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I JSRD - I nternational Journal for Scientifi c Research & Development| Vol. 3, I ssue 10, 2015 | ISSN (onli ne): 2321-0613

All rights reserved by www.ijsrd.com 423

The Experimental Approach of Manufacturing Hardened Barrel Screw

on Traditional Lathe Machine with Different ParametersDilip M Patel

1 DR. Ashwin D patel

2

1PhD. Scholar 2Principal

1,2Department of Mechanical Engineering

1

Rai University, India

2

Ipcowala Institute of Engg and Technology, Anand, India Abstract — Now a day manufacture has to think for most

economical, less time consuming, accurate and perfect

sequence of production process for manufacturing the

product. He has to adopt the various parameters focusing on

the above stated facts. The researcher has find out to control

the different parameters for optimum process based on

economical point of view by which the manufacturer can

save round above 30 % cost of product.

The Traditional lathe machine is used as machine tool

instead of (SPM) special purpose milling machine. He hasmade three alterations.

1) Parameter – using milling attachment.

2)

Parameter – using special profiled milling cutter.3) Parameter – using indexing attachment with main

spindle.For the above aspect the researcher has done number of

experiments to decide the optimal process and then by doing

the same process on SPM & lathe. He has concluded the

level of efficiency, economical & optimal process control.

Key words: Barrel Screw, Traditional Lathe machine

different parameter

I. I NTRODUCTION

Barrel Screws are devices suitable for handling a widevariety of materials that have good flow ability

characteristics. The screw feeder has a helicoidally surfacefitted on a shaft that rotates inside a fixed tube. The material

which comes out of the silo is pushed by the helicoids flight

along the base of the tube in the direction of transport. The

advantages of the screw feeder include the possibility ofhaving different openings, each with its own shut-off organ

for unloading the material.

A number of years ago Rexnord proposed a set of

selection guidelines, one for conveyors and the other for

elevators that are useful for an indicative choice of

conveyors on the basis of loading and unloading methods,

the course of transport and the features of the material (flow

ability, composition granulometry, temperature, friability,

abrasiveness and corrosivity.)Manufacture screw on traditional lathe machine by

changing its different – drive viewing on the reduction ofcost process utility and easy methoding. When the screw

feeder, we are talking it’s use is wide and the profile is

somewhat complex on one shaft the pitch of screw may very

as well as start may be single, double or triple. The working

of screw feeder is in a hollow cylindrical cavity known as

barrel.The simply target is generate the thread profile on

lathe machine and to harden it by biometric layer depletion

during the process profile different effecting parameters are

control and on one layer the optimal parameters are

achieved. The cutter to shape the screw profile is specially

designed the speed, depth of cut, the lost criteria and the

attached equipments is also sharply taken in to

consideration.

The working condition of screw inside the barrels

and other effecting parameters is taken into account wear &

tear, heating condition, temperature, speed of screw, the

screw feeder effected portion is harden by diametallic

deposition.

A. Barrel Screw:

A Screw to be shaped like an Archimedean spiral square

threaded profiled on shaft. It works in a closed chambered

Jacket known as Barrel Screw rotate according to required

speed in barrel and it feed plastic material from one side

located Hopper where the raw material is allowed to fall in a

Barrel on other side die consist of male & female to piece

receives the raw plastic material in a liquid form and it

shape the plastic material into required form.

Fig. 1: Plastic Injection Molding Machine

In fact the screw work as a material conveyor to be feed in a

barrel from one side to another side outside the barrel

surface the heater are installed which maintain the required

heat for plastic raw material easily to flow in the barrel and

get to be shaped in a Die Cavity as per required shape and

size.Barrel Screw is used for:(1) Extrusion Plastic Machinery –

(2) Injection Moulding Machine(3)

Blow Moulding Machinery

The above three plastic plants are used for producing

different plastic parts they are generally used for Industrial

and Domestic purpose.

