ECWS Internship Programe (Repaired)

Bahir Dar University
Bahir Dar Institute of Technology

Faculty of Mechanical and Industrial Engineering
Mechanical Engineering program
Internship Report
Project Title: Design and simulation of milling attachment on lathe

Hosting Company: Ethiopian Construction Works Corporation
ID No.
By: Habtamu Geremew 0600871
Fiker Bayleyegn 0600745
G/Mariam Tariku 0600319
Mentor: Mr. Wudu Wondmgegn (Msc)
Company Supervisor: Mr. Adane Belachew
June 16, 2017

INTERNSHIP AND PROJECT REPORT AT ECWC 2009E.C
DECLARATION
We hereby declare that this work, which is being presented on the report within the internship, at
Ethiopian Construction Works Corporation for the partial fulfillment of internship program. The
report is carried out from feb.15, 2017 to jun.15, 2017 under the supervision of Mr. Wudu
Wondmgegn, who is instructor in Bahir Dar institute of technology; Mechanical Engineering
department in Bahir Dar University, is the result of our own report except as cited in the
references.
All relevant resources of information used in this paper have been duly acknowledged.
Name of student Signature Date
Habtamu Geremew _____________ _____________

Fiker Bayleyegn _____________ _____________
G/Mariam Tariku _____________ _____________
This is to certify that the above statement made by the candidate is correct to the best of my
knowledge and belief. This report has been submitted for presentation with my approval.
Name of school adviser signature Date
_________________________ ______________ __________
June 16, 2017
Bahir Dar Institute of Technology; Ethiopia i

Acknowledgments
First, we would like to thank our almighty God for everything. Our special thanks is perceive for
the workers who helped us in gathering relevant information for performing our internship
program and we would like to thank the personnel of the company who directed us how to apply
tasks and communicate in a good way with each other. Our gratitude also goes to our mentor Mr.
Wudu Wondmgegn, who directs us how to perform work in the company and who gave us
supporting ideas and advise from the beginning up to the end of this work.
Bahir Dar Institute of Technology; Ethiopia ii

Executive Summary
This report contains the history of Ethiopian Construction Works Corporation and its main
products and services as well as its main customers and the main goal, mission, vision and values
of the company. Including the organizational structure and its workflow, it contains the
challenges that we have faced and measurements under taken for them in the internship program.
In addition, it includes benefits that we have gained in terms of improving our practical skills,
upgrading theoretical knowledge, improving personal communication skills and improving
leader ship skills. Moreover, we explore problems and try to give solutions; from which we
design milling attachment on lathe to increase working capacity and maintenance of same
machine parts. Finally, we gave recommendation and conclusion for the entire internship
program experience and project work.
Bahir Dar Institute of Technology; Ethiopia iii

Table of Contents
CHAPTER ONE
1. Company Background ................................................................................................................ 1
1.1 History of the company......................................................................................................... 1
1.2 Main Services and end users of these services ..................................................................... 2
1.3 Organizational Structure ....................................................................................................... 3
1.4 Work Flow of the Company ................................................................................................. 4
CHAPTER TWO
2. Overall Internship Experience .................................................................................................... 5
2.1 Over all Internship Benefit.................................................................................................... 5
2.2 Section of the company we have been working.................................................................... 5
2.3 The work tasks we have been executing ............................................................................... 6
2.4 Engineering Techniques and Methods used ....................................................................... 11
2.5 Engineering Tools ............................................................................................................... 11
2.5.1 Hand tools .................................................................................................................... 11
2.5.2 Important Power Tools ................................................................................................ 13
2.6 Major challenges and problems while performing the work tasks ..................................... 14
2.7 Measures to overcome these challenges and problems....................................................... 15
2.8 Gain from improving Practical Skills ................................................................................. 15
2.9 Theoretical knowledge upgrading....................................................................................... 15
2.10 Team working skills .......................................................................................................... 16
2.11 Advantages on leadership skills ........................................................................................ 16
2.12 Work Ethics Skills ............................................................................................................ 16
2.13 Entrepreneurship skill ....................................................................................................... 16
2.14 Interpersonal communication skill.................................................................................... 17
2.15 Recommendation and Conclusion .................................................................................... 17
Bahir Dar Institute of Technology; Ethiopia iv

2.15.1 Recommendation ....................................................................................................... 17
2.15.2 Conclusion ................................................................................................................. 17
CHAPTER THREE
3. Project Work ............................................................................................................................. 18
3.1 Summery of the Project ...................................................................................................... 18
3.2 Literature review ................................................................................................................. 19
3.3 Problem statement and justification .................................................................................... 20
3.4 Objective ............................................................................................................................. 21
3.4.1 Main objective ............................................................................................................. 21
3.4.2 Specific objectives ....................................................................................................... 21
3.5 Methodology ....................................................................................................................... 22
3.6 Selection of material ........................................................................................................... 23
3.7 Component Design.............................................................................................................. 23
3.7.1 Predicted sketch design ................................................................................................ 23
3.7.2 Design of vise .............................................................................................................. 24
3.7.3 Dimension analysis of the main frame......................................................................... 34
3.7.4 Design of indexing mechanism .................................................................................... 35
3.8 Result and Discussion ......................................................................................................... 45
3.9 Manufacturing method and Cost Analysis .......................................................................... 50
3.9.1 Components manufacturing method ............................................................................ 50
3.9.2 Cost analysis ................................................................................................................ 51
3.10 Conclusion and Recommendation .................................................................................... 53
3.10.1 Conclusion ................................................................................................................. 53
3.10.2 Recommendation ....................................................................................................... 53
CHAPTER FOUR
Bahir Dar Institute of Technology; Ethiopia v
4. General Conclusion and Recommendation ............................................................................... 54
4.1 General Conclusion............................................................................................................. 54
4.2 General Recommendation................................................................................................... 54
References ................................................................................................................................. 55
Appendices ................................................................................................................................ 56
Data tables, part drawing, assemble drawing and explode drawing ..................................... 56
Bahir Dar Institute of Technology; Ethiopia vi

List of Tables
Table 1 overall flow of the design process ................................................................................... 22
Table 2 Result for the design ........................................................................................................ 45
Table 3 Estimated material volume for components .................................................................... 51
Table 4 Mechanical property of typical material .......................................................................... 56
Table 5 Diameters and areas of metric threads (adopted from shigley’s mechanical engineering
designs) ......................................................................................................................................... 56
Table 6 Recommended values of lead angle and pressure angle .................................................. 56
Bahir Dar Institute of Technology; Ethiopia vii

List of Figures
Figure 1 Organization structure ...................................................................................................... 3
Figure 2 Block diagram of workflow.............................................................................................. 4
Figure 3 Engine assembly [10]. ...................................................................................................... 8
Figure 4 Some of materials that we manufacture in ECWC: a) starter motor spacer b) dead center
taper c) pulleys d) center bolts and nuts e) adjuster screw ............................................................. 9
Figure 5 Maintenance of power hacksaw and shaper handle [10]. ............................................... 10
Figure 6 Engineering method [11]. ............................................................................................... 11
Figure 7 Hand tools [10]. .............................................................................................................. 13
Figure 8 Power tools [10]. ............................................................................................................ 14
Figure 9 Idealizations within sketch ............................................................................................. 24
Figure 10 Forces exerted on the clamp (vise jaws)....................................................................... 26
Figure 11 Square thread ................................................................................................................ 28
Figure 12 CATIA modeling of moveable jaw, adjuster screw, vise holder screw, socket ring
and lock pin ................................................................................................................................... 31
Figure 13 CATIA V5 modeling of fixed jaw and connecter(vise holder) .................................... 32
Figure 14 Component of vise holder/connecter: connecter bolt, nut and washer ......................... 34
Figure 15 Modeling of main frame ............................................................................................... 34
Figure 16 Worm & worm gear [6]. ............................................................................................... 36
Figure 17 Forces acting on worm teeth [6]. .................................................................................. 38
Figure 18 Modeling of worm gear and worm ............................................................................... 40
Figure 19 Gear housing................................................................................................................. 40
Figure 20 Loads acting on gear shaft ............................................................................................ 41
Figure 21 CATIA modeling of indexing plate, shaft and gear key .............................................. 43
Figure 22 Bearing for gear shaft ................................................................................................... 44
Figure 23 Assembly of milling attachement on lathe ................................................................... 47
Figure 24 FEA of vise on VON MISES stress and displacement................................................. 48
Figure 25 Finite Element Analysis of indexing mechanism ......................................................... 49
Bahir Dar Institute of Technology; Ethiopia viii

