CHAPTER 1 INTRODUCTION 1.

1 ABOUT BHEL Bharat Heavy Electricals Limited (BHEL) is a name which is recognized across the industrial world. It is the largest engineering and manufacturing enterprise in India and one of the leading international companies in the field of power equipment manufacture. BHEL offers a wide spectrum of product and services to core sectors of the Indian economy, viz., power generation and transmission, industry, transportation, oil & gas, renewable energy, defence, etc. The first plan of BHEL was set up at BHOPAL in1956, which signalled the drawn of the Heavy Electrical Industry in India. In the early sixties, three more major plants were set up at Haridhwar, Hyderabad and Tiruchirapalli that form the core of the diversified product range, systems and services that BHEL range of services extend from project facility to after sales service successfully meeting diverse needs through turnkey capability. The company has 14 manufacturing units, 4 power sector regional centres, 8 service centres 18 regional offices besides project sites spread all over India and abroad. The company has formed a strategic business unit for ceramics at Bangalore. BHEL is today the largest engineering and manufacturing enterprise of its kind in India with a well recognized track record of performance making profits continuously since 1971 1972 and paying dividends since 1976 1977. BHEL manufactures over 180 products under 30 major product groups and caters to core sectors of the India economy viz. Power Generation and Transmission, Industry, Transportation, Telecommunication, Renewable Energy, etc., The quality & reliability of its products is due to the emphasis on design. Engineering and Manufacturing to international standards by acquiring and adapting some of the best technologies from leading companies in the world together with technologies developed in its own R & D centres. BHEL has acquired certification to both ISO 9000 & ISO 14000 standards for its operation and has also adopted the concept of total quality management. BHEL has adopted Occupation Health and Safety standards as per OHSAS 18001. Two of its divisions have acquired

certification to OHSAS 18001 standard and the other units are in the process of acquiring the same. BHEL has installed equipment for over 62,000 Mega Watt of power generation for utilities, captive and industrial users. BHEL has supplied 2, 00,000 MVA transformer &distribution network. 1.2 BHEL TRICHY BHEL `s Tiruchirapalli complex is Indias largest manufacture of boilers and auxiliaries providing total boiler land solution for utility, Industrial, Captive power and Heat recovery applications. The BHEL Triuchirapallai complex comprises five units. High Pressure Boiler Plant (HPBP) - Triruchirapalli Seamless Steel Tube Plant (SSTP) - Triruchirapalli Boiler Auxiliaries Plant (BAP) Piping Centre (PC) Industrial Valve Plant (IVP) 1.3 POWER CAPABILITY BHEL has supplied boilers and auxiliaries accounting for nearly 70% of the total installed thermal power generation capacity in India. BHEL has successfully executed boiler projects in Malaysia and the Middle East and continues to secure repeat orders from overseas customers for servicing and renovation of boilers. For power generation application, BHEL designs, Engineers, Manufactures, Supplies, Erects and Commissions boilers of any rating upward of 30 Mega Watt. For higher capacities, BHEL also offers customers the option of once through type steam generators in addition to conventional natural and controlled circulation types. BHEL supplies steam generators rating up to 450 ton/hrs for industrial application to suit the requirements of industries viz. fertilizer, petro chemical, refinery, steel, paper and other process industries. BHEL utility boilers account for over 65% of the total installed thermal
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- Triruchirapalli - Triruchirapalli - Triruchirapalli

power generation capacity in India Boilers of various types are supplied including vertical package (oil / Gas fixed). Vertical units (Oil gas / Coal fired), fluidized bed combustion (Coal and other solid fuels), chemicals recovery, waste of heat recovery, stoker fired chemical recovery boilers of capacity ranging from 100 to 1350 ton/day of dry solids are manufactured for the paper and pulp industry. 1.4 TRANSMISSION & DISTRUBUTION [T&D] B.H.E.L. manufactures wide-ranging products and system for T&D applications. Manufacturing include power transformer in instrument transformer, type transformer series and shunt-reactor capacitor blanks, vacuum and SF6 circuit breakers, energy meter SCANDA system and insulators. A strong engineering based enable the company to undertake turnkey delivery of sub-station up to 400KW level, series compensation system (for increasing power, transforming capability of transmission lines and improving system stability and voltage improvement) and HVDC system reactor for reactive power. 1.5 INDUSTRIES B.H.E.L. is a major contributor of equipment and system to industries; cement, sugar, fertilizer, refineries, petrochemicals, paper, oil and gas, metallurgical and other process industries. The range of system and equipment supplied includes; captive power plant, cogeneration plants, DG power plants, industrial steam turbines, industrial boiler and auxiliaries, waste heat recovery boilers, gas turbine, heat exchangers and pressure vessels, centrifugal compressors, electrical machines, pumps, valves seamless steel tubes, electrostatic precipitators fabric filters, fluidised bed combustion boilers, chemical recovery boilers, pressure control and material handling systems. 1.6 OIL & GAS B.H.E.L. is a major contributor of oil and gas sector industry in the count ry. B.H.E.Ls product range includes deep drilling oil rings, mobile rigs, well head and X-mas tree, full bore Gate valve, sub-sea. Well head block valves, seamless pipes, motor compressors, heat exchangers. B.H.E.L. is the single largest supplier of well head and X-mas tree and oil rigs to ONGC and other oil companies over the world.