1) Use of Barrel Screw for Different Plastic Machinery Plants:

- Injection Moulding

- Extrusion Moulding

- Laminatic Plant

- Blow Moulding

- Calendaring

- Vacuum Forming

-

Plastics as Engineering Material



The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters

(IJSRD/Vol. 3/Issue 10/2015/086)


2) Different Types of Screw:

- Single Screw

- Barrier Screw

- Twin Screw and Barrel

- Parallel Twin Screw and Barrel

- Single Screw and Barrel

- Grooved Feed Barrel

-

Barrier Screw- Maddoc Barrier Screw

- Single Barrel

- Twin Hole Barrel Rear Barrel

- Twin Barrels

- Grooved Feed Bush

II. SCREW BARREL UTILITY

A. Pipe Plant:

- PVC Pipe Manufacturer (U PVC, R PVC, CPVC)

- HDPE Pipe Manufacturer

- PVC Braided Pipe Plant

-

PVC Suction Hose Pipe- PVC Soft Tubing Plant

B. Sheet Plant:

- Air Bubble Sheet Plant

- PP Sheet Plant

- HIPS Sheet Plant

- PVC Sheet Plant

- Thermo Forming

C. Film Plant:

- PVC Film Plant

- Lamination Film Plant

-

Blown Film Plant

- Tape Plant

- Multi-Layer Film Plant

- Cable Manufacturer (Any Type of Materials)

- Compounding Plant

- Injection Moulding Machinery

- Blow Moulding Machinery

- Any type of Plastic Pallet Manufacturing

D. Barrier Screw (Double Thread):

- Single Thread Screw

E. Screw Manufacturing Different Method, Screw

Classification & Screw

- Application

- Production of Screw Threads – Possible Methods AndTheir Characteristics:

The various methods, which are more or less widely

employed for producing screw threads, are:

1) Casting characteristics

- only a few threads over short length

- less accuracy and poor finish

- Example – threads at the mouth of glass bottles, spuncast iron pipes etc.

2) Forming (Rolling) characteristics

-

blanks of strong ductile metals like steels are rolled between threaded dies

- large threads are hot rolled followed by finishing andsmaller threads are straight cold rolled to desired finish

- cold rolling attributes more strength and toughness tothe threaded parts

- Widely used for mass production of fasteners like bolts, screws etc.

3) Removal process (Machining)

-

accomplished by various cutting tools in different

machine tools like lathes, milling machines, drilling

machines (with tapping attachment) etc.

- widely used for high accuracy and finish

- Employed for wide ranges of threads and volume of

production; from piece to mass production.

4) Semi finishing and finishing (Grinding) characteristics

- usually done for finishing (accuracy and surface) after performing by machining or hot rolling but are often

employed for direct threading on rods

- precision threads on hard or surface hardened

components are finished or directly produced bygrinding onlyemployed for wide ranges of type and

size of threads and volume of production

III. SIGNIFICANCE OF PROPOSED RESEARCH

Now a day plastic & relative product is hugely used inIndustries as well as domestic purposes. The process mainly

used to manufacture plastic is injection molding, blow

molding plastic, film making etc.

The raw materials are continuously feed in to the

barrel and long working life by certain heat treatment

process of metal deposition

IV. R ESEARCH METHODOLOGY

This Project is based on an experimental research. It is

commonly used in sciences and engineering the number of

experiments are carried out considering different parameters

and how the parameters changes and causes to change other

are verified.

The Experimental method is a systematic and scientificapproach to researcher in which the researcher manipulates

one or more variables, controls and measures any change in

other variable.

The experiment has been carried out on conventional

lathe machine and CNC Thread Milling Machine. In orderto perform different machining operations on a lathe and

CNC Thread Milling Machine. The raw material of barrel

screw that is EN41B Round Bar of ∅110 mm is taken and it

is to be holding on lathe chuck and it is machined by HSS

Single Point cutting tool and milling cutter. The number ofmachining operation is performed considering the following

parameters.

- Job Speed

- Feed

- Depth of CutThe six machining operation is carried out on EN41B

material round bar on lathe machine and CNC Thread

Milling Machine in order to manufacture barrel screw withthe same parameters and by changing some of parameters.






The three machined barrel screws are Screw No. 1

manufactured on lathe machine and Screw No. 2

manufactured on CNC Thread Milling Machine with samefeed and job speed and Screw No. 3 is manufactured on

CNC Thread Milling Machine with varying job speed and

Feed.

Screw No. 1, Screw No. 2 and Screw No. 3 are

tested in laboratory and considering the following tests.

-

Dimension Check – Up

- Surface Finish

- Hardness

- Micro Structure

- Chemical AnalysisAnd also comparison in terms of manufacturing cost.