CHAPTER ONE
1. Company Background
1.1 History of the company

The Ethiopian Construction Works Corporation does not reach to the current position in one-step
and name. After Italy take out from Ethiopia the Imperial highway authority (IHA) was born by
proclamation number 115/1943E.C as Semi-Autonomous Agency. The objective to be
accomplished was portrayed by the word “the authority shall have the duty of developing and
maintaining the Highway System of our Empire”. Mr. Joneal Humbard, an American Engineer,
was named as the director of the Authority and a member of the board of Commissioners. The
Ethiopian Road Authority when established in 1943E.C as IHA had about 650 permanent
employees of which all supervisory personnel, engineers and majority of construction
equipments operators and machinist expatriates. The Alemgena Training Center was established
in 1956 and the center was the first of its kind in Ethiopia. During the military government, the
re-established Ethiopian Roads Authority includes the Rural Roads Department. After 1983E.C,
Ethiopia embarked on a compressive economic reform program putting in place the condition in
for a transition from command-based economy to market oriented one. The ERA was also
reestablished by proclamation No. 63/1985E.C with a view to providing a strong administration
under the leader ship of the board [1].
At the end of the Ethiopian fiscal year 2007, the federal government of the Democratic Republic
of Ethiopia announced the establishment of the Ethiopian Construction Works Corporation,
which is formed through the amalgamation of the former Ethiopian Water Works Construction
Enterprise and the Ethiopian Road Construction Corporation. The formation of the new
corporation indicates the strengthening of the competitive power and enhancement of operational
efficiency of the two former enterprises. Thus, it can be said that the corporation can have a
major impact in the construction industry in terms of both efficiency as well as competitiveness.
The Ethiopian Construction Works Corporation has been established for state-of-the-art
construction solutions.
Bahir Dar Institute of Technology; Ethiopia 1

1.2 Main Services and end users of these services

Among the services, the corporation provides the following:
 To engage in domestic and overseas construction works as a contractor, upgrading and

maintenance of roads, bridges, works relating to dams, irrigations, hydropower
generation, water supply systems, sewerage systems, drainage, deep water wells,
construction of buildings, airfields, railways, ports and other civil works.
 To engage in the assembling of construction equipments and machinery, manufacturing

spare parts, providing maintenance service, produce construction materials for its
activities, and sell them as may be appropriate.
 To acquire, own and administer irrigation dams, deep-water wells and water supply
canals.
 To produce qualified human resources with required discipline, number and quality for
the corporation by using its own training facilities or international researcher, educational
and training institutions [10].
Currently the corporation has three operational sectors, namely transport infrastructure
construction, water infrastructure construction, and construction machinery and equipment
management units. From which, Debre Markos Road Maintenance Project is one of its branch.
It has the following main services and works in the perspective of internship work:
 Manufacturing of spare parts

 Overhauling of engines, gearboxes
 Welding operations
 Body repairing
 Maintenance of construction equipments and machines like generators, compressors
 Servicing of cars
 Electric and Wood work
The end users of products from this company go to the public because end works of the company
on infrastructure to the community. The Debre Markos Road maintenance project district

maintains and services the company’s equipments and gain revenue from the main branch, which
it earns from infrastructure projects.
1.3 Organizational Structure
BOARD
GENERAL
MANAGER
Legal &
Protection of Internal Audit service
Right-of-Roads
Information &
Public Relation
Service
Operations Department Engineering & Regulatory Human Resource &

Deputy General Department Deputy Financial Department
Manager General Manager Deputy General Manager
Civil Contract Finance Division

Procurement service Administration
Human Resource
Own Force construction Development
Deign, Research &
Department Division
Network Management
Division
Equipment & supply
Division Personal
Administration
Planning & Division
Own force Programming Division
maintenance District
Figure 1 Organization structure

1.4 Work Flow of the Company

When equipment needs maintenance, it follows common way. The first man who recognizes the
problem could be driver, operator, or coordinator. Thus, the problem will be report to the office.
It is noted that the maintenance have flow of Repair for Service (RFS) and shop repair order
(SRO).Then the following shows the process:
Driver or Operator
Reception and
inspector
Heavy duty Machining

Finance division Garage and
maintenance room
coordinator
Electrical Light duty Wielding

shop Garage room
Servicing
rooms
Figure 2 Block diagram of workflow

CHAPTER TWO
2. Overall Internship Experience
2.1 Over all Internship Benefit

The internship helps us to develop the practical knowledge that we have learned theoretically in
the previous semesters. Without practice, it is difficult to apply our theoretical knowledge to
solve problems of the community and participate in the Engineering areas. The internship helps
us to acquire deep practical knowledge. Additionally it helps us to rehearse the theoretical
concepts that we get in the university training program.
Moreover, we have gained the following benefits:
 Entrepreneurship skills
 Interpersonal communication skills
 Leadership skills and
 Teamwork skills
Generally, the internship plays important role to create skillful generation that helps us to build
modern technology in the future.
2.2 Section of the company we have been working

The company has different working section. Even if it has different section, we recommended to
work based on our mission.
Particularly we worked in:
 Machining section
 Heavy duty (power train and engine servicing)
 Light duty mechanic section
 Body room
 Welding section and
 Electrical shop

2.3 The work tasks we have been executing

After we join the Ethiopian Construction Works Corporation we have done a valuable works for
the company with workers and alone. From those works, the following are the major:
1) Engine maintenance work
This section helps us to apply our theoretical concept of thermodynamics and IC engine. From
those the following are major engine concepts that we see besides maintaining an engine.
 Number of cylinder and arrangement of them

 Arrangement of valve and valve trains with firing order
 watch over of the diesel and gasoline engine
 Arrangement of engine components
 Method of ignition
 Turbocharger arrangement
 Electrical and rear wheel drive (RWD) verses front wheel drive (FWD).
The flow of engine maintenance can be seen as follow:
A) Problem identification
Because an engine has many moving parts and it is the heart of a machine or vehicle,
preventative maintenance is needed in order to maximize its power and efficiency. However, if it
is not possible, corrective maintenance is necessary. In every maintenance work, the first task is
problem identification. Standard maintenance items include observation the engine oil and filter,
air filter, engine coolant, spark plugs, and drive belts. The others to be observed may be the
condition of color of smoke, which indicate status of lubrication, cooling system and working
condition.
B) Possible over look
Once the problem has been identified, a possible solutions and method has been stated, goes up
to the final step of engine maintenance. Some of the problems and possible solution as follows:
 Plan work procedures, using manuals and charts

 Inspect and lubricate engines and parts during routine service

 Follow checklist of potential trouble spots. This includes belts, hoses, spark plugs,
brakes, and fuel systems
 Get descriptions of cars' symptoms from customers or service estimators
 Examine cars, using a systematic approach to diagnose problems. May be drive test.
C) Disassembly, repair, modify and replacing of parts
The next step is to decide if total disassemble of the engine is necessary followed by its
detachment from main body part. Steps followed when disassembling the engine by using
equipments such as different sizes of wrench, torque wrench, Allen Keys and belt wrench. After
disassemble the engine, separate parts replaced or repaired.
If the part exists in the store, it will be delivered to the mechanic, and replaced in place of the
defected parts. For Parts that require repair or modification, send to the machine shop. Thus,
from which we have done during maintenance of engine are:
 Clean spare parts using naphtha

 Replacement of gaskets or use maker as gasket if it is not available
 Check and replaces piston cap, bearing, snap rings, seal and liner
 Grinding of valves, valve timing and valve space adjustment
 Repair of radiator, starter motor, manifolds, and injector, and
 Maintain fuel pump, oil pump, water pump, filter of oil and fuel, hoses and replacement
of oil.
D) Assembly and check up
After the process of maintaining finished the engine is assembled based on the recommended
congregation criteria like basic torque adjustment. In assembly process, there are different work
tasks to do. From those filling of oil to the oil pan, filling of the fuel filter and priming it, proper
hose adjustments are the majors. Allows engine operation in different operating regimes and
offers measurement of several physical variables associated with it. After the engine is tasted on
the test stand, it is assembled on the vehicle or machine. Finally, a drive or operation test takes
place.

