EVALUATION OF ALTERNATE MATERIAL FOR LATHE BED

Transcription

1 EVALUATION OF ALTERNATE MATERIAL FOR LATHE BED By TAPAN A PANDYA [ ] Guided by ASHUTOSH KUMAR Assistant Professor M. Tech. (Industrial Engineering) A Thesis Submitted to Gujarat Technological University in Partial Fulfillment of the Requirements for The Degree of Master of Engineering in Mechanical Engineering (Production) MAY 2016 ATMIYA INSTITUTE OF TECHNOLOGY AND SCIENCE YOGIDHAM GURUKUL, KALAWAD ROAD RAJKOT GUJARAT

2 CERTIFICATE This is to certify that research work embodied in this thesis entitled Evaluation of Alternate Material for Lathe Bed was carried out by Mr. Tapan A Pandya (Enrollment No: ) studying at Atmiya Institute of Technology and Science, Rajkot, Gujarat (Institute code: 003) for partial fulfillment of Master of Engineering degree in Mechanical (Production) Engineering to be awarded by Gujarat Technological University. This research work has been carried out under my guidance and supervision and it is up to my satisfaction. Date: Place: Rajkot Mr. Ashutosh Kumar Assistant Professor, Mechanical Engineering Department Dr P.S.Puranik Head of the Department, Mechanical Engineering Department Dr. G. D. Acharya Principal AITS, Rajkot Seal of Institute II

3 INDUSTRY CERTIFICATE III

4 COMPLIANCE CERTIFICATE This is to certify that research work embodied in this thesis entitled Evaluation of Alternate Material for Lathe Bed was carried out by Mr. Tapan A Pandya (Enrollment No: ) at Atmiya Institute of Technology and Science, Rajkot, Gujarat (Institute code: 003) For partial fulfillment of Master of Engineering degree to be awarded by Gujarat Technological University. He has complied with the comments given by the Dissertation phase-i as well as Mid Semester Thesis Reviewer to my satisfaction. Date: Place: Rajkot Tapan A Pandya Enrollment No: Mr. Ashutosh Kumar Assistant Professor, Mechanical Engineering Department IV

5 PAPER PUBLICATION CERTIFICATE This is to certify that research work embodied in this report entitled Evaluation of Alternate Material for Lathe Bed carried out by Mr. Tapan A Pandya (Enrollment No: ) at Atmiya Institute of Technology and Science (Institute code: 003) for partial fulfillment of Master of Engineering degree to be awarded by Gujarat Technological University, has published article entitled Evaluation of Alternate Material For Lathe Bed for publication by the International Journal of Futuristic Trends in Engineering and Technology in Volume 02 Issue XII, November Date: Place: Rajkot Tapan A Pandya Enrollment No: Mr. Ashutosh Kumar Assistant Professor, Mechanical Engineering Department Dr P.S.Puranik Head of the Department, Mechanical Engineering Department Dr. G. D. Acharya Principal AITS, Rajkot Seal of the Institute V

6 THESIS APPROVAL CERTIFICATE This is to certify that research work embodied in this entitled Evaluation of Alternate Material for Lathe Bed carried out by Mr. Tapan A Pandya (Enrollment No: ) at Atmiya Institute of Technology and Science, Rajkot, Gujarat (Institute code: 003) is approved for award of the degree of Master of Engineering with specialization of Mechanical (Production) Engineering by Gujarat Technological University. Date: Place: Examiners Sign and Name: ( ) ( ) VI

7 DECLARATION OF ORIGINALITY We hereby certify that we are the sole author of this thesis and that neither any part of this thesis nor the whole of the thesis has been submitted for a degree to any other University or Institution. We certify that, to the best of my knowledge, the current thesis does not infringe upon anyone s copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other material from the work of other people included in my thesis, published or otherwise, are fully acknowledged in accordance with the standard referencing practices. Furthermore, to the extent that we have included copyrighted material that surpasses the boundary of the fair dealing within the meaning of the Indian Copyright (Amendment) Act 2012, we certify that we have obtained a written permission from the copyright owner(s) to include such material(s) in the current thesis and have included copies of such copyright clearances to our appendix. We declare that this is a true copy of my thesis, including any final revisions, as approved by my thesis review committee. We have checked write up of the present thesis using anti-plagiarism database and it is in allowable limit. Even though later on in case of any complaint pertaining of plagiarism, we are sole responsible for the same and I understand that as per UGC norms, University can even revoke Master of Engineering degree conferred to the student submitting this thesis. Date: Tapan A Pandya Enrollment No: Mr. Ashutosh Kumar Assistant Professor, Mechanical Engineering Department Institute Code: 003 VII