1.7 RENEWABLE ENERGY Technologies that can be offered by B.H.E.L. for exploiting non-conventional energy and renewable source include: wind electrical generator, photovoltaic generators, solar heating system, solar lantern and battery-power road vehicles. The company has taken up R&D efforts for the developments of multi-functional amorphous silicon solar cells and fuel cell based system. 1.8 INTERNATIONAL OPERATIONS B.H.E.L. is one of the largest exporters of engineering products and services from INDIA, ranking among the major power plant equipments supplier in the world. Over the years B.H.E.L. has established in around 60 countries in the world, ranging from the United States in the West to the New Zealand in the Far East. Apart from over 1,100MW of boiler capacity contributed to Malaysia and execution of four prestigious power project in OMAN, some of the other major success achieved by the company have been in CHINA, SAUDI ARABIA, LIBYA, GREECE, CYRUS, MALTA, EGYPT, BANGLADESH, SRI LANKA, IRAQ, INDONESIA etc. 1.9 VISION, MISSION & VALUES VISION A world class engineering enterprise committed to enhancing stakeholder value. MISSION To be an Indian Multinational Engineering Enterprise providing Total Business Solutions through Quality products, Systems & Services in the fields of Energy, Industry, Transportation, Infrastructure and other potential areas. VALUES Zeal to excel and zest for change. Integrity and fairness in all matters. Respect for dignity and potential of individuals. Strict adherence to commitments. Ensure speed of response.
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 Faster learning, creativity and team work. Loyalty and pride in the company. BHEL Trichy, a major manufacturing unit of BHEL family, is an ISO9001, 14001 and OHASAS 18001 company. The product profiles include Seamless Steel Tubes, Electrostatic precipitators and Wind Electric Generators and Desalination plants. B.H.E.L. mainly uses 5S in its Total Quality Management program. The 5S practice is a house keeping technique used to establish and maintain a productive and quality environment in an organisation. A well-organised work place results in a safer, more efficient and more productive operation. It boosts the morale of the workers, promoting a sense of pride in their work and ownership of their responsibilities. 5S was invented in Japan. It stands for five Japanese words that start with the letter S: SEIRI-Tidiness, SEITON-Orderliness, SEISO-Cleanliness, SEIKETSU-Standardisation and SHITSUKE-Discipline.

CHAPTER 2 LITERATURE REVIEW The lathe is one of the oldest machine tools and came into existence from the early tree lathe which was then a novel device for rotating and machining a piece of work held between two adjacent trees. A rope wound round the work with its one end attached to a flexible branch of a tree and the other end being pulled by a man caused the job to rotate intermittently. Hand tools were then used. With its further development a strip of wood called lath was used to support the rope and that is how the machine came to be known as lathe. This device continued to develop through the centuries and in the year 1797 Henry Maudslay, an Englishman, designed the first screw cutting lathe which is the forerunner of the present day high speed, heavy duty production lathe, a machine tool which has practically given shape to our present day civilization by building machines and industries as discussed in [4]. 2.1 FUNCTION OF THE LATHE The main function of the lathe is to remove metal from a piece of work to get it the required shape and size. This is accomplished by holding the work securely and rigidly on the machine and then turning it against cutting tool which will remove metal from the work in the form of chips. To cut the material properly the tool should be rigidly held on the machine and should be fed or progressed in a definite way relative to the work as discussed in [1]. 2.1.1 TYPES OF LATHE Lathes of various designs and construction have been developed to suit the various conditions of metal machining [3]. But all of them employ the same fundamental principle of operation and perform the same function. The types generally used are: 1. Speed lathe. a. Wood working b. Centring c. Polishing d. Spinning 2. Engine lathe. a. Belt drive
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b. Individual motor drive c. Gear head lathe 3. Bench lathe. 4. Tool room lathe. 5. Capstan and turret lathe. 6. Special purpose lathe. a. Wheel lathe b. Gap bed lathe c. T-lathe d. Duplicating lathe 7. Automatic lathe. The speed lathe: In construction and operation this is the simplest of all types of lathe. It consists of a bed, a headstock, a tailstock and a tool post mounted on an adjustable slide. There is no feed box, lead screw or conventional type of carriage. The tool is mounted on the adjustable slide and is fed into work purely by hand control. This characteristic of the lathe enables the designer to give high spindle speeds which usually range from 1200 to 3600r.p.m. As the tool is controlled by hand, the depth of cut and the thickness of chip are very small. The engine lathe or Centre lathe: This lathe is the most important member of the lathe family and is the most widely used. The term engine is associated with the lathe owing to the fact that early lathes were driven by steam engines. Similar to the speed lathe, the engine lathe has got all the basic parts, e.g. bed, headstock and tailstock. But the headstock of an engine lathe is much more robust in construction and it contains additional mechanism for driving the lathe spindle at multiple speeds. Unlike the speed lathe, the engine lathe spindle can feed the cutting tool both in cross and longitudinal direction with reference to the lathe axis with the help of a carriage, feed rod and lead screw. With these additional features an engine lathe has proved to be versatile machine adapted for every type of lathe work. The bench lathe: This is a small lathe usually mounted on a bench. It has practically all the parts of an engine lathe or speed lathe and it performs almost all the operations, its only difference being in the size. The tool room lathe: A tool room lathe having features similar to an engine lathe is much more accurately built and has a wide range of spindle speeds ranging from a very low to a quiet high speed up to 2500r.p.m. This is equipped, besides other things, with a chuck, taper
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turning attachment, draw in collet attachment, thread chasing dial, relieving attachment, steady and follower rest, pump for coolant etc. This lathe is mainly used for precision work on tools, dies, gauges and in machining work where accuracy is needed. The machine is costlier than an engine lathe of the same size. The capstan and turret lathe: These lathes are development of the engine lathe and are used for production. The distinguished feature of this type of lathe is that the tailstock of an engine lathe is replaced by a hexagonal turret, on the face of which multiple tools may be fitted and fed into the work piece without re-setting of work or tools, and a number of identical parts can be produced in the minimum time. Special purpose lathe: As the name implies, they are used for special purpose and for jobs which cannot be accommodated or conveniently machined on a standard lathe. The wheel lathe is made for finishing the journals and turning the tread on a railroad car and locomotive wheels. The gap bed lathe, in which a section of the bed adjacent to the headstock is recoverable, is used to swing extra-large diameter pieces. The T-lathe is a new member of the lathe family is intended for machining of rotors for jet engines. Automatic lathe: These are high speed, heavy duty, mass production lathes with complete automatic control. Once the tools are set and the machine is started it performs automatically all the operations to finish the job. The changing of tools speeds and feeds are also done automatically. After the job is complete, the machine will continue to repeat the cycles producing identical parts even without the attention of an operator. An operator who has to look after five or six automatic lathes at a time will simply look after the general maintenance of the machine and cutting tool, load up a bar stock and remove finished products from time to time as discussed in [3]. 2.2 CUTTING-TOOL NOMENCLATURE Cutting-tool nomenclature means systematic naming of the various parts and angles of a cutting-tool. The surfaces on the point of a tool bear definite relationship to each other that are defined by angles. The principles underlying cutting tool angles are the same whether the tool is a single-point tool, multi-point tool or a grinding wheel [7]. The basic angles needed on a single-point tool may be best understood by removing the unwanted surface an oblong tool blank of square section. However the compete nomenclature of the parts of a single-point tool is shown in the figure.2.1. These are: shank, face, flank, heel, nose, base, back, rake, side
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rake, side clearance, end clearance, end cutting edge, wide cutting edge and lip angle. These elements define the shape of a tool.