Figure 3 Engine assembly [10].
2) Manufacturing of spare parts
The machining process can be machining a part to modify for changing standard and assembled
to the intended vehicle or manufacture a new component based on the specification. In the
company we have been participate in following works:
 Manufacturing of spacer for starter motor

 Manufacturing of center bolts, bridge assembly bolts, torque rod bolts, nuts, washers,
connector studs, pins and screws
 Manufacture of tandem bushing, brake bushing, and torque rod bushing
 Drilling operation of life spring and modify life spring
 Rethreading operations of bolts and nuts,
 Manufacturing of some spare parts of machine like dead center tapers, spacer and handle
for shaper machine
 Design and manufacture pipe fittings
 Manufacture of pulleys, Guide rails, hand brake, pump valves, tanker cups and shafts and
 Facing brake plates, electrical hacksaw operations, press operations.

(a) (b)
(c) (d)
(e)
Figure 4 Some of materials that we manufacture in ECWC: a) starter motor spacer b) dead center
taper c) pulleys d) center bolts and nuts e) adjuster screw

3) Misalliances work tasks
The following are major areas that we participate in addition to the above:
 Maintenance of gearbox by shaft manufacturing, gear and synchronizer ring changing,
lubrication
 Body maintenance and welding processes
Figure 5 Maintenance of power hacksaw and shaper handle [10].

 Radiator overhaul and air filter cleaning
 Tire and its attachments maintenance
 Repair of transmission including universal joint

 Repair of generators and

 Maintenance of machines like shaper machine and electric hacksaw has our valuable
effort.
2.4 Engineering Techniques and Methods used

We use the following engineering
gineering techniques while performing our work tasks:
 Data gathering and statistical manipulation

 Motion study and work design
 planning and
 Work implementation.
Figure 6 Engineering method [11].
2.5 Engineering Tools
2.5.1 Hand tools

1. Wrenches: It used to turn nuts, and bolts. Open end,
d, box (closed) and combination
wrenches.

2. Ratchets: used to remove nuts from the joint and tighten nuts with bolts in one direction
torque. It has detachable parts called, socket and extension.
3. Socket wrench set: The socket wrench used in combination with different types of handles
and extension bars for safe and speedy loosening and tightening in difficult positions.
4. Chisel: are driven by hammer to cut or smooth metal by hammering.
5. Screwdriver: used to drive or turn screws. It can be flat or Philips head.
(a) Open end wrenches (b) Closed end wrenches (c) Combination wrenches
(d) Ratchets: extension &sockets (e) Screw driver (f) Cutter/pliers

(g) Torque wrench (h) Standard hand tool kit
(i) Die and pitch gage

Figure 7 Hand tools [10].
6. Torque wrenches: used to tighten bolts and nuts with proper tightening torque.
7. Adjustable wrench: has a jaw that can be adjusted to various sizes and used to tighten and
remove different size bolts and nuts.
8. Pliers (pinesaps): used to grip, twist and cut wire.
9. Taps and dies: for making internal and external threads. Additionally we use reamer, hand
hacksaw, caliper, bench vise, belt wrench, and hummer.
2.5.2 Important Power Tools

1. Air compressor: driven by an electric motor and used to compress air.
2. Hydraulic jack: It used to carries the body of cars during service.

3. Machine: lathe, shaper, press, drilling, milling, power hacksaw and grinder.
(a) Machines in shop (lathe, power hacksaw, shaper, milling, press)
(b) Air compressor (c) Oxyacetylene welder
Figure 8 Power tools [10].
2.6 Major challenges and problems while performing the work tasks
 Problem on communication with workers
 Problem of getting trust when we try to maintain or manufacture by our own
 Unwilling of the workers to show due to misunderstanding of us

 Being unfamiliar to the machines and works for some time

 Getting of malfunction machine
 Challenges of working conditions like no safe working area
 Luck of professional assistance or coordinator who assists us when we are in difficulty
 Problem of kaizen, and
 The language they use for naming Engineering tools and vehicle components.
2.7 Measures to overcome these challenges and problems

 They know English translation name for tools with italic, we asked to tell in English.
 For breaking there misunderstanding, we try to show our good perspective to them.
 For getting trust, we try to show our ability with concept and practice.
 Through process, we learn those unfamiliar machines by overlooking and asking the
operators.
 Finally, we design a milling attachment on lathe to solve problem of milling to the
company.
2.8 Gain from improving Practical Skills

In terms of improving our practical skill, we have gained the following benefits:
 Develop our skills by relating the theory with the practical knowledge,
 Train how to search problems from vehicles using different browsing method,
 Train how to maintain vehicles and machines.
 Improve our ability in machine work.
2.9 Theoretical knowledge upgrading

Certainly, this internship helps us to upgrade our theoretical knowledge. Even if we gain
theoretical concept in university education curriculum, we acquired extra knowledge in the
internship program. The complex ideas that we have learned theoretically earlier also clarify and
we have understood it easily. Thus, it helps us to rehearse and improve the previous theoretical
awareness.

2.10 Team working skills

In terms of improving our team working skills, we got the advantages in which working together
is much more productive than working individually. Because when we do the practical activities
in a team, we will be efficient due to sharing ideas among the members.
Therefore, the internship program contributes a lot in making us to work projects in-group. It
also helps to be sociable and makes to take the ideas of others in order to be successful.
2.11 Advantages on leadership skills

It is known that leader is a person who has strong principles, courage who dedication to a clear
vision, knowing a mission and fulfilling responsibility. We improve our leadership skill by
taking the following activities of the leader.
 Encourage and motivate workers to do their work tasks

 Communicate with all workers without any forced action
 Listen problems and focus on its solution and
 How to Control works
2.12 Work Ethics Skills

In work place, there are many behavioral responsibilities, which need to fill full.
 How to be punctual
 Except for special cases absence is forbidden
 Respect for others and positive communication
 Accountable
 Gain basic understanding about industrial psychology in ethical way
 Committed for work and
 Create good atmosphere to smooth relation with other partners.
2.13 Entrepreneurship skill

Entrepreneurs are people who are able to develop new business and affect the overall condition
of the global economy.

We have gained benefits in terms of developing entrepreneurship skills in that the internship
program helps us to increase our attitude to be creative and innovative through practical
knowledge. It also helps us to develop how new problems get solution and how to be effective on
this outcome in developing business.
2.14 Interpersonal communication skill

We improve this skill by making smooth relation with workers and developed interpersonal
communication skills. Thus, we gain the ability to
 Speak clearly and confidentially,

 Listen and understand workers’ idea and
 Give and convince workers to solution for a problem.
2.15 Recommendation and Conclusion
2.15.1 Recommendation
The workers or employers are facing with many problems. Therefore, the company should be
active to minimize the problems that we have explained before. The company also does not use
modern technologies to solve these problems. We recommend adopting new technology is better.
The company should train employers to follow manual procedures and techniques when they
give service.
The coordinators should have full of strength to control the employers and the intern students.
Most of the times they forget to control them and even they do not give directions to the intern
students without the questions from the trainer.
2.15.2 Conclusion
The internship program in Ethiopian Construction Works Corporation helps us to gain vast and
deep practical knowledge and gains skills on entrepreneur, leadership, interpersonal
communication and teamwork. It helps us to have full of confidence to do the practical activities
without doubt. We conclude that the internship program is very helpful and should be appreciate.
Moreover, as mechanical engineering student in Bahir Dar University this shows the aim of the
campus is successful.

CHAPTER THREE
3. Project Work
3.1 Summery of the Project

This work starts by problem identification and giving solution to it. The solution has mechanical
forecasting to a problem and proper designing of components. The paper aims at designing and
simulation of milling attachment on lathe. It is intended to design a mechanism that enables
milling operation namely end mill, side mill and gear cutting on lathe. We attempted to make
versatile operation for a medium duty lathe. The attachment can carry out an indexing
mechanism and vise like milling machine with back and forth movement of lathe carriage. This
mounted on toolpost, where we fix the work piece and a mandrel or a chuck mechanism is
designed to hold the cutting tool. This mandrel or chuck mechanism is attached to the head stock
spindle, which is the main source for motion of the cutting tool.
In the design process a major designing process of frames, jaws, gears, shafts, screws, handle,
indexing plate and bearing selection have been takes place. Full design of this enables us to
machine slots with different orientation, splines and light duty gears namely spur gear and helical
gear.