V. EXPERIMENTAL SET-UP & DESCRIPTION

A. Lathe Machine specification:

The length between centers =10’’

= 3048 MM

The overall length of machine =14’’ = 4267 MM

The centre weight of measured =14’

= 355.6 MM

the swing diameter over bed =16’

= 406.4 MMThe length of bed = 12’’

= 3662 MM

Fig. 1: Lathe Machine

Fig. 2: Lathe Machine

VI. PARAMETRIC CHANGES

A. Milling Attachment:

Milling attachment as shown in figure is developed for

threading the barrel screw. A separate AC variable drive

motor is installed via V. Pulley block a central shaft with

taper shank sleeve and collect chuck is fixed with box type

fabricated structure both end of shaft is supported by Ball

Bearing. The attachment is installed on cross slide of lathemachine with front support live rest.

Fig. 3: Milling AttachmentEnd mill cutter ∅ 25 mm and specially profiled taper round

nose cutter is installed in collect chuck.

VII. OBSERVATION TABLE AND GRAPHS

A. Lathe Machine:

Process :-1

Turning

Material:-EN41 Φ 110 mm Length: 3360 mmRound Bar

Machining:-

From Φ 110 mm to Φ 100.5 mmlength:3360 mm

Tool: P20 Carbide Tipped Turning tool

Observation Table 5.2.1.1

Sr.

No

Total

Depth

of cut

(mm)

Feed

of tool

(mm /

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job

Speed

(R.P.M.)

1 5 7 34.54 480 100

2 3 5 33.97 672 100

3 1.5 3 32.02 1120 100


Sr.

No

Total

Depth

of cut

(mm)

Feed

of tool

(mm /

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job

Speed

(R.P.M.)

1 5 15 51.81 224 150

2 3 10 49.45 336 150

3 1.5 5 48.04 672 150


Sr.

No

Total

Depth

of cut

(mm)

Feed

of tool

(mm /

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job

Speed

(R.P.M.)

1 5 20 69.08 168 200






2 3 15 65.94 224 200

3 1.5 10 64.05 336 200

Process :-

1Turning

Material:-EN41 Φ 110 mm Length : 3360 mm

Round Bar

Machining:-

From Φ 110 mm to Φ 100.5 mmlength:3360 mm

Tool: P20 Carbide Tipped Turning tool


Sr.

No

Total

Depth

of cut

(mm)

Feed

of tool

(mm /

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job

Speed

(R.P.M.)

1 5 7 34.54 480 100

2 3 5 33.97 672 100

3 1.5 3 32.02 1120 100

Fig. 4: Feed of tool vs. Cutting Time

Fig. 5: Depth of Cut vs. Cutting Speed

Process :-2

Turning (Spline)

Material:-EN41 Φ 110 mm Length : 3360 mm Round

Bar

Machining:-

From Φ 100.5 mm to Φ 89.7 mm length:200

mm


Sr.

No

Total

Depth

of cut

(mm)

Feed

of tool

(mm /

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job

Speed

(R.P.M.)

1 5 7 31.55 28.57 100

2 4 5 29.98 40 100

3 1.8 3 28.73 66.66 100



Process :-3

Spline Milling

Material:-EN41 Φ 110 mm Length : 3360 mm

Round Bar

Machining:-

Spline Milling 6 slot size: 89.7 mm to77.9 mm

Width 16 mm, Depth 11.5 mm Slot

length 170 mm

Tool:Hss milling cutter Dia 16 mm 4 flute

Initial slot is generate by 16 MMDiameter End Mill Cutter then the tapercut is generated by radius End Mill Form

Cutter


Sr.

No

Total

Depth of

cut (mm)

Feed of

tool (mm

/ min)

Cutting

speed (mm/

min)

cutting

time

(min)

1 5 10 70.41 17

2 4 15 66.48 11.33

3 1.8 20 66.34 8.5

4 1 20 61.93 8.5

480672

1120

0

500

1000

1500

7 5 3 C u t t i n g T i m e ( m i n )

Feed of Tool (mm/min)

Feed of tool vs. Cutting Time

34.54 33.97 32.02

51.81 49.45 48.04

69.08 65.94 64.05

0

10

20

30

40

50

60

70

80

5 3 1.5 C

i u t t i n g S p e e d ( m m / m i n )

Depth of Cut (mm)

Depth of Cut vs. Cutting Speed

100 R.P.M

150 R.P.M

200 R.P.M

28.5740

66.66

0

50

100

7 5 3

C u t t i n g T i m e ( m i n )

Feed of Tool(mm/min)