8 ACKNOWLEDGMENTS The accomplishment of this project work is not only due to my efforts. In fact, I stand on the shoulders of many people. So, with great pleasure I take this opportunity to express my gratitude towards all the individuals who have helped and inspired me in my project work. The dissertation work taught me many things and added knowledge to my memory bank. I am deeply indebted & would like to express my gratitude to my guide Mr. Ashutosh Kumar & Dr P.S.Puranik HOD in Mechanical Engineering Department, Atmiya Institute of Technology and Science for his great efforts and instructive comments in the dissertation work. I would like to express my special thanks to Industrial guide Mr. Vivek Jethva at GEETA MACHINE TOOL PVT LTD for their support in my dissertation work. I am also thankful to Mr. Nilesh Jadvani from our College for contributing my Project. I express my thanks to my dear friends & my classmates of Atmiya Institute of Technology and Science for their help in this research and for their company during the research. Last but not the least, I am thankful to God for giving me the light and strength to work on this new concepts. Place : Rajkot Date : Tapan A Pandya ( ) VIII

9 TABLE OF CONTENT Chapter Content Page No Title Page I Certificate II Industry Certificate III Compliance Certificate IV Paper Publication Certificate V Thesis Approval Certificate VI Declaration of Originality VII Acknowledgements VIII Table of Contents IX List of Figures X List of Tables XV Abstract XVI Chapter:1 INTRODUCTION Machine Tool Lathe Machine Traditional Material for Lathe Bed Cast Iron Characteristics, Application, Advantages & Limitations of Cast Iron Alternative Material for Lathe Bed 6 Chapter:2 LITERATURE SURVEY Literature Survey Introduction about Industry Problem Statement Objectives 19 Chapter:3 METHODOLOGY Introduction of Analytical Hierarchy Process (AHP) 20 IX

10 3.2 Steps of AHP Application of AHP for Material Selection for 24 Lathe Bed 3.4 Manufacturing Process of Epoxy Granite Lathe 29 Bed 3.5 Design of Epoxy Granite Lathe Bed for Equal 30 Stiffness 3.6 Introduction of Granite, Epoxy Resin and 35 Hardener Granite Resin & Hardener Manufacturing of Sample of 150 gm Manufacturing of Sample of 1 Kg Comparison of Properties for Varying Resin 40 Content 3.10 Manufacturing of Lathe Bed Collection of Black Granite as Raw 42 Material Resources for Crushing the Granite cut 43 Pieces Sieving in Different Size Sources for Resin and Hardener Resources for Moulding Material for 47 Good Finishing Resources for Finishing Making of Mould from Thermocol Filling the Mould with Epoxy Granite 53 Material De moulding the Mould Summary of Sources of Different Activity 55 Chapter:4 ANALYSIS OF EPOXY GRANITE LATHE BED X

11 4.1 Measurement of Forces on the Lathe Bed Analysis of Cast Iron Forces on Cast Iron Lathe Bed Deformation Analysis of Cast Iron Lathe 60 Bed Stress Analysis of Cast Iron Lathe Bed Stain Analysis of Cast Iron Lathe Bed Analysis of Epoxy Granite Lathe Bed Consideration of Forces on Epoxy 63 Granite Lathe Bed Deformation Analysis for Epoxy Granite 64 Lathe Bed Stress Analysis for Epoxy Granite Lathe 65 Bed Stain Analysis for Epoxy Granite Lathe 66 Bed 4.4 Summary of Analysis 67 Chapter:5 RESULTS AND DISCUSSION Manufacturing Lead Time Comparison Cost Comparison Wear Test Comparison of Cast Iron Lathe Bed and Epoxy 71 Granite Lathe Bed Chapter:6 CONCLUSION Conclusion Future Scope 73 REFERENCES APPENDIX Appendix A Review Card 77 Appendix B Compliance 83 Appendix C Paper Publication Certificate 84 Appendix D Plagiarism Report 85 XI

12 LIST OF FIGURES Figure No Figure Description Page No 1.1 Sigma All Geared Precision Lathe-Machine Tool Geeta Machine Tool Pvt. Ltd Manufacturing Process of Epoxy Granite Methodology Existing C.I Lathe Bed Existing Cast Iron Bed with Dimension Dimensions for Steel, Cast Iron and Epoxy 33 Granite for equal Stiffness 3.6 Proposed Epoxy Granite Lathe Bed with 34 Dimension 3.7 Black Granite as an Industrial Waste Resins and Hardener Waste cut Piece of Black Granite Hammering the Granite to get Crushed Granite Sieving in Different Size of 0.5, 1.7, 2.36 mm Moulding of the Sample Epoxy Granite Sample Moulding of the Sample Epoxy Granite Sample Mould for making the Specimen Specimen with Varying Resin Content 17%, % and 23% 3.18 Specimen before Test Specimen after Test Comparison of Properties for Varying Resin 41 Content 3.21 Site scene of Shivam Marbles -A Site scene of Shivam Marbles -B Collection of about 100 Kg Waste Cut Pieces of Granite 43 XII