Fig 2.1 Cutting tool nomenclature of old parting tool

Fig 2.2 Cutting tool nomenclature for carbide insert parting tool

Fig 2.3 Parting tool holder for sharp insert type carbide tip Table 2.1 Specification of the parting tool holder

S (in)

Tmax H=h1 (in) 0.827 (in)

b (in)

Designation

Type

0.750 0.750 NCBE 20-1212 R/L-GX 24- GX 24-2-21 2-21

0.118 0.827

1.000 1.000 NCBE 25-1616 R/L-GX 24- GX 24-2-21 2-21

0.827 0.157-0.197 0.827

1.000 1.000 NCBE 25-1616 R/L-GX 24- GX 24-3-21 3-21 1.250 1.000 NCBE 32-8585 R/L-GX 24- GX 24-3-21 3-21

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0.827 0.236 0.827

1.000 1.000 NCBE 25-1616 R/L-GX 24- GX 24-4-21 4-21 1.250 1.000 NCBE 32-8585 R/L-GX 24- GX 24-4-21 4-21

0.315

0.827

1.000 1.000 NCBE 25-1616 R/L-GX 24- GX 24-5-21 5-21

Fig 2.4 Walter parting tool holder From fig 2.2, 2.3 and 2.4, The shank is that portion the tool bit which is not ground to form cutting edges and rectangular in cross-section. The face of the cutting tool is that surface against which the chip slides upward. The flank of the cutting tool is that surface which faces the work piece. The heel of a single point tool is the lowest portion of the side-cutting edges. The nose of the tool is the conjunction of the side- and end-cutting edges. A nose radius increases the tool life and improves surface finish.
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The base of the tool is the under-side of the shank. The rake is the slope of the top away from the cutting edge. The larger the rake angle, the larger the shear angle and subsequently the cutting force and power reduce. A large rake angle is conductive to good surface finish. Each tool has a side and back rake. Back rake indicates the plane which forms the face or top of a tool has been ground back at an angle sloping from the nose. Side rake indicates that the plane that forms the face or top of a tool has been ground back at angle sloping from the side-cutting edge. Side rake is more important than the back rake for turning operation. The side clearance or side relief indicates that the plane that forms the flank or side of a tool has been ground back at an angle sloping down from the side-cutting edge. The end cutting edge angle indicates that the plane which forms the end of a tool has ground back at angle sloping from the nose to the side of the shank, whereas the side cutting edge angle indicates that the plane which forms the flank or side for a tool has been ground back at an angle to the side of the shank. The lip or cutting angle is the included angle when the tool has been ground wedged-shaped as discussed in [7]. 2.3 TOOL LIFE AND WEAR The tool life is an important factor in a cutting tool performance since considerable time is lost whenever tool is ground and re-set. A tool cannot cut for an unlimited period of time. It has its definite life. If a cutting tool have a long life it is essential that the face of the tool be as smooth as possible. Tool life is the time a tool will operate satisfactory until it is dulled [8]. A blunt tool causes chatter in machining poor surface finish, increase in cutting forces and power consumption, overheating of the tool. 2.4 TOOL FAILURE The failure of the cutting tools may be the result of as discussed in [9]: Wear on the flank of the tool: flank wear is a flat portion worn behind the cutting edge which eliminates some clearance or relief. Flank wear takes place when machining brittle materials like C.I. or when feed is less than 0.15 min/rev [9].

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Wear at the tool chip interface occurs: in the form of a depression or carter. This is caused by the pressure of the chip as it slides up the face of the cutting tool. Both flank and crater wear takes place when feed is greater than 0.15 mm/rev at low or moderate speeds [9]. A combination of the flank wear and caterings [9]. The spalling or crumbling: of the cutting edge. A cutting tool that has improperly ground relief angles either rub on the material or be weak because of excessive clearance angles [9].

The loss of hardness because of excessive heat but under cutting conditions when the temperature and stresses are high, plastic deformation may cause loss of form stability that is cutting ability of the tool [9]. 2.5 FACTORS AFFECTING TOOL LIFE The life of a tool is affected by many factors such as cutting speed, feed, and depth of cut, chip thickness tool geometry, material of the cutting fluid and rigidity of the machine. Physical and chemical properties of work materials influence tool life by affecting form stability and rate of wear of tools. The nose radius also tends to affect tool life. Researchers have identified a number of factors which are established by experimental verification as mentioned in [2]. 2.6 CUTTING SPEED Cutting speed has greatest influence on tool life. As the cutting speed increases the temperature also rises. The heat is more concentrated on the tool than on the work and the hardness of the tool matrix changes so the relative increase in the hardness of the work accelerates the abrasive action. The criterion of wear is dependent on the cutting speed because of predominant where may be for flank or crater if cutting speed is increased. It has been found that at cutting speed is increased. It has been found that at cutting speeds greater than 100m/min in carbide turning of steel crater wear may become predominant. The relation of the cutting speed to the tool life is expressed by the Taylors equation from [8]: V V T =C

= cutting speed in m/min = tool life in minutes.