3.2 Literature review

Various literatures on milling attachment to lathe, basic principles, which used for fabrication of
the attachment and basic core ideas, are described as follow:
i. "Design and fabrication of gear cutting attachment to lathe for machining a spur gear;"
M. Sagar Kumar (ass. Prof.) at K. Greddy college of engineering: International Journal of
Innovations in Engineering and the Technology (IJIET): the paper aims advertisement the
design and fabrication of gear cutting. It only used for fabricate spur gears. Additionally
it is designed for specific gear which the design does not cover the movement of the
attachment for different gear sizes [3].
ii. “Keyway and gear cutting attachment to lathes” on Jan. 30, 1940 by T.E. Smith, (USA
patent no. 2188447 A.): First, he proposed the principle of gear and key way cutting
attachment on lathe machine. He used a separate motor for rotating cutting tool and
indexing was done on lathe chuck. This attachment was very complex and large in
construction [4].
iii. “Gear cutting attachment” by John W. Barons, Baltimore, and “application serial
no.’131,002”: John W. Barons used for giving feed while T.E. Smith used intermittent
feed devise.
iv. “Milling attachment;” Joseph C. Harbison; eliminated the use of motor and replaces the
chuck indexing by compound indexing. Cutting tool was mounted on arbor and arbor was
mounted between chuck and tailstock.

3.3 Problem statement and justification

Lathe is suitable for operation like turning, boring, facing, tapering, thread cutting, knurling and
parting operation. However, it is not suitable for operations like key way cutting, side milling
and gear cutting. In the time of internship program, we face different problems and we gave
solutions specially, on machine maintenance. In the company, there is a milling machine
problem. It may be maintained, but no longer used. In our own, we try a lot to maintain but we
cannot fix it. Absent of spare parts and being century makes it difficult. Thus, we attempt to
design an attachment on lathe in order to solve this problem. Comparatively milling machine
cost is high. So light duty industries exposed to extra lost for simple milling operations.
Therefore, it is better to use attachment with low cost. This will reduce the investment for
medium and small-scale industries, subsequent reduce the manufacturing cost of gears and
blocks in addition to solve problem in our company. In a convectional lathe as soon as the
machine is switched on, the work piece fixed to the chuck rotates. This is a major limitation of
the convectional lathe keeping in view of the present project.

3.4 Objective
3.4.1 Main objective

Our main aim is to prove lathe as a versatile machine and to design milling attachment to lathe
itself.
3.4.2 Specific objectives

The specific objectives of this project are:
 To design vise mechanism

 To design indexing mechanism
 To verify the design in computer aided way
 To show simulation to the design

3.5 Methodology
The project starts by identify a problem. This helps to create different question to the design for
improving the product. After identify the problem; we propose an objective to the work, which
lead the path for being success or not. Next, we continue with literature review and research
about our work. This consist a review of the design and works including paper researches.
After imagination and sketching with conceptual design, it proceeds to the main designing. In the
main designing, the major tasks that will be done are force analysis, stress analysis, dimension
analysis and simulation. Starting from designing of vise, it goes through screws, vise holder and
indexing mechanism. Finally finite element analysis for failure check up and digital mock up
will takes place after cost prediction and giving specification to the design.
In short, the overall process can be summarized as follow:
Table 1 overall flow of the design process
Phase Title
Phase 1 Establishment of target

Phase 2 Basic conceptual and sketch design
Phase 3 Selection of components as per suitability
Phase 4 Selection of material
Phase 5 Design and dimension analysis
Phase 6 Part drawing and modeling
Phase 7 Assembly, FEA and simulation

3.6 Selection of material

To design our project we need to select proper material that enables us to carry out our
specification. The selection includes a property of good strength, durability, machinablity, and
weldablity. It is known that during operation it exposed to a great vibration, so the material
should be tough and be elastic material. The best material is the one that serves the desired
objective. The following factors also should be considered while selecting the material in
addition to the above factor. These factors are:
 Availability of the material

 Suitability of the materials for the working conditions and
 The cost of the material
In the company from high carbon steel up to low carbon steel, mild steel, cast iron and high
strength-low alloy is available. Therefore, to design this project we select high strength-low alloy
steel, which have good property on weldablity, machinablity, malleability, toughness. For
designing gear, it is advisable to use others materials like malleable cast iron (2% C and 1% Si)
due to its good wearing properties, excellent machinablity and easy of producing complicated
shapes by casting method. Thus, we will use malleable cast iron. Availability and suitability of
these materials in company makes advantages for engineering purposes. The table on the
appendices shows the mechanical properties [9].
3.7 Component Design
3.7.1 Predicted sketch design

In some extent, the design cannot go beyond paper until now. Even though there are paper
works, no one integrate the basic milling operation. They only focus on spur gear cutting. For

our design, it is better to join conceptual idea, some ideas from others paper and some
unsatisfactory prototype work. For visualization, first we organize our idea in sketch form as
follow.
Figure 9 idealizations within sketch
3.7.2 Design of vise

The standard formula for the various forces associated with the operations of jigs and fixtures are
similar to our design. Now to start our design we must know the forces, which transmitted from
the cutter to the attachment. The attachment exposed to trust load, cutting load, clamping load.
Trust force (Ft) can be calculated as;

Ft =1.16*k*d (100*s) 0.85 (1)
Where; d = maximum diameter available for the end mill
= 25 mm
s = feed range for longitudinal and it is machine specified
= 0.05 – 0.8 mm/rev
k = material factor; for high-strength low alloy steel
= 1.2
Substituting;
Ft = 1.16*1.2*25(100*0.8)0.85
= 1492.6 kg f
Therefore, trust force = 1492.6*9.81N = 14,627N

Cutting force makes bending load on the vise jaws.

4.5 ∗ K ∗ f ∗ d ∗ b (2)
F =
C
Where; K = material constant
= 500MN/m2 = 500N/mm2
f = feed (mm/s)
d = depth of cut
= 1.25mm for rough hard work
b = width of cut
= 120mm, dimension specification from tool post geometry
cs=cutting speed
π∗d∗N (3)
c =
60 ∗ 1000
Where; d = diameter of cutter
N = spindle speed; should be minimum
= 60 in rpm
π ∗ 25 ∗ 60
Thus, c = = 78.5 ∗ 10 m⁄s = 78.5 mm⁄s
60 ∗ 1000
4.5 ∗ 500 ∗ 0.8 ∗ 45 ∗ 1 60 ∗ 1.25 ∗ 25 ∗ 120

∴ F = = 64.4kN
58.9
Torque applied = cutting force × 2 (assume cutting force concentrated at the tip of the cutter)
∗
T = 64.4 ∗ = 805N. m (4)
Clamping force (Q) estimated as:
Q = torque ∗ safety factor (5)

It is known, most attachments designed by safety factor of three [5].
Q = 805 ∗ 3 = 2415N = 2.4kN
3.7.2.1 Designing of jaws

Now the following specification and data are necessary for designing:
 Power transmitted = 6.6 KW

 Vise width = 120mm

 Maximum feed = 0.8mm/rev
 Maximum depth of cut = 1.25mm
 Designed by high strength low alloy steel
 Factor of safety = 3
 clamping force (calculated value) = 2.4kN
 Torque applied due to cutting force(calculated value) = 0.81kNm and
 Trust force (calculated value) = 14.6N
Three loads applied on the vise as shown below:
Figure 10 Forces exerted on the clamp (vise jaws)

From the figure we specified that a= 30mm and depth = 120mm.
Now we are going to specify the thickness of the jaw. The jaw exposed to two bending moments
and one compression force. Thus for connivance it is better to superpose and use general case of
eccentric axial loading.
P M y M z (6)
σ = ± ±
A I I
It is true that all the three components have compression effect at one point. So take that point
for the dimension analysis.
F 14.6
We have: P= = = 7.3kN
2 2
A = t ∗ 120mm = 120t mm
M = 0.81kNm = 0.81MNmm

t
y=
2
1
I = 120t = 10t
12
M = 30mm ∗ 3.6kN = 108kNmm
t
Z=
2
1
I = (30 + 20)t = 4.2t
12
σ = allowable strength = yield strength⁄safty factor (7)
σ 345
∴σ = = N⁄mm = 115 N⁄mm
F. S 3
Substituting
7300 810 ∗ 10 ∗ t⁄2 108 ∗ 10 ∗ t⁄2

115 = + +
120t 10t 4.2t
115t − 60.8t − 53,357 = 0

Using mat lab:
>> %mat lab polynomial solution to find thickness of vise’s jaw
>> P=[115 -60.8 -53357];
>> t=roots(P)
t=
21.8060
-21.2773 ∴ = . ≈ =
Making a fillet profile using maximum thickness dimension of 25mm and minimum thickness
dimension of 22mm is necessary.