13 3.24 Miller at Mansi Minerals Stone Crusher Small Size Crusher at Dipen Trading Crushed Granite after Crushing Sieving in Different Size 0.5, mm (Fine, 46 Medium, Coarse) 3.29 Sieving in Different Size 0.5, mm (Fine, 46 Medium, Coarse) 3.30 Samples of Resin & Hardener Resin and Hardener for Manufacturing of Lathe 47 Bed 3.32 Use of Plastic Plate for Mould Use of Thermocol Mould Use of Thermocol with Plastic Wrapper Hand Grinding Wheel Surface Roughness Measurement Cross section of the Lathe Bed made on Wooden 51 Sheet 3.38 Measurement and Cutting of the Sheet according 51 to Requirement 3.39 Preparation of the Mould of the Lathe Bed with 52 Thermocol step Preparation of the Mould of the Lathe Bed with 52 Thermocol step Preparation of the Mould of the Lathe Bed with 52 Thermocol step Preparation of the Mould of the Lathe Bed with 53 Thermocol step Filling the Mould with Epoxy Granite Material Demoulding the Mould Epoxy Granite Lathe Bed M.S Bright bar of 43 mm Diameter & 300 mm Length 56 XIII

14 4.2 Force Measurements on the Lathe Bed by Lathe 56 Tool Dynamometer-A 4.3 Force Measurements on the Lathe Bed by Lathe 57 Tool Dynamometer-B 4.4 Forces on the Lathe Bed Forces on the Cast iron Lathe Bed Deformation Analysis of Cast Iron Lathe Bed Stress Analysis of Cast Iron Lathe Bed Stain Analysis of Cast Iron Lathe Bed Forces on Epoxy Granite Lathe Bed Deformation Analysis for Epoxy Granite Lathe 64 Bed 4.11 Stress Analysis for Epoxy Granite Lathe Bed Strain Analysis for Epoxy Granite Lathe Bed Wear Testing Machine 70 XIV

15 LIST OF TABLE Table No. Description Page No. 1.1 Parameters for Analyzing Structure Material for Lathe Bed Properties of Cast Iron Comparison of Mechanical Properties of Alternative 10 Materials Used in Machine Tool Structure 2.2 Mechanical Properties of Different Material Intensity of Importance for AHP Number of Comparison Value of RI for Different Value of n Comparison of Mechanical Properties of Alternative 24 Materials used in Machine Tool Structure 3.5 Parameters for Analyzing Structure Material for Lathe Bed Intensity of Importance for AHP Number of Comparison Value of RI for Different Value of n Summary of Sources of Different Activity Forces considered on the lathe bed Comparison of Cast iron Lathe Bed and Epoxy Granite 67 Lathe Bed 5.1 Manufacturing Lead Time of Cast Iron Lathe Bed Manufacturing Lead Time of Epoxy Granite Lathe Bed Cost of Epoxy Granite Cost Comparison of Cast Iron Lathe Bed and Epoxy Granite 69 Lathe Bed 5.5 Initial Cost Comparison Comparison of Cast Iron and Epoxy Granite for Wear Test Comparison of Cast Iron Lathe Bed and Epoxy Granite 72 Lathe Bed performance 5.8 Other Comparison of Cast Iron Lathe Bed and Epoxy Granite Lathe Bed 72 XV

16 EVALUATION OF ALTERNATE MATERIAL FOR LATHE BED Submitted by Tapan A Pandya ( ) Supervised by Mr. Ashutosh Kumar Assistant Professor, M. Tech. (Industrial Engineering) ABSTRACT Performance of a Machine Tool is highly depends on the Bed. The Bed of the Machine Tool should be sufficiently rigid to prevent deflection under tremendous cutting forces transmitted through the tool-post and carriage to the Lathe Bed. It must be massive with sufficient depth and width to absorb vibration. Traditional Material of Bed like Gray cast iron, mild steel has some inherent disadvantages like Long Manufacturing Lead time, Low damping, a tendency to Rusting, etc. The Alternative Materials may include Granite, Polymer Concrete, Synthetic Granite, Fiber-reinforced Cement Composites, etc. The outstanding damping and high stiffness has a beneficial effect on both tool wear and work piece surface finish. Epoxy Granite can fulfill this requirement. Epoxy granite is a mixture of an epoxy resin-hardener system (binder) and a graded aggregate system of granite (filler). The use of Epoxy Granite as an alternate material for Lathe Bed reduces the Manufacturing Lead Time of Lathe Bed and reduces Manufacturing Cost. XVI