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= exponent which depends on the tool and the workpiece. The value of exponent n is about 0.1 for high-speed steel tool, 0.20-0.25 for carbide tools and 0.4-0.55 for ceramic tools.

= constant which is numerically equal to cutting speed that gives a tool life of one minute.

2.7 FEED AND DEPTH OF CUT The tool life is influenced by the feed rate also. With a fine feed the area of chip passing over the tool face is greater than that of a coarse feed for a given volume of swarf removal, but to offset this chip will be greater. Hence the resultant pressure will nullify the advantage; it is however possible to balance the two opposing influences to obtain an optimum feed rate. The effect of feed and depth of cut on tool life is given in [8] by: V Where, s t = 257/ [ * * ] m/min

= feed in mm/min = depth of cut in mm.

2.8 CHARACTERISTICS OF CUTTING TOOL MATERIALS Hot hardness: The material must remain harder than the work material at elevated operating temperatures. Wear resistance: The material must withstand excessive wear even though the relative hardness of the tool-work materials changes. Toughness: The term toughness actually implies a combination of strength and ductility. The material must have sufficient toughness to withstand shocks and vibrations and to prevent breakage. Cost and easiness in fabrication: the cost and easiness of fabrication should have within reasonable limits as discussed in [11].

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2.9 TYPES OF TOOL MATERIALS The selection of proper tool material depends on the type of service to which the tool will be subjected. No material is superior in all aspects, but rather each has certain characteristics which limit its field of application. The principal cutting materials are: 1. Carbon steels 2. Medium alloy steels 3. High-speed steels 4. Stellites 2.10 CUTTING FLUIDS Cutting fluids sometimes referred to as lubricants or coolants are liquids and gases applied to the tool and work piece to assist in the cutting operations as discussed in [14]. 2.10.1 Purpose of cutting fluids 1. To cool the tool 2. To cool the work piece 3. To lubricate and reduce the friction 4. To improve the surface finish 5. To protect the finished surface from corrosion 6. To cause chips break up into small parts 7. To wash the chips away from the tool 2.10.2 Properties of Cutting fluids 1. High heat absorption for readily absorbing heat developed. 2. Good lubricating qualities to produce low-coefficient of friction. 3. High flash point so as to eliminate the hazard of fire. 4. Stability to so as to not to oxide in the air. 5. Neutral so as not to produce any bad smell even heated. 2.10.3 Choice of cutting fluids The choice of cutting fluid depends upon the following factors depends upon the following factors [12]: 1. Type of operation 2. The rate metal removal
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5. Cemented carbides 6. Ceramics 7. Diamonds 8. Abrasives

3. Material of the work piece 4. Material of the tool 5. Surface finish requirement 6. Cost of cutting fluid. 2.10.4 Type of Cutting Fluid 1. Water 2. Soluble oils 3. Straight oils 4. Mixed oils 5. Chemical-additive oils 6. Chemical compounds 7. Solid lubricants Type of cutting fluids used in our Modern Cut-Off machine is soluble oil.

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CHAPTER 3 ABOUT MODERN CUT-OFF MACHINE

Fig 3.1 Modern cut-off machine at industry Modern cut-off (MCO) machine which is shown in the fig 3.1 is manually operated machine. In which three operations can be performed, they are parting, boring and chamfering. The parting tool is placed vertically in machine and the boring tool is placed at an angle of 45 deg in the machine at the left side of the machine and the chamfering tool is placed to the right of the machine at an angle of 45 deg [14]. The tubes of various grades are used in the MCO machine grade C, T11, T22, T91. The first operation in the MCO machine is either boring or chamfering operation. Then finally the parting operation is to be done. The rotating spindle speed of the machine is 700r.p.m. This speed can be increased or decreased suitably using a knob which is available at top of the machine. Various kind of hydraulic connections are made to operate the MCO. 3.1 COMPONENTS OF MODERN CUT-OFF MACHINE Parting tool
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Boring tool Chamfering tool Collet Collet cover Belt drive Carbide tip cutting tool Tool post Tool holder

3.1.1 PARTING TOOL

Fig 3.2 Parting tool The parting-off tool as shown in the fig 3.2, the operation of the parting tool is cutting a work piece after it has been machined to the desired size and shape. A parting-off operation is shown in the figure. The tool should be fed very slowly to prevent chatter. The feed varies from 0.07 to 0.15 mm per revolution and the depth of cut which is equal to the width of the tool ranges from 3 to 10mm.The parting tool is first fed through a certain depth, its then withdrawn, and two more cuts are made at the two sides of the central groove as discussed in [9]. 3.1.2 BORING TOOL A boring tool is similar to left hand external turning tool so far its cutting edge is concerned. A cemented carbide tip boring tool is shown in figure. In a boring tool, the tool cutting edge must have sufficient front clearance in order to clear the work. In order to strengthen the tool point double clearance, primary and secondary, may be provided as discussed in [10].

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3.1.3 CHAMFERING TOOL

Fig 3.3 Chamfering tool The fig 3.3 shows Chamfering tool. A straight turning tool may be used as a chamfering tool when the cutting edges are set at the angle of chamfer. Where a large number of chamfer works are to perform a special tool with its side cutting edge angle ground to the angle of chamfer used. A chamfering tool is shown in the above figure as from [2]. 3.1.4 COLLET & COLLET COVER A cone shaped chuck used for holding cylindrical pieces in a lathe. The cover surrounding the collet is called as the collet cover [3]. 3.1.5 BELT DRIVE

Fig 3.4 Belt drive

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The belt drive is shown in the fig 3.4; the belt drive is one of the common and effective devices of transmitting motion and power from shaft to the other by the means of a thin inextensible band running over two pulleys. This is largely used for general purposes in mills and factories especially when the distance between the shafts is not very great. Belts can transmit, however up to a distance of about 10m with a maximum surface speed of 1400m/min when flat belts are used, while a maximum surface speed of 1500 m/min can be used with v-belts. There are two types namely open-belt drive and crossed-belt drive as discussed in [4]. 3.1.6 CARBIDE TIP CUTTING TOOL

Fig 3.5 Carbide tip cutting tool Carbide tip cutting tool in fig 3.5 contain carbon in amounts ranging from 0.08 to 1.5 per cent. The right cutting edge for the cutting tool gives low feed, minimal burr/nib at the center, low cutting force. They lose their required hardness at temperatures from 200-250C [12]. 3.1.7 TOOL POST

Fig 3.6 Tool post The tool post as in fig 3.6 is located on the top of the compound rest to hold the tool and to enable it to be adjusted to convenient working position [11].

