additional adjustment. The tests were carried out when manufacturing the twelve-point outer surface the size of S10. An analysis of vibrograms from the shape-formation process has established the most rational variant of equipment for manufacturing profiled outer surfaces. We have manufactured pilot outer profiled surfaces, such as hexagon the size of S10, the TORX surface the size of E14, and others. They confirmed a possibility for successful manufacturing of different profiled outer surfaces using the proposed tooling. Using the proposed technique, which implies low cost and does not require specialized equipment, could significantly expand the scope of application of conjugated surfaces with a profiled shape in mechanical engineering

Studies of thin-walled parts deformation by gripping force during turning process on an example of bearing ring

In this paper thin-walled part deformation during finishing turning process caused by gripping force of hydraulic lathe chuck was investigated. Bearing ring was taken as an example of thin-walled part undergo finishing turning operation. Finite Element Method (FEM) was used to define the deformation of examined part. The aim of presented research was to compare the deformation of bearing ring caused by gripping force of hydraulic 3-jaw chuck and 6-jaw chuck for different values of total gripping force. The data obtained from conducted simulations allowed to evaluate the influence of gripping force on machining part deformation which is directly related with its geometrical accuracy.

Скінченно-елементне моделювання закріплення тонкостінного кільця в трикулачковому патроні

The article analyzes the designs of lathe chucks and establishes the main directions for their optimization design. Dependences were found for determining the elastic deformations of a thin-walled ring when it was fixed in a three-jaw — depending on the type of fixation. The dimensions of the supporting surface of the jaws were optimized by the criterion of the minimum error in the shape of the hole of the cylindrical ring fixed in it. The optimization was carried out in two stages. The first stage covers the optimization of the width of the support surface, and the second covers the optimization of its diameter. A study of the behavior of the finite element model for a wide range of loads and ring sizes, in particular their curvature (ratio of the thickness of the cross-section of the ring to its median radius) in the range 1/5…1/20, found that the error in the shape of the hole of the ring fixed in the cartridge: increases linearly with increasing cam load, and inversely proportional to their third-degree curvature (for rings of small curvature) decreases with increasing cam width. In this case, for the ratio of the diameters of the bearing surface of the cam to the base (outer) surface of the ring: less than the one maximum errors are reached; close to one error decreases; more than one practically does not change. Graphical dependences the error in the hole shape of the steel ring from the width of the cam support surface and the ratio of the cam and ring diameters in contact. Investigation of the deformation of the constructed finite element model of the technological system ring-cams of a three-jaw self-centering chuck determined the optimal parameters of the cam surface by the criterion of the least error in the shape of the hole in the ring. Verification of the finite element model, performed by comparing the results of numerical analysis with analytically calculated values of the ring deformation and the error of its hole shape during fastening in a cartridge with narrow jaws confirmed its adequacy and accuracy. The discrepancy between the results for both methods was less than 2,5 %, which is quite enough for engineering forecasting.

Toolmarks made by lathe chuck jaws

This paper presents a forensic method to evidentially tie a workpiece with a specific lathe. Examining using this method can prove or exclude a connection between the two. The importance of this method is mostly due to the growing trend among lawbreakers of manufacturing improvised firearm parts using machining processes. This method is based on comparing jaw impressions made by the chuck on a workpiece.

Chucks for thin-walled blanks

A lathe chuck with components that ensure greater contact area with the blank is considered. This design reduces the elastic deformation of the blank.

The Effect of Process Parameters on Machining Volume and Depth Of Cut In Turning Operation Of AISI 1040 Steel With Abrasive Water Jet

In this study the effect of processing parameters during turning of AISI 1040 steel with abrasive water jet on machining volume and depth of cut. In the study, in order to keep the experiment quantity low, former studies in literature were taken into consideration and therefore experiments were realized with processing parameters and experiences that are most suitable to pre-experiments. In experimental studies pump pressure (350 MPa), abrader dimensions (in garnet form and dimension 80 mesh) and nozzle diameter (1.2 mm) were kept constant. 1040 steel with dimensions of O 30 and 240 mm were processed at four different abrader flow rate (50, 150, 250 and 350 gr/min), nozzle distance (2, 5, 8 and 11 mm), nozzle feed rate (5, 15, 25 and 35 mm/min) and lathe chuck revolutions (25, 50, 75 and 100 rpm). According to the findings the most highly material removal rate of 5 mm / min nozzle feed rate 1387.25 mm3 in the amount has been achieved. The maximum depths of cut 0.94 mm spindle speed of 100 rpm were obtained.

Rotary Hammer Forging, a New Manufacturing Process

Rotary forging process has recently been developed in which the material is deformed partially and incrementally and a deformation zone is developed and swept through the material. Since the upper die in rotary forging is always in contact with the workpiece top surface, and presses continuously the workpiece until it takes the final shape in one stroke (i.e. resembling conventional press forging), it might be more definite to name it as rotary press forging. Rotary press forging produces many defects. The author has invented a process, namely, rotary hammer forging, which reduces these defects. The aims of the present work are to introduce the rotary hammer forging process, to study the effects of the fundamental process parameters, and to find out the advantages of RHF. Special set-ups with a rotary die mounted on a lathe chuck being hammered with a pneumatic piston mounted on the lathe carriage have been used. It has been found that the specimen's geometry and the inclination angle affect the extruded length, the mushrooming effect, the eccentricity, the twisting angle, the buckling and the forming time. The defects of buckling, mushrooming, eccentricity and twisting are less severe in rotary hammer forging than rotary press forging. Hence, rotary hammer forging is more beneficial and superior than rotary press forging.

Wear Analysis of Thermal Spray Coatings on 3D Surfaces

Even though the application of thermal spray coatings on complex geometries gained a greater interest in the last decade, the effect of different geometrical features on the wear behavior is still ill-defined. In this study, the wear resistance of FTC-FeCSiMn coated 3D surfaces was investigated. The wear test was carried out by means of two innovative testing procedures. The first test is a Pin-on-Tubes test where the rotating motion is realized by a lathe chuck. The specimens in the second test were fixed on the table and a robot arm operated the pin. This wear test was applied on specimens with concave or convex surfaces. The residual stresses, which were determined by means of an incremental hole-drilling method, show a dependency on the substrate geometry. The obtained stresses were put in relation to the different radii. After the wear test, a 3D-profilometer determined the wear volume and the sections of the coatings were characterized by a scanning electron microscope. The results indicate that the wear resistance is strongly influenced by the geometry of the substrate.

Research on Safety Protection Technology of Conventional Lathe CA6140

At present, in the overall quality of university education in our country, the mechanical engineering training is an important part. The actual operation of lathe is a key element in this process, and the first and foremost problem in lathe operating is security. In order to increase the personal safety of students and equipment safety, local technical transformation on CA6140 lathe was carried, including the security guards power chuck, chuck and other anti-collision travel limit. The practical application shows that after transformation, there had none of collision accidents due to unload lathe chuck wrench.