17 INTRODUCTION CHAPTER 1 INTRODUCTION 1.1 Machine Tool A Machine Tool is defined as a stationary, power-driven machine used to cut, shape, or form materials such as metal and wood. The machine tools can be generally classified into seven types Lathes, Shapers and tools can be Planers, Power drills or Drill presses, Milling machines, Grinding Machines, Power saws and Presses. [27] Machine Tool is a machine that gives the desired shape to the work with required accuracy of removing metal from the work in the form of chip. Beds, columns, bases, head stock are known as structure in a machine tool. 70 to 80% of the total machine is due to its structure. [6] Thus the function of the machine tool structure 1) To resist the cutting & feed force during machining operation and support & 2) Guide the work piece and cutting tool. [6] For a proper design of machine structures, the knowledge of material, their availability, properties, magnitude and nature of the forces are required. The ideal material must have high stiffness, good damping capacity, good cast ability, low thermal deformation. Various materials such as concrete, acralic concrete, wrought steel, Epoxy Granite composite and ceramic resin concrete views as alternate material of cast iron. [24] There are two common features, which are fundamental to the satisfactory fulfillment of above requirements for all structures. These are: Proper selection of material High static and dynamic stiffness [6] 1.2 Lathe Machine The Lathe is one oldest machine tool used to remove material. In early, tree lathe was used in which a rope wound round the work with its one end attached to the Atmiya Institute of Technology & Science Page 1

18 INTRODUCTION flexible branch of a tree and other end being a pulled by a man caused the job to rotate intermittently. [28] The strip of wood called lath was used to support the rope so this machines came to be known as lathe. This device continued to developed through centuries and in the year 1797 Henry Maudslay, an Englishman, designed the first screw cutting lathe which is used now a day in industries. [28] The main function of a lathe is to remove metal from piece of work to give it the required shape and size. This is accomplished by holding the work securely and rigidly on the machine and then turning it against cutting tool which removes metal from the work in the form of chips. To cut the material properly the tool should be harder than the material of the work piece, should be rigidly held on the machine and should be fed in a definite way relative to the work. [28] Figure 1.1- All Geared Precision Lathe-Machine Tool [30] Following are the principle parts of Lathe Machine: Bed Headstock Tailstock Atmiya Institute of Technology & Science Page 2

19 INTRODUCTION Carriage Feed Mechanism [28] The Lathe Bed forms the base of the machine. The headstock and the tailstock are located at either end of the Bed and Carriage rests over the Lathe Bed and slides on it. The bed being the main guiding member of tool, for accurate machining work, must satisfy the following condition: It should be sufficiently rigid to prevent deflection under tremendous cutting pressure transmitted through the tool-post and carriage to the Lathe Bed. It must be massive with sufficient depth and width to absorb vibration It must resist the twisting stress set up due to the resultant of cutting force and force tending to move tool away from the work in a horizontal direction. It should avoid distortion or warp. [28] Wide flat guide provide reduction in wear. V guide provides better guide for carriage and tailstock, ensure accurate alignment and chip automatically fall. Due to small bearing surface in V guide, it results increases in wear. To take the advantage of both, the Bed with flat and V guide is used. [28] Table 1.1 Parameters for Analyzing Structure Material for Lathe Bed Sr No Material Properties Status Value Influence on the Behaviour of the Machine Tool 1 Material and High Positive influence on the dynamic properties structural damping 2 Density Low Positive influence on the dynamic properties 3 Thermal expansion Low Positive effect on geometric accuracy co efficient 4 Young s modulus High Positive influence on the static and dynamic stiffness 5 Poisson ratio High Positive influence on the machine tool torsion stiffness 6 Thermal conductivity Low or high Does not effect Atmiya Institute of Technology & Science Page 3

20 INTRODUCTION 1.3 Traditional Material for Lathe Bed Cast Iron Gray Cast basically is an alloy of Carbon and silicon with iron. It contains % C, % Si, 0.4-1% Mn, 0.15 % P and 0.10% S. Graphite flakes occupy about 10% of the metal volume. Length of flakes may vary from 0.05mm to 0.1mm. [29] The metallic matrix of cast iron consists of pearlite and ferrite. [29] It has high compressive strength, low tensile strength, and high rigidity. It has high fluidity and ability to make sound casting. It has relatively low melting temperature 1130 to 1250 C. It easily machined to good finish. It forms a discontinuous chip. It prevents chattering when used for machine frames. It has shrinkage 1 mm/100mm. [29] The soft ferrite grades are used to get the toughness and ductile properties. The harder pearlite grades are used when higher strength is required. Mixtures of pearlite and ferrite grades are also available. For different and better combination of properties heat treatment is used. The factors which are affecting on the properties of material are metallurgical structure. Cast iron is generally considered an inflexible material of brittle non malleable metal. It cannot work by blacksmiths. It is not worked with forged. Cast iron is worked with melting the metal and pouring in mould. It is excellent material for machine tool frame and parts due to its stiffness and damping properties. Cast iron is widely used for bases due to the stable structure of the material. It holds its shape when it is subjected to contraction and expansion due to temperature fluctuations. So it is ideal material for the lathe bed. This material gives good damping, easy to machine in various sizes Characteristics, Application, Advantage & Limitation of Cast Iron It is non malleable, brittle and hard means it cannot be stretch, bend or hammered into shape. It is more fusible than steel. It has crystalline structure and it is brittle and weak in tension. Under excessive tensile loading it shows fracture with prior distortion. Cast iron has good compression strength. According to different requirement, different composition and method are used. Atmiya Institute of Technology & Science Page 4