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3.1.8 TOOL BIT & TOOL HOLDERS A tool holder as shown in the fig 3.7 is small piece of cutting material having a very short shank which is inserted in a forged carbon steel tool holder and clamped in position by bolt or screw [6].

Fig 3.7 Tool holder A tool tip may be of solid type or tipped one according to the type of cutting tool material. The common type of tool holder using HSS tool bit. The tool bit is inserted in a slot set at angle of 15 to the base. This inclination reduces the effective clearance angle and increases the top rake angle by 15. 3.2 WORKING OF THE MODERN CUT-OFF MACHINE

Fig 3.8 Modern cut-off machine

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Modern cut-off (MCO) machine as shown in fig 3.8 is manually operated machine. In which three operations can be performed, they are parting, boring and chamfering. The parting tool is placed vertically in machine and the boring tool is placed at an angle of 45 deg in the machine at the left side of the machine and the chamfering tool is placed to the right of the machine at an angle of 45 deg. The first operation in the MCO machine is either boring or chamfering operation. Then finally the parting operation is to be done. The rotating spindle speed of the machine is 700r.p.m.Various kind of hydraulic connections are made to operate the MCO machine suitably [8]. 3.3 PROBLEM IDENTIFICATION What is the problem? The problem at present is the tool breakage which is occurring often during the parting-off operation. The tool which currently used is already shown in the picture.1. The tool which is available at present can effectively part-off the grade C, T11, T22 but not the T91 as it is a harder grade of tube. So we have to modify the parting tool holder with the available resources. Here we have the tabulation for number of cuttings made by each tool before it is getting damaged and these readings are taken before any modification has been made. What is the expected outcome? The expected outcome of the project is the improvement in the number of cuttings made per shift thus the production is improved. Before modification Table 3.1 Before modification TOOLS FOR DIFFERENT TUBES 1 (Grade C) 2 (T 91) 3 (T 11) 4 (T 22) AVERAGE GRADE NO. OF CUTTINGS MADE ( per shift ) 254 53 264 267 210

The various factors which affect the tool life are spindle speed, wedge angle and flank thickness. We altered the working conditions according to each case and tabulated the
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number of cuttings made during each alteration. We have made calculations for the readings which are taken before any modification shown in the Table 3.1. Varying the spindle speed Table 3.2 Varying the spindle speed TOOLS FOR DIFFERENT TUBES 1 (Grade C) 2 (T 91) 3 (T 11) 4 (T 22) AVERAGE GRADE NO. OF CUTTINGS MADE ( per shift ) 221 97 243 203 191

Deviation: From Table 3.2 the experiment done by us shows decrease in the average cuttings when compared to the machine before modification. The deviation is by 19 cuttings less when compared. Increasing the wedge angle Table 3.3 Increasing the wedge angle TOOLS FOR DIFFERENT TUBES 1 (Grade C) 2 (T 91) 3 (T 11) 4 (T 22) AVERAGE GRADE NO. OF CUTTINGS MADE ( per shift ) 294 96 280 238 227

Deviation: From Table 3.3 the experiment done by us shows increase in the average cuttings when compared to the machine before modification. This deviation is by 17 cuttings more when compared.

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Increasing the flank thickness Table 3.4 Increasing the flank thickness TOOLS FOR DIFFERENT TUBES 1 (Grade C) 2 (T 91) 3 (T 11) 4 (T 22) AVERAGE GRADE NO. OF CUTTINGS MADE ( per shift ) 254 85 289 242 218

Deviation:

From Table 3.4 the experiment done by us shows increase in the average

cuttings when compared to the machine before modification. This deviation is by 8 cuttings more when compared. Therefore we identify that few tools can withstand more than 200 cuttings but few gets damaged by 50-90 itself so we decided to alter the parting tool holder with an insert type of parting tool so that it gives more stability for the parting tool holder and the tool post to withstand higher grade tubes also. We must not change the reference of the parting tool holder as the fitting part remains unaltered. 3.4 OUR MODIFICATION We have modified in the parting tool holder post at the parting tool holder region. We take the same dimension of the present parting tool holder and we make a change by making insert type of tool to be fit into the tool holder rather the current setup. In the current setup a plate is attached tightly by means of screws and the tool is held up to do the parting operation effectively [8]. The tool holder which we are using in our modification is 25*25mm2. Cubic rod which has the insert type of carbide tip at its end. The main advantage is that stability will be increased as for this purpose only the insert type of tool holder has been manufactured. And also the cost of the tool can be reduced by a greater extent as the entire tool has to be changed in the previous case.

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3.5 PARTING TOOL HOLDER POST BEFORE MODIFICATION

Fig 3.9 Parting tool before modification Parting tool which is currently available has been shown in the above Figure 3.9. The parting tool holder uses the tool which is shown in figure.2.1.The parting tool is used to part-off various grades of tubes namely Grade C, T11, T22 and T91. The tool gets damaged often when it parts off the T91 tube. The current model is to be modified with insert type of tool, in this type of tool post a tool holder is to be used which is available already. The tool is getting damaged often and so we have tabulated the number of cuttings made in experiments we performed. The experiments performed include varying spindle speed, varying the wedge angle and increasing the shank thickness. We decide to modify this setup with an insert type of parting tool holder which is available in the tool crib. A tool tip may be of solid type or tipped one according to the type of cutting tool material. The common type of tool holder using HSS tool bit. The tool bit is inserted in a slot set at angle of 15 to the base. This inclination reduces the effective clearance angle and increases the top rake angle by 15. So