Thus the two jaws has 120mm×50mm×25mm dimension and for facilitate the clamping
operation add a plate of 2.5mm thickness of 40mm width with Allen screw on jaws or
manufacture as combined form.
3.7.2.2 Calculation for designing the adjuster screw

Before designing the vise frame, it is necessary to design the adjuster screw. We take the length
of the screw as 180mm from data specification and the above specifications are incorporated.
Square threads, because of their high efficiency are widely used for transmission of power in
either direction. Thus, such types can use as vise adjuster.
Figure 11 Square thread

The screw exposed to a compression due to clamping force and shear stress due to cutting force.
We have a cutting force of 64.4kN and a clamping force of 2.4kN. Here stress due to initial
screwing up forces (tensile stress due to stretching of bolts, torsion due to friction, bending due
to alignment) are not considered, because of less influence compare to external forces and which
almost incorporated in clamping force. The design bases on the combination of tensile and shears
stress.
We know that
Q (8)
σ =π
4 (d )
p F ⁄4 (9)
τ= =
A πd
4
Where; P = shear force = cutting force⁄4 (since it transfer in to two jaws and then act
in opposite way.)
σt = tensile stress

Q = clamping force
d = nominal diameter
dc = core diameter= 0.84d
τ = shear stress
Using maximum principal shear stress:
τ 1 (10)
τ = = (σ ) + 4(τ)
F. S 2
Substitute the numeric and the expressions:
145 1 Q F ⁄4
= (π ) + 4(π )
3 2 4d
4d
2.4 ∗ 10 64.4 ∗ 10 ⁄4
97 = (π ) + 4( π )
4 (0.84d) 4 d
1.49 ∗ 10
d = = 1.59 ∗ 10 mm
(97)
d= 1.59 ∗ 10 mm = . ≈
Check for maximum principal tensile stress:
σ 1 (11)
σ( ) = + (σ ) + 4τ
2 2
⎡ ⃓
⃓ 64.4 ∗ 10 ⎤
⃓ 4 ⎥
1⎢ 2.4 ∗ 10 ⃓
⃓ 2.4 ∗ 10 ⎛ ⎞
σ( ) = ⎢ π +⃓
⃓( π ) + 4 ⎜ π ⎟ ⎥⎥
2 ⎢ (0.84 ∗ 20) ⃓ (0.84 ∗ 20) 20
⎢ 4 ⃓ 4 4 ⎥
⎣ ⎷ ⎝ ⎠ ⎦
σ( ) = 56.95MPa since σ = 115MPa it is quite safe.
From standard, table 3 on appendices:
d = nominal major diameter = 20mm

p = pitch = 2.5mm

l1 = length of threaded portion = 148mm

l2 = length of unthread portion = 32mm
h =depth of thread = 0.5p = 0.5*2.5 = 1.25mm
H = height of square head = d =20mm
W = width across flat head = 1.5d= 30mm
Drilled at 5mm from the end of threaded portion by 5mm drill
Moreover, socket ring to protect axial movement of the screw:
l3 = length of socket = 10mm

dp = diameter of lock pin
Using shear due to clamping force
Q⁄2 (12)
τ =π
4d
145 2.4 ∗ 10 ⁄2
= π
3
4d
= . ≈
di = internal diameter of the socket = 20.5mm

Based on shear stress due to tearing of the socket
Q⁄2 (13)
τ =
2(d − d )(l ⁄2)
145 2.4 ∗ 10 ⁄2
=
3 2( − 20.5)(5)
= . ≈
do = outside socket diameter = 23mm

l4 = length of lock pin = 23mm + 3mm = 26mm
Note: we have two screws and the first one is full threaded which will mount on the movable
(slider) jaws.

The movable (slider) jaw needs additional flat surface of 60mm width, 10mm depth for easy
sliding and it should enable to take screw at the center of the jaw surface.
Figure 12 CATIA modeling of moveable jaw, adjuster screw, vise holder screw, socket ring
and lock pin
3.7.2.3 Fixed jaw’s frame design

The fixed jaw’s frame exposed to a bending moment of 805N.m, a compression stress due to
trust force 14.6kN and clamping force of 2.4kN that induces bending stress. The frame has a
length of 197mm and two parallel parts of cross section 30mm×depth (d).
Using the previous concept:

P M y M z
σ = ± ±
A I I
Where; σall = 115Mpa
P = 2.4kN
A = 2(30mm*depth(d)) = 60d
Mz = 805*103N.mm

Y =60mm
Iz = h −h = (120 − 60 ) = 126 ∗ 10 d (14)
My = 14.6kN*197/2mm = 1438*103N.m
Z =d/2
Iy = bh = (60)d = 5d (15)
Substitute the values
2.4 ∗ 10 805 ∗ 10 ∗ 60 1438 ∗ 10 d

115 = + +
60d 126 ∗ 10 d 2(5d )
115d − 423.3d − 143.8 ∗ 10 = 0 , using mat lab as we done before;
( )= . ≈
Figure 13 CATIA V5 modeling of fixed jaw and connecter(vise holder)

 The upper flange should have proper dimension to facilitate movement of the screw. It
have thread with M20*2.5 from 25mm from the frame surface and a mininum of 1.5d to
the outer surface. i.e1.5d =1.5*20=30mm with thickness of 22mm.

 On the opposite side at top and botton, (10 + 30)mm from the former surface, there is a
hole diameter of 20mm with 22mm thickness. The surface has a minimum of 30mm
measure to the surrounding from the center of the hole.
3.7.2.4 Dimention analysis of vise holder

The connecter or vise holder enables the vise to move longitudinally and it can swivel at an angle
by its axis. It has block with a screw for rotational movement controller. For tightening nut is
need. Using the above design on similarity, the dimensions look like as follow.
Let; d = diameter of bolt

t = thickness of the main frame = 30mm
h = height of the nut = 0.75d = 0.75*20 = 15mm
w = width along surface = 1.5d+3 = 1.5*20+3 = 33mm
ts= thickness
kness of washer = 0.15d = 0.15*20 = 3mm
Di =internal diameter of washer = d+1 = 21mm
Do=outside diameter of washer = 2*20+4 = 44mm

Figure 14 Component of vise holder/connecter:

connecter: connecter bolt, nut and washer
3.7.3 Dimension analysis of the main frame

The analysis bases the tool post dimension and the pervious analysis. It is “L” shaped stand.
 Thickness of the plate (t) = 30mm

 Height of the plate =center distance of the spindle from base + 1.5d = 47+1.5*20 = 77mm
 Hole diameter = 20.25mm,
5mm, counter bore diameter = 30.25mm,
30. 5mm, 2mm deep.
 At the top edge should be fillet with 30mm
30 radius.
 The base plate has a thickness of
o 20mm, and a rectangular measure of 150mm×85
150mm×85mm
with bore diameter of 16mm at 25mm from end.. The hole helps to take 16mm diameter
bolt of the tool post fastener. This bolt may need a spacer if long bolt is available.
Figure 15 Modeling of main frame

3.7.4 Design of indexing mechanism

A simple indexing mechanism consists of a 40 tooth worm wheel fastened to the index head
spindle, a single-cut worm, a crank for turning the worm shaft, and indexing plate and sector.
Thus designing of these components for mechanical strength is necessary.
3.7.4.1Design of worm and worm gear

The worm gears are widely used for transmitting power between non-intersecting shafts. Mostly
used as a speed reducer, consisting worm and worm wheel. Straight face, hobbed straight-faced
and concave face are major types of worm wheels.
Let DW = pitch circle diameter of the worm

DG = pitch circle diameter of the worm gear
TG = number of teeth for the gear
pc = circular pitch
pa = axial pitch
n = number of starts of the worm
l = lead of the worm
m = module
N = angular speed
λ = lead angle
We have
lead of the worm (16)

λ=
pitch circumferance of the worm
l p n p n πm ∗ n mn (17)
λ= = = = = … (∵ p = p = πm)
πD πD πD πD D
The lead angle, λ may be varying from 9° to 45°. F.A. Halsey shows a lead angle less than 9°
results in rapid wear and 12.5° is safe. Thus, we will use this one. Tooth pressure angle is
measured in a plane containing the axis of the worm and is equal to one – half the tread profile
angle. The recommended value to use is 14.5° [6].
For our design, V.R is 40. You can see general geometry of the worm gearing as follow.