21 INTRODUCTION The gray cast iron is most traditional form. It is easily cast. It cannot forged mechanically either hot or cold. Carbon content is in the form of flakes distributed throughout the metal in the metal in gray cast iron. In white cast iron it is in the combined form as carbide of iron. It has malleability and superior tensile strength. It is also known as spheroidal graphite or malleable iron. Now a day it is also manufactured by same process as in history. Iron ore is heated with coke and limestone in a blast furnace. Due to this, deoxidises the ore and impurities are driven off and it produces molten metal. Then it is poured in a mould which is according to desired shape and then it is allowed to cool to crystallise. Protective film is developed on the surface in cast iron. Due to this it is more resistant to corrosion than wrought iron or mild steel. Bituminous coating, waxes, paints, galvanizing, plating may be used as finishing. There are various treatments to be done to reduce rusting and corrosion in the environment. The main purpose of this treatment is to prevent the casting from oxidizing in the presence of humidity. Cast iron is relatively inexpensive, durable and easily cast iron into a variety of shapes. Due to this it is widely used in various applications. According to use there are in various composition, sizes and treatment to be used. Table 1.2 Properties of Cast Iron Property Cast iron E ( GPa) σ F.S. (MPa) 150 σ C.S. (MPa) 600 α (10-6 /k) 10 ρ (kg/m 3 ) 7150 ξ 10-3 Use of Cast Iron: Machine Bed Hardware-hinges and latches Stairs Structural connector in building Atmiya Institute of Technology & Science Page 5

22 INTRODUCTION Fences Tools and utensils Piping Stoves Reasons due to which Cast Iron is widely used: Manufacturing facility Low cost Better material damping Static stiffness Intricate shapes and large size casting is possible. [2] Limitation of Cast Iron: Long Manufacturing Lead Time Anti corrosion treatment required Pollution in foundry High weight High initial cost Presence of internal stress High shrinkage rate during curing [2] 1.4 Alternative Material for Lathe Bed Alternate Material of Cast Iron Material such as 1) Cast steel 2) Cement Concrete 3) Polymer Concrete 4) Epoxy Granite [1] There are advantages and disadvantages of Different Material that can use as lathe bed are shown below: A) Wood A hollow box can use as Lathe Bed. Atmiya Institute of Technology & Science Page 6

23 INTRODUCTION Advantage Inexpensive To make and easy to assemble Light in weight. Gives some natural damping. Disadvantages Warps when exposed to extreme temperature or moisture. Possibility of fire due to wood material. B) Granite It is natural stone Advantage Inexpensive material. Very rigid and stable Good damping Disadvantage Difficult to convert desired shape C) Concrete Advantage Very rigid Disadvantage Poor damping D) Aluminium Advantages Easy to work Easy to ship or transport Disadvantages Poor damping F) Epoxy Granite Advantages Hard Smooth Atmiya Institute of Technology & Science Page 7

24 INTRODUCTION Best damping properties Rigid Potentially economical Can be cast to tight tolerances Can be polished Disadvantage Procedure need to be cast Atmiya Institute of Technology & Science Page 8

25 LITERATURE REVIEW CHAPTER 2 LITERATURE SURVEY Literature survey is one the processes of identifying research gap from already published research paper and research work. Every global industry are searching for a new material and new design which improves the properties, quality of the product, reduces cost of manufacturing process, increasing the flexibility of the process. [25] Materials such as cast steel, cement concrete, polymer concrete and epoxy granite can also look as the alternate material of traditional cast iron as machine tool structure. It requires evaluating different material in respect of the tensile strength, compressive strength, stiffness, damping, dimensional stability etc. [2] 2.1 Literature Survey 1] S.S. Abuthakeer, et.al, Static and Dynamic Performance Improvement of Conventional Computer Numerical Control Machine Tool Bed with Hybrid Welded Steel, 2011 [1] The aim of this study is to improve the natural frequency, stiffness and damping capacity with the use of composite material of polymer concrete and polymer concrete in machine tool. High damping and structural stiffness are two basic requirement of the machine tool that is not fulfil simultaneously with the use of conventional material such as cast iron. So it is required to replace the cast iron with alternate materials. In this study, a machine tool bed made of sandwich structures of welded steel and polymer concrete is designed and manufactured.the result shows that damping ratio is improved by 2.7 times and natural frequency is improved by 24.7%. The study is also shows that there is improvement in deformation and strain, The result shows that the static and dynamic characteristics is superior to Cast Iron and Hybrid Welded steel can be a alternate material of Cast Iron. 2] N.Mahendrakumar, et.al, Study of Alternative Structural Materials for Machine Tools, 2014 [2] Atmiya Institute of Technology & Science Page 9