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in grinding the tool this 15 is to be added to the actual clearance angle and deducted from the rake angle as discussed in [6]. 3.6 DESIGN PROCESS

Fig 3.10 AutoCAD diagram The figure 3.10 shows the AutoCAD diagram. We used AutoCAD 2010 software to create a model of the modification of the parting tool holder by taking its dimensions and reference from the machine catalogue. This modification developed by us can hold the 25*25mm2. Rod of parting tool holder. The dimensions are kept the same so that the reference does not change for our modified tool holder. Only change is done at the tool holder which is indicated in the fig.3.6. The square type of modification which is to be done has been shown in the above AutoCAD diagram. 3.7 FABRICATION PROCESS The fabrication process in the modification of the parting tool holder is performed in a block of cast iron and making a gas cutting of the required dimensions by leaving an allowance of
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10mm in all directions. These are the operations involves in the fabrication process of the tool post as discussed in [3], namely: (i) (ii) (iii) (iv) (v) Drilling, Milling, Slotting, Tapping, Surface grinding.

Drilling is the operation of producing a cylindrical hole in a work piece by the rotating cutting edge of a cutter known as the driller [4]. Drilling in lathe is performed by anyone of the following methods: a. The work piece is revolved in a chuck or a faceplate and the drill is held in the tailstock drill holder or in a drill chuck. Feeding is affected by the movement of the tailstock spindle. This method adopted for drilling regular shaped workplaces. b. The drill is held and driven by a drill chuck attached to the headstock spindle, and the work is held against the pad or crotch movement of the tailstock spindle. Work pieces of very irregular shape which cannot be accommodated on a chuck or faceplate are drilled by this method. Milling is the operation of removing metal by feeding the work against a working cutter having multiple cutting edges. It is performed by anyone of the following methods[9]: a. For cutting keyways or grooves the work is supported on the cross slide by a special attachment and fed against a rotating milling cutter held by a chuck. The depth of the cut is given by vertical adjustment of the work provided by the attachment. b. The work may supported between centres and held stationary. The attachment mounted on the carriage drives the cutter from an individual motor. The feeding movement is provided by the carriage and the vertical movement of the cutter is arranged in the attachment. A number of grooves on the periphery of the work may be cut by rotating the work by a fixed amount and machining it against the cutter. Slotting falls under the category of reciprocating type of machine tool similar to shaper or a planer [14]. In a slotter the ramp holding the tool reciprocates in a vertical axis. The slotter is used for cutting grooves, keyways and slots of various shapes, for making regular and irregular surfaces both internal and external, for handling large and awkward work pieces, for
27

cutting internal or external gears and many other operations which cannot be conveniently machined in any other machine tool. Tapping is the operation of cutting internal threads of smaller internal diameter using multipoint cutting tool called the tap. In a lathe the work is mounted on chuck or on a faceplate and revolved at very slow speed. A tap of required size is held on special fixture is mounted on the tailstock spindle. Axis of the tap should coincide exactly with the axis of the work. The tap will automatically feed into the work with the help of special fixture [11]. Surface grinders are employed to finish plane or flat surfaces. They are also capable of grinding irregular, curved, convex, and concave surfaces. Conventional surface grinders may be divided into two main classes: one class has reciprocating tables for work ground along straight lines while the other covers the machines with rotating work tables for continuous rapid grinding [4]. The fabrication process involves the following set of procedures: The whole tool post was gas cut in a CNC gas cutting machine in the industry. 135mm plate of SA299 material was chosen for this purpose. Co-ordinate dimension were put in the gas cutting plant keeping 10mm allowance on all sides. The gas cut profile was moved to tool room for final machining. This profile was programmed in a CNC vertical machining centre and was machined to remove the excess material which was given during gas cutting. After machining it to the profile, the tool post was sent to the marking table. Key slot and tapped holes used for grinding and clamping the tool post and the machine were marked. The slots for holding the parting tool were also marked on the tool post. The key slot of 19mm was machined on a vertical milling machine. The slot for holding the parting tool was machined in a slotting machine. For slotting, a hole of diameter 20mm was drilled on the required portion of the tool post and was enlarged to the required size of the tool shank. All the holes were put on the tool post in a drilling machine of diameter 10mm; all the holes were tapped of M12 size.

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3.8 MODIFIED MODERN CUT-OFF PARTING TOOL HOLDER

Fig 3.11 Modified parting tool holder The modified parting tool holder is shown in the Figure 3.11. This tool holder is designed by procedure which was explained briefly above pages. The finally finished work piece which has under gone drilling, milling, slotting, tapping and surface finishing has been shown in the above diagram. From this picture we can clearly notice the modification which has been done in the parting tool holder part of the parting tool post. The tool holder which is to be used in the parting tool holder is already available in the tool crib and we use this particular tool holder so that it gives high stability and can withstand high tolerance. It is an insert of tool holder, in which the tip is made of CARBIDE [8]. A tool tip may be of solid type or tipped one according to the type of cutting tool material. The common type of tool holder using HSS tool bit. The tool bit is inserted in a slot set at angle of 15 to the base. This inclination reduces the effective clearance angle and increases the top rake angle by 15. So in grinding the tool this 15 is to be added to the actual clearance angle and deducted from the rake angle as discussed in [6].

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3.9 TOOL HOLDER WHICH IS USED AFTER MODIFICATION

Fig 3.12 Tool holder which is used after modification A tool holder which is used after modification is as shown in the fig 3.12, it is small piece of cutting material having a very short shank which is inserted in a forged carbon steel tool holder and clamped in position by bolt or screw [6]. A tool tip may be of solid type or tipped one according to the type of cutting tool material. The common type of tool holder using HSS tool bit. The tool bit is inserted in a slot set at angle of 15 to the base. This inclination reduces the effective clearance angle and increases the top rake angle by 15. The table which has been taken shows excellent and brilliant improvement of production in the Modern Cutoff machine. The average cutting which has been done in the previous cases never exceeds 150. But now the average cutting has become 1395. The main and remarkable increase in production which satisfied many of the supervisors and our guide was the cutting done in the T91 grade of tube, as it was giving many tool damages for each 50 cuttings. But now it has crossed over 500 and more cuttings.