Figure 16 Worm & worm gear [6].

Based on our geometry take the distance between the shafts(x) is 40mm and the design of worm
and worm gear discussed as follow:
The normal lead can be finding from

1 1 V. R (18)
= +
2π sin λ cos λ
40 1 1 40
= +
l 2π sin 12.5 cos 12.5
l 5.5
∴ l = 5.5mm and axial lead, l = = = 5.6mm
cos λ cos 12.5
We know number of start is one. Therefore, the axial pitch and lead are equal.
∴ p = l = 5.6mm
p 5.6
m= = = 1.8mm
π π
According to Shigley’s mechanical engineering design, take the standard value of module, m = 2
mm. Therefore, the above specification can be rewrite as:
Pa = π × m = π×2 = l= 6.283mm (19)

l = l cos λ = 6.283 cos 12.5 = 6.134mm (20)
And the center distance,

l 1 V. R 6.134 1 40
x= + = + = 42mm
2π sin λ cos λ 2π sin 12.5 cos 12.5
We know that:
l
tan λ =
πD
l l 6.283
D = = = = 6.2mm
π tan λ πtan λ πtan 12.5
The face length of the worm or the length of threaded portion is:
L = P (4.5 + 0.02T ) (21)

L = 6.283(4.5 + 0.02 ∗ 1) = 28.4mm
This length should be increased by 25 to 30mm for the feed marks produced by the vibrating
grinding wheel as it leaves the threaded root, therefore let us take: LW = 52mm
Moreover, the worm has

h = 0.623pc = 0.623*6.283mm = 3.9mm
a = 0.286pc = 0.286*6.283mm = 1.80mm
Dow = D + 2a = 6.2mm + 2(1.6mm) =9.8mm
Where; a = addendum
h = depth of tooth
Dow = outside diameter of worm
The worm gear will have

DG = m.TG = 2*40mm = 80mm
DOG = DG + 0.893pc = 80 + 0.8903(6.283mm) = 85.5mm
b = 2.15pc +5mm = 2.15(6.283mm) + 5mm = 18.5mm
d=1.25m=1.25*2mm=2.5mm
R = 0.882 pc + 14 mm = 19.5mm
Where; b = face width

d = dedendum
R =radius of gear face

Now let us check the designed worm gearing from the standpoint of tangential load, dynamic
load, static load, endurance strength and related forces.
Figure 17 Forces acting on worm teeth [6].

 Tangential force on the worm (WT) = axial force or thrust on the worm gear
= cutting force
Now we are going to calculate for the gear cutter
4.5Kfdb
F =
c
For gear cut in the company, there is up to 130mm diameter cutter and from the previous:
K = material constant = 500N/mm2

f = feed = 0.8mm/rev*45rev/sec = 36mm/sec
b = width of cut = pc/2
d =depth of cut = 0.623pc
We have a cutter of maximum diameter 130mm with pc 26mm. In addition, we specify the
cutting speed should be between 45rpm & 345rpm with material that will cut should have a
maximum yielding strength of 300Mpa.
d 130 2π
c = rps ∗ = 345 ∗ ∗ = 2,348 mm⁄sec
2 2 60
4.5 ∗ 300 ∗ 36 ∗ 0.623 ∗ 26 ∗ 26 2
∴ F = = 4,364N
2348
Thus,
 WT =4.4kN
 Axial force or thrust force on the worm or tangential force on the worm

WA = W /tanλ = 4.4kN/tan12.5 = 19.8kN (22)

 Radial or separate force on the worm
WR = W tanϕ + thrust force = 19.8tan14.5° + 14.6kN = 19.7kN (23)
a) Check for the tangential load.
We have: WT = 4.4kN
Velocity factor, c = =1 (∵ during cutting peripheral velocity is zero) (24)
Moreover, the tooth form factor (y) or Lewis factor for 14.5° involutes teeth is:
0.654 0.654 (25)
= 0.124 − = 0.124 − = 0.1069
42
In addition, material constant for the gear is 345Mpa.

Thus from beam strength
W = (σ c )bπmy (26)
∗
W = (18.5 ∗ π ∗ 2 ∗ 0.1069) = 1.5kN; This is less than the applied one.
Thus, it is need to modify the thickness. From the balance;
4.4k = ∗ 1 ∗ bπ ∗ 2 ∗ 0.1069 , b = 53mm Which yields designed tangential load of 4.5kN.
b) Check for dynamic load
We know that the dynamic load,

.
W = = = 4.5kN and W = 4.4kN, (27)
Therefore, the design is safe from the standpoint of dynamic load.
Check for endurance streangth, heat dissipation and wear is not necessary. The system is not
power transmitting mechanism. Actually, it works in minimum tangential load by hand during
indexing, makes minimum load induce on the mesh.

Figure 18 Modeling of worm gear and worm
3.7.4.2 Dimension analysis of gear housing

It should have the capacity to incorporate the gear and the worm. Thus based on the dimension of
the jaws and the geometry of the mesh, the box has a dimension as follow internally.
. .
 Height of box = + + 5 mm = (42 + + 5)mm = 94.65mm
 Width of the box = (b + 5)mm = (53 + 5)mm = 58mm

 Depth of box = (D + 5)mm = (85.5 + 5)mm = 90.5mm
It exposed to a compressive damping force of 2.4kN. The area exposed to this is (58mm+2t)
(90.5+2t) (58*90.5). Take t = 5mm is enough and drilled at proper position to take shaft.
Figure 19 Gear housing

3.7.4.3 Design of shafts

1. Shaft for the worm gear
It exposed to an axial force of 4.4kN and a bending load of 14.6kN due to cutting force and trust
load respectively. It acts as a cantilever. Take the length as:
 t + 5mm + l = (5 + 5 + 50)mm = 60mm on the first end and 10mm on the

other end with total length of 60mm+53mm+10mm=123mm.The load acts at
50mm from the center bearing support.
We have a general formula:
1 αFd (1 + k ) αFd (1 + k )
M = k ∗M+ + k ∗M+ + (k + 1) (28)
2 8 8
= ∗ ( ) (1 − ) and we have
32
Figure 20 Loads acting on gear shaft

For solid shaft, k = zero and do =d.
α = column factor, which is considered when the shaft is long. So take it as one.
Km = recommended fluctuating load constants
= 1 for gradually applied or steady load for stationary shafts

M = maximum bending load

= 14.6kN*50mm (swing length) =876kNmm
F = axial load = 4.4kN
d = d =diameter of shaft
σ = allowable bending stress
T = twisting load = zero
Substituting the values and terms in to the governing equation:
π 445 1(4.4 ∗ 10 )d
∗ d = 1(876 ∗ 10 ) +
32 3 8
Simplify the expression yields d = 16.3mm, take =
This also shows the gear has a drill of 20mm through hole with a key dimension of w =
d/4=5mm, t = 2d/3=3.3mm, and l = b + 3 = 56mm.
2. Design of worm shaft
A little consideration shows that during cutting it exposed to the tangential load due to cutting
force. The trust load on the gear shaft splits away the gear from the warm, so it does not have
such extent load on the worm shaft. Simply we can take the outer diameter of the worm.
= . ≈
It has length, (t + 2.5 + diameter of the wheel + 2.5 +t + 10mm)

L = 2*5mm + 5mm + 85mm + 10mm = 110mm which part of it will be worm.
3.7.4.4 Dimension analysis of the indexing plate and handle

The indexing plate is a round plate with a series of six or more circles of equally spaced holes;
the index pin on the crank can inserted in any hole of the circle. Cincinnati type consists of one
plate drilled on both sides with circles divided as follows [7]:
First side – 24, 25, 28, 30, 34, 37, 39, 42, 43 holes
Second side – 46, 47, 49, 51, 53, 54, 57, 58, 59, 62, 66 holes