34.54

33.97

32.02

34.54

33.97

32.02

30.531

31.532

32.533

33.534

34.535

5 3 1.5 C u t t i n g S p e e d ( m m

/ m i n )

Depth of cut (mm)

Depth of cut vs. Cutting Speed








Process:- 4

Thread Milling

Material

:-

EN41 Φ 110 mm Length : 3360 mm Round

Bar

Machining:-

Helix machining of 100 mm pitch Length:2735 mm

and machining from Φ 100.5 mm to Φ 92.5mm Parallel core

assuming cutting speed of screw dia

considering cutter RPM

Tool:HSS Milling cutter 4 flute Φ 25 mm Cutter

Speed: 250 R.P.M.


Sr.

No

Total

Depth

of cut

(mm)

Feed

of

tool

(mm

/

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job Speed

(Min per

Revolution)

1 4 6 78.89 455.83 16.66

2 3 8 74.18 341.87 12.5

3 1 10 71.82 273.5 10


Process:- 5

Thread Milling

Material

:-


Bar

Machining:-


and machining from Φ 92.5 mm to Φ 75.5

mm Parallel core

Tool:Hss Milling cutter 4 flute Φ 25 mm Cutter

Speed: 250 R.P.M.


Sr.

No

Total

Depth

of cut

(mm)

Feed

of

tool

(mm

/

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job Speed

(Min per

Revolution)

1 5 6 72.61 225 16.66

2 5 7 68.68 192.85 14.28

3 5 8 64.76 168.75 12.5

4 2 9 60.83 150 11.11


Process:- 6

Thread Milling

Material

:-


Bar

Machining:-


and machining from Φ 92.5 mm to Φ 75.5

mm Tapper core

Tool: Hss Milling cutter 4 flute Φ 25 mm CutterSpeed: 250 R.P.M.


Sr.

No

Total

Depth

of cut

(mm)

Feed

of

tool

(mm

/

min)

Cutting

speed

(mm/

min)

cutting

time

(min)

Job Speed

(Min per

Revolution)

1 5 6 72.61 166.66 16.66

2 5 7 68.68 142.85 14.283 5 8 64.76 125 12.5

4 2 9 60.83 111.11 11.11

1711.33 8.5 8.5

0

20

10 15 20 20

C u t t i n g T I m e

( m i n )



70.4166.48 66.34

61.93

70.4166.48 66.34

61.93

55

60

65

70

75

5 4 1.8 1 C u t t i n g S p e e d ( m m

/ m i n )

Depth of cut (mm)

Depth of cut vs. Cutting

Speed

31.5529.98 28.73

31.5529.98 28.73

25

30

35

5 4 1.8

i n g

S p e e d ( m m

/

m i n )

Depth of cut (mm)

Depth of cut vs. Cutting

Speed

225192.85 168.75 150

0

100

200

300

6 7 8 9

C u t t i n

g T i m e ( m i n )

Feed of tool (mm/min)








B. CNC Milling Machine Observation Table with varying

feed:







166.66142.85

125 111.11

0

50

100

150

200

6 7 8 9

C u t t i n g T i m e ( m i n )











VIII. CONCLUSION

The three screws are manufactured on final stage Screw No.

1 on lathe machine with different parameter Screw No. 2 on

CNC Milling machine with same3 observation as per Screw

No. 1 and Screw No. 3 on CNC Milling by taking the

different feed and different job speed.

A. Comparing these three screws. The following

conclusions have been drawn.:

- The manufacturing process sequence is finalised

- There is no change in machining time for Screw -1 and

Screw -2 and the machining time is less for Screw – 3.

- The all three screw are inspected dimensionally and

find the accuracy is as per drawing.- The cost consideration has been calculated and per

hour machining cost is 300 Rs. / hr for lathe and 850

Rs./hr for CNC Milling Machine

- The initial investment of lathe and different parameteraccessories are less than thread milling CNC Machine.

- The maintenance is easy for lathe machine withdifferent parameters & accessories.

- The manufacturing process is easy and simple in thecase of lathe machine.

- In CNC Thread Milling Machine the complication ofoperation may be occurring.

- This research work opens new door in the field ofmanufacturing.






- Productivity is more because the ultimate cost of production is less in case of lathe machine.

- The three parameters to be changed on lathe machineis a new trend of manufacturing barrel screw.

B. Limitation:

The rate of production on CNC Milling Machine is more

than lathe machine with different parameters.

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