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Tabulation taken after the modification Table 3.5 After modification TOOLS FOR DIFFERENT GRADE TUBES NO. OF CUTTING MADE BEFORE MODIFICATION (per shift) 1 (Grade C) 2 (T 91) 3 (T 11) 4 (T 22) AVERAGE 254 53 264 267 210 NO. OF CUTTING MADE AFTER MODIFICATION (per shift) 1766 786 1431 1597 1395

Deviation is 1185 cuttings more when compared to old parting tool holder as from Table 3.5 This Table 3.5 which has been taken shows excellent and brilliant improvement of production in the Modern Cut-off machine. The average cutting which has been done in the previous cases never exceeds 150. But now the average cutting has become 1395. The main and remarkable increase in production which satisfied many of the supervisors and our guide was the cutting done in the T91 grade of tube, as it was giving many tool damages for each 50 cuttings. But now it has crossed over 500 and more cuttings. 3.10 TOTAL COST ESTIMATION 3.10.1 CALCULATION OF MACHINING TIME FOR EACH OPERATION 3.10.1.1 FOR MILLING Cutting a channel of 19mm wide and 10mm deep along 117mm length. Added table travel= Ddas discussed in [5]

Where, D=diameter of cutter=80mm d=depth of cut=10mm Added tool/table travel=10mm Total tool/table travel = length of job + added tool table travel =117 + 10
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=127mm Rpm of cutter, N S N = 1000 * S/ ( ) (3.1)

= Cutting velocity in m/min; D=Cutter diameter in mm. = 1000*25/ (3.14*80) = 99.52rpm~100rpm

Time for cutting, T = Total table travel / (Feed/rev* rpm) = 127/ (0.25*100) = 5.08min Set-up time = 30 sec

(3.2)

Therefore, total time for milling = 5.08 + 0.30 = 5.38 min. 3.10.1.2 FOR DRILLING Time for drilling = depth of hole to be produced/((Feed/rev) * (r.p.m)) from [5] = L/ (f * N) (i) For tool post holes: D=12mm; L=30mm; S=75m/min; f=0.175mm/rev Using Eqn. (3.1), N = 1000 * S/ ( ) (3.3)

= 1000 * 75/(3.14*12) =1990.45rpm Length of cut, L Time for drilling, T = depth of hole= 30mm = L/ (f*N) = 30/ (0.175*1990.45) = 0.086 min
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for 8 holes,

0.086*8

= 0.688 min.

Setup time for drilling 1 hole = 30 sec Setup time for 8 drilling holes = 4min Therefore total time for drilling 8 holes = 4mins + 0.688 = 4.68 min (ii) For tool holder holes: D=12mm; L=11.75mm; S=75m/min; f=0.175mm/rev Using Eqn.(3.1), N = 1000 * S/ ( ) = 1000 * 75/ (3.14*12) =1990.45rpm Length of cut, L Using Eqn.(3.3), Time for drilling, T = depth of hole = 11.75mm = L/ (f*N) = 11.75/ (0.175*1990.45) = 0.034 min For 6 holes, 0.034*6 Setup time for drilling 1 hole Setup time for 6 drilling holes = 0.204 min = 30 sec = 3min

Therefore total time for drilling 6 holes = 3 + 0.204 = 3.204 min Therefore, the total drilling time = 4.688 + 3.204 3.10.1.3 FOR SLOTTING Plate size K F = 50*49.5mm; S= 6m/min = Return time/ Cutting time = 0.25 = 2mm/stroke as from [5]
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= 7.892 min.

= Ratio of return time to cutting time.

Clearance at each end = 5mm Length of stroke = length of plate + clearance on both side = 50 + (2*5) = 60mm T = L (1+K)/ (S*1000) * w/f = 60(1+ 0.25)/ (6*1000) * 49.5/ (2) = 0.0125 * 24.75 = 0.31 min = 18.6 sec Setup time for slotting = 45 sec Total time for slotting = 45 + 18.6 = 1.36 min 3.10.1.4 FOR TAPPING (i) For tool post holes as from [5]: D= 12mm; pitch= 4mm; L= 30mm; S= 8mm/min Using Eqn.(3.1),N = 1000 * S/( ) (3.4)

= 1000 * 8/ (3.14*12) = 212.31rpm T = L + (D/2)/( Pitch*rpm) = 30 + (12/2)/ (4*212.31) = 0.042 min Return speed = * cutting speed Return time = * tapping time = * 0.042 = 0.028 min

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Total time

= 0.028 + 0.42 = 0.07 min

For 8 holes,

0.07 * 8

= 0.56 min = 10 sec = 80 sec = 1.2 min = 1.2+0.56 = 1.76 min

Setup time for 1 hole Setup time for 8 holes Total setup time Total time for tapping

(ii)

For tool holder holes: Diameter of tap used, D=12mm; pitch= 4mm; Length of tapped portion, L=12mm;

S=8mm/min Using Eqn. (3.1), N = 1000 * S/ ( )

= 1000 * 8/ (3.14*12) = 212.31rpm T = L+ (D/2)/ (Pitch*rpm) = 12+ (12/6)/ (4*212.31) = 0.016 min. Return speed = * cutting speed Return time = * tapping time = * 0.016 = 0.0106 min T = 0.0106 + 0.016 = 0.0266 min

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For 6 holes,

0.0266*6

= 0.1596 min = 10 sec = 80 sec = 1.2 min

Setup time for 1 hole Setup time for 8 holes Total setup time Total time for tapping tool holder holes Total time for tapping

= 1.2 + 0.0266 = 1.226 min = 1.76 + 1.2266 = 2.986 min

3.10.1.5 FOR GRINDING Total grinding time = (length of cut* no. of passes)/ ((Feed/rev)*(rpm)) = (606*4)/ (10*120) = 2.02 min (No. of passes is approx. = 4) as from [5] Setup time = 20 sec = 0.33 min = 2.35 min (3.5)