We take a plate of 110mm diameter, 5mm thickness, drilled by 12mm to take worm’s shaft with
holes as shown below. The selector consists of two radial beveled arms that can be set at any
angle to each other and then moved together around the center of the index plate. The handle has
crank with spring-loaded pin. Take the length of the crank as 57mm and width of 14mm with
thickness of 2.0mm. It should have a slot width of 10mm. A spring loaded pin with length of
25mm with 5.0mm diameter is enough.
Figure 21 CATIA modeling of indexing plate, shaft and gear key
3.7.4.5 Selection of bearing

We are going to select a single row deep groove ball bearing for radial load of 14.6kN and an
axial load of 4.4kN, operating at a negligible speed for an average life of 6 years in 4 hours per
day. Assume uniform steady load; we have:
WR =14.6kN, WA =4.4kN, N take 1 rpm by conformity
The life of the bearing in hours,
LH = 6*300*4 = 7200hr …. (Assuming 300 working days per year)
The life of the bearing in revolutions,
L =60N*LH = 60*1*7200 = 432,000 (29)
We know the basic dynamic equivalent radial load,
W =X*V*WR+Y*WA (30)

In order to determine the radial load factor (X) and axial load factor (Y), we required WA/CO and
WA/WR. Since the value of basic static load capacity (CO) is not known, therefore let us take
WA/CO = 0.5. From R.S. Kurmi & J.K. Gupta machine design, the values of X & Y
corresponding to WA/CO = 0.5 and WA/WR = 4.4kN/14.6kN = 0.3 are: X = 0.56 Y = 1.6
Since the rotational factor (V) for most of the bearing is 1, there for basic dynamic equivalent
radial load:
W = 0.56 ∗ 1 ∗ 14.6 ∗ 10 + 1.6 ∗ 4.4 ∗ 10 = 15216N
In addition, from those tables, we find that for uniform steady load, the surface factor (k ) for
ball bearing is one. Therefore the bearing should be selected for W = 15216N.
We know the basic dynamic load rating

⁄ ⁄
∗
C=W = 15216 = 11.5kN … (∴ k = 3, for ball bearing) (31)
From shigley’s mechanical design & the above one, we select a bearing No.205 which has the
following basic capacities.
CO = 7.1kN and C = 11kN
Now WA/CO = 4.4kN/7.1kN = 0.62 and we have X = 0.56 &Y = 1

Substituting
W = 0.56 ∗ 1 ∗ 14.6 ∗ 10 + 1 ∗ 4.4 ∗ 10 = 12,576N
⁄
∗
∴ Basic dynamic load rating C = 12,576 = 9,506N.
Considering shafts diameter, the bearing number 304 with c = 10.5kN is preferable which has
Bore = 20mm. [8]
Figure 22 Bearing for gear shaft

3.8 Result and Discussion

Table 2 Result for the design
No. Part name Specification dimension discussion
1 Moveable Width 120mm The design is based on

jaw Plate depth 50mm eccentric axial loading,
Thickness 22mm dimension of tool post and
lathe center position
2 Fixed jaw Height 197mm
#unsymmetrical bending
Stand thickness 38mm
3 Adjuster Thread length 180mm Design based on dimension of

screw Size M20x2.5;sq jaw and combined bending
stress
4 Vise adjuster thread length 200mm Bases similarity dimensioning

screw unthread length 27mm and maximum principal shear
Size M20x2.5;sq stress
5 Lock pin Diameter 5mm The dimension of screw is pre

Length 26mm criteria in combination to shear
stress due to clamping force
6 Socket ring Length 10mm
internal diameter 20.5mm
external diameter 23mm
Center drill dia. 5mm
7 Main frame Width 150mm Similarity designing and

Depth 85mm precondition dimension of tool
Height 77mm post
V. plate thickness 30mm

H. plate thickness 20mm
8 Nut Size M20x2.5 Standardizing of thread which

fitted to it
9 Worm Pressure angle 14.5̊̊ The first thing is to specify and

Module 2mm standardize based on our work
Lead angle 12.5̊ and check for failure criteria
Pitch diameter 6.2mm
Shaft diameter 10mm
Shaft length at both 24mm & 34mm
end
Pitch diameter 80mm
10 Worm gear Face width 83mm
Radius of gear face 19.5mm
Bore diameter 20mm
11 Gear Internal dimension 58x90.5x95mm Based on dimension of

housing Thickness of plate 5mm indexing mechanism
12 Indexing Thickness 2mm Based on the maximum force

handle Pin diameter 5mm applied on the worm due to
Pin length 25mm hand rotation
13 Indexing Diameter 110mm Taking standard

plate Thickness 5mm
14 Bearing Standard no. 304 Taking standard

Bore 20mm
15 Gear shaft Diameter 20mm Using maximum principal

Length 123mm stress in combination to axial
load

As you can see in the above, the design of milling attachment on lathe is partially fulfilled. Now
we are going to verify our design in computer aided way. We use CATIA V5 for showing
relevant design criteria. Part modeling and multi view, assembly of parts, simulation using digital
mockup/DMU kinematics, FEA by means of Generative structural analysis has been discussed.
Let us remind you that the yielding strength of high strength low alloy steel is 345MPa, which
the design bases. Simply you can understand this from the stand point of material science and by
observing the following diagrams in stand point of mechanical engineer. The design is good
when we see it from CAD CAM side. For more you may see the video, which is attached for
showing the simulation and FEA with the working principle to the work of our work.
Figure 23 Assembly of milling attachement on lathe

Figure 24 FEA of vise on VON MISES stress and displacement

Figure 25 Finite Element Analysis of indexing mechanism

We hope you get the core idea. The mechanism works as you see in the above figures and the
video. In the result table, we do not include some miner and complex components. It is necessary
to look in the drawing and design part. It is noted that the mass of the attachment is
approximately 12.5kg. It is estimated from its volume and density. .
3.9 Manufacturing method and Cost Analysis
3.9.1 Components manufacturing method
Fabrication method of jaws, connecter block and main frame

These components are just combination of rectangular parts. First, a block is machined to a
proper dimension using milling machine. Then drilling operation is taken place. The drilling
operation used for preconditioning to thread cutting or simply for bore. Using a square thread
cutter, the bore gets toothed profile based on the design. Next wielding of the jaw and the frame
is takes place. Grinding and painting are the preceding operations.
Fabrication method of screws and worm

Manufacturing of screw or worms starts from facing and turning a metal rode in to proper size.
After the head of the thread is made using milling machine for the screw, thread is cut using a
proper thread profile cutter on lathe or die. It is noted that worm cutting must be in careful way
to get proper fitting pitch to the gear.
Fabrication method of gear housing

Gear housing may be made by two methods. The first one is just by bending metal sheets and
joining them by welding. The second on is simply joining of sheets by welding. Then after, it is
drilled to take a worm and gear shaft.
Fabrication method of gear

There are a large number of ways of forming the teeth of gears, such as sand casting,
shell molding, investment casting, permanent-mold casting, die casting, and centrifugal
casting. Teeth can also be formed by using the powder-metallurgy process. One
of the newest and most promising of the methods of forming teeth is called cold forming, or cold
rolling, in which dies are rolled against steel blanks to form the teeth. Gear teeth may be

machined by milling, shaping, or hobbing. They may be finished by shaving, burnishing,

grinding, or lapping.
Gear teeth may be cut from a pre-machine blank work with a form milling cutter shaped to
conform to the tooth space. With this method it is theoretically necessary to use a different cutter
for each gear, because a gear having 25 teeth, for example, will have a different-shaped tooth
space from one having, say, 24 teeth. Actually, the change in space is not too great, and it has
been found that eight cutters may be used to cut with reasonable accuracy any gear in the range
of 12 teeth to a rack. A separate set of cutters is, of course, required for each pitch.
3.9.2 Cost analysis

Here we are going to predict cost of our design. The cost is based on direct analysis (using mass
relation). It bases cost due to volume of metal per density. Thus, an estimated volume is shown
below before manufacturing.
Table 3 Estimated material volume for components
Component Volume (mm3) Component Volume(mm3)
Moveable jaw 205,125 Worm 10,132
Fixed jaw 757,000 Housing 210,900
Screw, lock pin 330,386 Gear key and handle 2,910

and socket ring
Main frame 552,000 Indexing plate 49,516
Gear 30,305 Shaft 9,253
The total volume except the gear is 2,127,222 mm3.
Mass=ρ× volume=7860kg/m3×2,127,222mm3×10-9 m3/mm3 =16.72 kg.
Mass of gear =7300×30,305×10-9 kg=0.221kg