26 LITERATURE REVIEW Composite Material such as Polymer Concrete, Epoxy Granite and Ferrocement can be an alternate material of traditional material Cast Iron as Machine Tool Structure. In this study, the process of Manufacturing of Epoxy Granite and Fiber reinforced polymer matrix are discussed. Table 2.1 Comparison of Mechanical Properties of Alternative Materials used in Machine Tool Structures Property Cement Concrete Polymer Concrete Epoxy Granite E ( GPa) σ F.S (MPa) σ c.s (MPa) α (10-6 /k) ρ(kg/m 3 ) ξ In this study, Epoxy Granite is defined as a hot curing Mixture of binder and filler. In this the epoxy resin-hardener act as a binder and granite act as filler. This mixture is poured in the mould and then vibration is given for compacting. The mixture is cured for 24 hours at room temperature. The major manufacturing sequences and equipments can be used for epoxygranite are the following: a. Granit slabs crushing into aggregates (stone crusher) b. Sieve analysis of aggregates (ASTM standard sieves) c. Mixing of aggregates, epoxy resin and hardener (muller) d. Mould layout preparation (steel dies with inserts) e. Mould filling and horizontal shaking for mould compaction (horizontal shaker) and f. Curing after mould making. 3] Vitor A. Ducatti, et.al, Comparative Study with Alternative Materials for Manufacture of Machine Tool Structures [3] In this, the alternative materials of Machine Tool Structure are studied. The comparative study for dynamic test results is discussed. The part selected as a test prototype represents a Lathe Bed in actual scale. Based on this, twelve pattern prototypes were manufactured and dynamic tests are performed by different material such as Cast Iron, Cast Steel, Fiber-reinfored mortar, Polymer mortar, Polymer mortar with reinforcement cage. Atmiya Institute of Technology & Science Page 10

27 LITERATURE REVIEW Prototypes were named using the following abbreviations: AR1, AR2 and AR3 for the fiber-reinforced mortar with 1%, 2% and 3% volume fraction of fiber, respectively; AA for the ferrocement; AP for the polymer mortar. Material Table 2.2 Mechanical Properties of Different Material Compressive Strength [MPa] Modulus of Rupture [MPa] Tensile Strength [MPa] AR AR AR AA AP Elastic Modulus [GPa] 4] S.B.Chandgude, et.al, Material Selection in Structural Design of Mini Milling Machine, 2014 [4] Analytic Hierarchy Process (AHP) Method is widely used for solving the complex decision problem. It decomposes a decision making problem into a system of objectives or criteria. This is developed by Saaty. Analytic Hierarchy Process (AHP) follows following steps Step 1: Determine the objective and the evaluation criteria. Step 2: Find out the relative important Matrix of different criteria with respect to the goal or objective. Construct a pair-wise comparison matrix using a scale of relative importance. Step 3: The next step is to compare the alternatives pair-wise with respect to how much better (i.e., more dominant) in satisfying each of the criteria. Step 4: The next step is to obtain the overall or composite performance scores for the alternatives by multiplying the relative normalized weight of each criteria with its corresponding normalized weight value for each alternative and making summation over all the criteria for each alternative. 5] D. Li, et.al, Optimization Design of Lathe-beds Based on FEA, 2009 [5] The Lathe Bed is a very important part of the Lathe Machine. The performance of the machine is largely depends on the Bed. In this, optimization of a Lathe Bed is studied. In this, three dimensional modelling and finite element analysis Atmiya Institute of Technology & Science Page 11

28 2010 [7] High structural stiffness and high damping are most important functional LITERATURE REVIEW method is studied. The model analysis shows that the optimal design gives better structure performance and this is feasible. With the use of model analysis, natural frequencies and mode of vibration are studied. The weak parts are found and used to improve the design. 6] A M Joshi, et.al, Finite Element Analysis of CNC Lathe Head Stock, 2009 [6] In this paper, Cutting forces are calculated based on several assumptions, regarding cutting conditions and values of cutting parameters, which will generate maximum cutting force. 7] Ding Jiangmin, et.al, Composite Concrete Bed for CNC Machine Tool, requirement for Machine Tool Bed. Conventional metallic material has high stiffness but low damping. Epoxy Concrete can fulfil the requirement but its cost is high. In this the Composite Concrete Bed for CNC Machine Tool which is composited of epoxy concrete structure faces and steel fiber cement concrete core. The beds satisfy the requirement and cost is also low. The Epoxy Concrete is more expensive ($300/m3 to $2000/m3). The conventional Cement Concrete ($50/m3 to $80/m3) is economical and has better damping, but due to its inferior stiffness and exterior impact resistance. Cement material composite is obtained by adding short and discrete steel fibers of small diameter in the mix, known as steel fiber cement concrete. In this steel fibers are act as load carrying component in the composite. The matrix in the composite acts as binder, protect and transfer load among fibers. In concrete the steel fibers of short length and small diameter are added and the resulting concrete is poured into the mould. It shows that steel fiber concrete is marginally less rigid than cast iron. The advantages of this are low cost, simple manufacturing process and good dynamic properties. 8] Tian Yaogang, et.al, Mechanical and Dynamic Properties of high Strength Concrete modified with Lightweight Aggregates pre saturated Polymer Emulsion, 2015 [8] Atmiya Institute of Technology & Science Page 12