Total time for grinding = 2.02 + 0.33 3.10.1.6 FOR GAS CUTTING Total length of gas cutting Time taken to cut the 238*166mm plate

= 606mm as from [5]. = (length/2) * no. of plates cutting = (606/2)* 1 = 30.3 min

Setup time Total time for gas cutting

= 10 sec = 0.1667 min = 30.3 + 0.1667 = 30.46 min

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3.10.2 CALCULATION OF TOTAL MACHINING COST Table 3.6 Calculation of total machining time OPERATION NO. min 1 2 3 4 5 6 Gas cutting Drilling Milling Slotting Tapping Grinding 30.46 7.892 5.38 1.36 2.986 2.35 Hour 0.5076 0.1315 0.0896 0.0226 0.0497 0.039 150 300 400 200 100 100 TOTAL OPERATION TIME MACHINE HOUR RATE (Rs.) 76.14 39.45 35.84 4.53 4.976 3.9 164.84 COST (Rs.)

The Table 3.10.2 shows the calculation of total machining time and to find the total machining time. 3.10.3 LABOUR COST The labour charges are Rs.50/hr. The total machining time is 0.6541 hr. Therefore the labour charges are 0.6541*50 3.10.4 PURCHASE COST 1kg cast iron We have used 4kg block, so cost of cast iron Cost of new parting tool holder Total purchase cost Therefore the total cost of the parting tool holder = Rs.500 = Rs.2000 = Rs.4000 = Rs.6000 = machining cost + labour cost + purchase cost = 164.84+32.71+6000 = Rs.6197.55~Rs.6198
37

=Rs.32.71

Totally the amount spent for fabrication

= Rs. 6198.

3.10.5 CALCULATION FOR THE RECOVERY OF INVESTED AMOUNT No. of cuttings made per shift (old) No. of cuttings made per shift (new) Cost of one old parting tool No. of old tool getting damaged/shift No. of old tool damaged/day Cost spent in tool wastages/day = 300 = 1,200 = Rs.63 =2 =6 = 6 * 63 = Rs.378 Cost saved in tool wastage by old tool Labour charges/shift Labour charges saved due to modification Therefore, Total charges saved per day = Rs.378 = Rs.100 = Rs.300 = Rs.378+Rs.300 = Rs.678 Cost of carbide insert Net charges saved = Rs.600 = Rs.678 - Rs.600 = Rs.78/shift. Amount saved per day = Rs.78 * 3 = Rs. 234/day. Number of days required for recovering the invested amount Payback time (or) = 6198/234 = 27days

Therefore within 27 days the invested amount can be taken back.

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3.11 ADVANTAGES OF MODIFIED PARTING TOOL HOLDER (i) (ii) (iii) (iv) (v) The whole tool post need not be changed in modified parting tool holder. Increase in production. Greater output is obtained in comparatively lesser loss. Tool change time is reduced as the tool lasts longer. The life of the cutting tool may be considerably enhanced this reduces cost of replacement and time for resetting. (vi) (vii) New holder is used to support for insert type of shank. Easy to mount into the holder.

(viii) Availability of inserts in plenty. (ix) (x) Rigidity is more. Output percent value is high.

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CHAPTER 4 CONCLUSION Thus, we definitely conclude that the modification which is done by us show increase in production and decrease in the loss of materials. This modified parting tool holder operation does not depend mainly on the skill of the labour so it can give same output at any worker working in this machine. We have also estimated the number of days required to recover the invested amount. 4.1 RESULT Modification cost Average increase in number of cuttings Payback period = = = Rs.6198 1185 27 days

4.2 SUGGESTIONS FOR FURTHER IMPROVEMENT The suggestion which we provide for further improvement of modification is to introduce a new modified CNC machine, so that the accuracy can be improved up to 0.08mm in the operations performed in the machine.

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REFERENCES [1] Balasubramaniam, M; Jayabalan, V; Balasubramaniam, V; Manufacturing science; J of Manufacturing Science & Engineering: ASME Trans, v 131, n6, pp.26, Dec 2009 [2] Fripp, D; Metalworking Production, v 154, n6, pp.116, Sep 2010 [3] Govindan, P; Josh, S.S; Machine tools; Intl. J of Machine Tools & Manufacture, v 50, n5,pp.68, May 2010 [4] Hajra Choudhury, S.K; Hajra Choudhury, A.K; and Nirjhar Roy, Elements of workshop technology-Vol. ii machine tools.-2007 [5] Jayakumar, V; Process planning and cost Estimation; Process Planning and Cost Estimation- fifth edition-2010 [6] Juneja, B.L; Manufacturing process; Manufacturing Process, theory and practice. Sehgal educational consultants & Publishers (P) ltd [7] Kalvoda, T; Hwang, Y.R; Machine Tools; Intl. J of Machine Tools & Manufacture, v 50,pp.234, n5, May 2010 [8] Krummrich, K; Van Busknik, G; Machine Design, v 76, n9, pp.456, May 2004 [9] Kuz, K; Gaskin, ES; Production & Process planning; J of Manufacturing Science & engineering; ASME Trans, v131, n6, pp.345, Dec 2009 [10] Mehta; Production engineering; Metal working production, v 154, n6, pp.234, Sep 2010 [11] Nassar, SA; Abboud, A; Machine Design; J of Mechanical Design; ASME Trans, v 131, n12, pp.54 Dec2009 [12] Pan, E; Ye, L; Shi, J; Chang, TS; Manufacturing Science; J of Manufacturing Science & engineering; ASME Trans, v131, n6, pp.123, Dec 2009 [13] Pandey, P.C; and Shan, H.S; Modern Machining Process- Hindustan Machine Tool, Production Technology- Tata McGraw Hill publishing; New Delhi [14] Vijaya Sai, N; Komaraiah, M; Sita Rama Raju, A.V; Manufacturing Process; Manufacturing Technology Today, v 10, n1,pp.143 Jan 2011

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