Total mass=16.941 kg
The average cost of steel in global market is 0.8 dollar per kg.
Thus material cost =16.941 kg ×0.8 dollar/kg=13.55 dollar
Transportation, machine for manufacture, labor force, and electricity should have a minimum
cost of 10%, 7%, 50%, and 8% of material cost respectively.
 Thus we have (10+7+50+8)/100×13.55 dollar =10.17 dollar

 Cost of bearing=2×5 dollar =10 dollar
 Cost of paint, lubrication=2 dollar
For getting profit, the company should get a minimum of 35% of manufacturing and material
cost. Taking 40%
 0.35×(13.55+10.17+10+2)dollar =12.51 dollar
Cost for tax should be a minimum of 20% of the above sum up cost.
 0.20(13.55+10.17+10+2+12.51)dollar =9.65 dollar
Thus total cost =13.55+10.17+10+2+12.51+9.65=57.9 dollar
In Ethiopia bank exchange; 1dollar=23.11 birr
Thus cost of the attachment =57.9×23.11 birr =1338.1 birr

3.10 Conclusion and Recommendation
3.10.1 Conclusion
At the start of this design we gave a hypothetical /sketch design. Within a modification, the
design is fulfilled. We put our objective at the beginning. The design supports our objective. The
design stands for our aim in the design of milling attachment on lathe. The attachment design has
a blue print of material science, specification and computer aided design. The design enables to
work light duty tasks of milling on lathe. Thus, we can conclude that this paper makes a lathe
machine is a versatile machine and our unreserved effort is fulfilled.
3.10.2 Recommendation
In Ethiopian Construction Works Corporation, we saw that there is a problem in milling
machine. They use a milling machine for light duty works. If they buy a machine, the company
exposed to extra expenditure. Thus, we recommended that if they use this work, they would be
advantages. Most companies in Ethiopia losses extra budget to get milling operation. As a
mechanical engineer, we recommend that if they use the versatile one that is design by us will be
profitable and advantages’.

CHAPTER FOUR
4. General Conclusion and Recommendation
4.1 General Conclusion

This internship program shows a bridge between the student and the profession. Various types of
orientation programs, tasks and trainings that we have been undertaking during past four months
in the workshops and in the office give great knowledge in many areas. We are glad to see that
what we have learnt in the University. This makes us to be effective in problem solving and
project work process. It is known that the curriculum used for higher education system has new
features that involve practical and theoretical courses in internship program. It joins universities
and the community in qualified way for modernization a country and prepares the student for the
real working environment. Thus, this program is a good phenomenal to produce fit and
competent engineer.
4.2 General Recommendation

In internship program, we overlook different problems in different area start from the company
up to the university industrial linkage. In the company, we see a verity of problems. We advised
that if the company adopts modern machines and technologies, the company a little more be
successful. We also recommended that it should train the employees and adopt kaizen more, for
being more profitable.
To be universities as a source of skillful grower of technological man power, they should

increase work shop plants and adopt updated technologies. We recommend that universities
should not make students a book worm but a realistic inventor. The industrial linkage should
facilitate practical works to students in industries, innovative programs or funding to students for
problem solving works.

References
[1] .Ethiopians Road Authority golden jubilee; magazine, Addis Abeba, Ethiopia, April 5/
2001
[2] .http:www.google search/history of Ethiopian Construction Works Corporation.com
[3] .M.S. Kumar, Design and fabrication of a gear cutting attachment to lathe for machining
a spur gear, IJIET; Hyderabad, Telangana, 2016; pg277-285
[4] .T.E. Smith, Key way and gear cutting attachment to lathe; USA, 1940
[5] .Design and fabrication of jig for contour profile, researches paper; volume III, nov.2014
[6] .R.S. Kurmi and J.K. Gupta, Text book of machine design; 14th edition Eurasia
publisher, New Delhi, 2005
[7] .J.R. Walker, Machining fundamentals; The Good heart-Wilcox, USA, 2000
[8] .R.G. Budynas and J.K. Nisbett; Shigley’s Mechanical Engineering Design; 9th edition,
McGraw-Hill, USA,2011
[9] .F.P. Bear, E.R. Johnston and J.T. DeWolf, mechanics of material;4th edition, McGraw-
Hill, USA, 2006
[10] .photos captured from ECWC

[11 ].http:www.gogle search/engineering method diagram.com

Appendices
Data tables, part drawing, assemble drawing and explode drawing

Table 4 Mechanical property of typical material
Material Density Ultimate strength(MPa) Yield strength Modulus of Modulus of

2
(Kg/m ) (MPa) Elasticity (GPa) Rigidity(GPa)
Tension Comp. Shear Tension Shear
H.S.L.A.S. 7860 500 345 145 200 77.2
C.IRON 7300 345 620 330 165 65
Table 5 Diameters and areas of metric threads (adopted from shigley’s mechanical engineering
designs)
Table 6 Recommended values of lead angle and pressure angle















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Bahir Dar University

Bahir Dar Institute of Technology

Project Title: Design and simulation of milling attachment on lathe

June 16, 2017

Name of student Signature Date

Habtamu Geremew _____________ _____________

Name of school adviser signature Date

_________________________ ______________ __________

June 16, 2017

Bahir Dar Institute of Technology; Ethiopia i

Bahir Dar Institute of Technology; Ethiopia ii

Bahir Dar Institute of Technology; Ethiopia iii

1.1 History of the company......................................................................................................... 1

1.2 Main Services and end users of these services ..................................................................... 2

1.3 Organizational Structure ....................................................................................................... 3

1.4 Work Flow of the Company ................................................................................................. 4

2.1 Over all Internship Benefit.................................................................................................... 5

2.2 Section of the company we have been working.................................................................... 5

2.3 The work tasks we have been executing ............................................................................... 6

2.4 Engineering Techniques and Methods used ....................................................................... 11

2.5 Engineering Tools ............................................................................................................... 11

2.5.1 Hand tools .................................................................................................................... 11

2.5.2 Important Power Tools ................................................................................................ 13

2.7 Measures to overcome these challenges and problems....................................................... 15

2.8 Gain from improving Practical Skills ................................................................................. 15

2.9 Theoretical knowledge upgrading....................................................................................... 15

2.10 Team working skills .......................................................................................................... 16

2.11 Advantages on leadership skills ........................................................................................ 16

2.12 Work Ethics Skills ............................................................................................................ 16

2.13 Entrepreneurship skill ....................................................................................................... 16

2.14 Interpersonal communication skill.................................................................................... 17

2.15 Recommendation and Conclusion .................................................................................... 17

Bahir Dar Institute of Technology; Ethiopia iv

2.15.1 Recommendation ....................................................................................................... 17

2.15.2 Conclusion ................................................................................................................. 17

3.1 Summery of the Project ...................................................................................................... 18

3.2 Literature review ................................................................................................................. 19

3.3 Problem statement and justification .................................................................................... 20

3.4 Objective ............................................................................................................................. 21

3.4.1 Main objective ............................................................................................................. 21

3.4.2 Specific objectives ....................................................................................................... 21

3.5 Methodology ....................................................................................................................... 22

3.6 Selection of material ........................................................................................................... 23

3.7 Component Design.............................................................................................................. 23

3.7.1 Predicted sketch design ................................................................................................ 23

3.7.2 Design of vise .............................................................................................................. 24

3.7.3 Dimension analysis of the main frame......................................................................... 34

3.7.4 Design of indexing mechanism .................................................................................... 35

3.8 Result and Discussion ......................................................................................................... 45

3.9 Manufacturing method and Cost Analysis .......................................................................... 50

3.9.1 Components manufacturing method ............................................................................ 50

3.9.2 Cost analysis ................................................................................................................ 51

3.10 Conclusion and Recommendation .................................................................................... 53

3.10.1 Conclusion ................................................................................................................. 53

3.10.2 Recommendation ....................................................................................................... 53

4. General Conclusion and Recommendation ............................................................................... 54

4.1 General Conclusion............................................................................................................. 54

Habtamu Geremew _ _

_____________