29 LITERATURE REVIEW The use of Polymer admixtures in cement concrete has proved to be more efficient to improve the damping capacity but it somewhat decreases compressive strength. It indicates that it is not possible to enhance the damping capacity of concrete with sacrificing its other mechanical properties. Therefore it is necessary to explore concrete possessing both desirable damping capacity and high strength. 9] Jaimon Dennis Quadros, et.al, Analysis of variance and response Surface Analysis of Thrust Force and Torque in Drilling Granite Fiber Reinforced Epoxy Composite by using Multi Facet HSS Twist Drill [9] Granite fiber reinforced epoxy composite gives effective strength to weight and stiffness to weight ratio. The matrix material is epoxy resin (LAPOX L-12) and hardener (K-6). This gives good resistance to alkalis and gives good adhesive properties. Powder if Granite used as reinforcement material. Lay up technique is used for making laminates of epoxy granite. Curing time is 24 hours for this process. 10] Dai Gil Lee, et.al, Damping Improvement of Machine Tool Columns with Polymer Matrix Fiber Composite Material, 1998 [10] To improve the damping capacity of the column of surface grinding tool, a hybrid column is manufactured with the composite plates to a cast iron column. It shows that the damping capacity of the hybrid column is higher than that of the cast iron column. Due to easy and inexpensive implementation, rubber is widely used for surface damping treatment but due to low stiffness it is not used for large & high stiffness structure. Polymer fiber provides good surface damping and high stiffness. So it can be used in Machine Tool column to improve the damping. Because of high specific stiffness, damping and high specific strength, Polymer fiber reinforced composite material is widely used in aircraft, spacecraft, automobile structures and machine element like robot structure. 11] M. Rahman, et.al, Development of a Polymer impregnated concrete damping carriage for linear guide ways for Machine Tools, 2000 [11] In this study, Steel used in carriage of CNC machine table is replaced with concrete because of high internal damping. The material used is normal Concrete, Atmiya Institute of Technology & Science Page 13

30 LITERATURE REVIEW Cellular Concrete and Polymer impregnated cellular concrete. It is found that Polymer impregnated cellular concrete is the most suitable material for the purpose. 12] C. Bruni, et.al, Hard turning of an Alloy steel on a Machine Tool with a Polymer Concrete Bed, 2007 [12] High rigidity and damping of the Polymer Concrete Bed is beneficial for both tool wear and work piece surface finish. The use of material having high internal damping reduces the effect of vibration on the tool and work piece and gives good surface finish. It is studied that the conventional material such as Welded Steel and Cast Iron can replace by an alternative material such as Ferro cement, Hydraulic Concrete, Polymer Impregnated Concrete and Polymer Concrete. 13] Dai Gil Lee, Design and Manufacture of Composite high speed Machine Tool Structures, 2007 [13] The high speed of the machine is restricted due to the vibration. To overcome this limitation, the slide of the CNC machine is designed with reinforced Composite materials. It is manufactured by joining high modulus carbon fiber epoxy composite sandwiches and Welded Steel with bolts and adhesives. Due to this arrangement the weight of the horizontal and vertical slides is reduced by 26% and 34% respectively and the damping is improved by times without sacrificing the stiffness. The accuracy can achieved is +/- 5 μm per 300 mm of the slide displacement. The design of Hybrid structure is at equal stiffness of the conventional Steel structure. 14] Jung Do Shu, Damping Characteristics of Composite Hybrid Spindle covers for High speed Machine Tools, 2001 [14] Vibration creates the noise and chatter marks on the machined surfaces. The improvement in vibration is achieved with the use of spindle cover made of 2 mm thick steel plate for high speed machine tool. The cover is from carbon epoxy composite material. 15] Vinay Babu Gada, The Impact of Cutting Conditions on Cutting Forces and Chatter Length for Steel and Aluminum, 2013 [15] Atmiya Institute of Technology & Science Page 14

31 LITERATURE REVIEW The tool life of the machine is highly dependent on the vibration of the machine. The vibration of the machine lowers the productivity and increases cost of production. Chattering or self excited vibration is the dynamic instability in the machine tool through an interaction between the structure and cutting. 16] Hyun Surk Kim, A Study on Epoxy Resin Concrete for the Ultra-precision Machine Tool Bed, 2013 [16] Resin matrix concrete material which is composed of polymer material, sand pebble and other reinforcing material is used as the bed material of Machine Tool Structure. In this, manufacturing process of Resin Concrete Bed is discussed. 17] Aguinaldo dos Santos, Cascade approach on Recycling for Marble and Granite product design, 2008 [17] Though Granite and marble are economical, there is little attention on the design and manufacturing for machine tool structure. In this, the study of creative solutions for the waste generated during the production of marble and granite product. 18] Shiqun Li, Influence of Interface Modification and Phase Separation on Damping Properties of Epoxy Concrete, 1996 [18] In the 1960s, Schutz suggests the Polymer Concrete as the alternate material of Steel and Cast Iron. It is to be suggested that the use of Polymer Concrete improves the surface roughness and tool life. 19] K.P. Roysarkar, Designing Machine Tool Structures with Epoxy Concrete, CEMRI, Durgapur [19] The material of the Machine Tool affects the accuracy, surface finish and metal removal rate. Central Mechanical Engineering Research Institute (CMERI) suggests the Epoxy Concrete as the alternate material for machine tool. In this paper, manufacturing process of Epoxy Concrete Bed is discussed. The conventional material such as Gray Cast Iron, Mild steel has some inherent disadvantages like long manufacturing lead time, low damping, a tendency to rusting, high cost etc. The alternative materials suggested in this paper are: Granite, Atmiya Institute of Technology & Science Page 15

32 LITERATURE REVIEW Polymer Concrete, Synthetic Granite, Ferrocement, Fiber-reinforced Cement Composites Ceramic resin Concrete etc. 20] Deepak D. Ubale, Experimental Investigation of Material Properties of Epoxy Granite, 2013 [20] The traditional structure material like Cast Iron shows some limitations like low damping, long manufacturing time, high cost. In this paper, Epoxy Granite is suggested as an alternative material. It has high stiffness, damping and co efficient of thermal expansion. In this paper, the properties of Epoxy Granite such as compressive strength, flexural strength, modulus of elasticity, damping was investigated experimentally. The specimen of the Epoxy Granite is prepared with the use of Granite as the filler. The Granite is crushed and sieved in different sizes. The size of coarse aggregate was mm, 3-5 mm, 5-8 mm and fine grain size was less the 0.5 mm. Resin used for this was Araldite 103 that works as matrix material. HY 951 is used as hardener. The proportion of the resin and Hardener is used is 90:10 for the specimen. The test specimen was cured for 24 hours at room temperature. 21] A.Selvakumar, Analysis of Alternative Composite Material for High speed precision Machine Tool Structures, 2012 [21] When alternate material is used as the replacement material for the Machine tool, it should be designed for equal stiffness. For equal stiffness depth of the Epoxy Granite is 1.35 times than Cast Iron. So it can be stated that d E/G = 1.35 times d Cast Iron. Same way for equal stiffness depth of the Epoxy Granite is 1.63 times than Steel. So it can be stated that d E/G = 1.63 times d steel. So it states that to maintain equal stiffness of Epoxy Granite material, the depth has increased by 35% as compared to Cast Iron and 63% as compared to Steel. The use of Epoxy Granite helps to dampen out the induced vibrations at faster rate compared to Steel and Cast Iron structures. Hence Epoxy Granite can use as an alternative material for high speed precision machine tool structures. 22] Antonio Piratelli-Filho, Behavior of Granite-Epoxy Composite Beams Subjected to Mechanical Vibrations, 2010 [22] Atmiya Institute of Technology & Science Page 16

33 LITERATURE REVIEW Due to Less dimensional stability associated to water absorption, the use of Concrete structure as Machine tool is unfeasible. Some companies of the Unites States start to supply the Epoxy Granite compounds. Size, purity of the ceramic particles, homogeneity and viscosity of the polymer are the process variables that affect the properties of the composites. 23] Sandesh Kamath, Experimental study on Mechanical Properties of Red Granite-Epoxy particulate Composites, 2014 [23] This paper presents a study on the red granite powder reinforced epoxy composite. The composites have been fabricated by varying the granite-epoxy ratio on weight percentage basis. The compression test results recorded a very good strength of 110 MPa for granite-epoxy ratio 75:25 with grain size ratio 50:50. The composite shows high damping for granite-epoxy ratio 80:20.The paper also describe the manufacturing process of Epoxy Granite. In this paper, Red Granite powder reinforced Epoxy composite is studied. The composite is manufactured by varying the Granite-epoxy ratio on weight percentage basis. The compression test for Granite-epoxy ratio 75:25 with grain size ratio 50:50 shows good strength of 110MPa. The high damping shows for the composition of Granite epoxy ration 80:20. This paper also indicates the manufacturing process of Epoxy Granite. 2.2 Introduction about Industry M/s. Geeta Machine Tools Pvt. Ltd is a leading Machine Tool Manufacturing ISO Company established in 1976, now restructured by acquiring the assets/ facilities in with machines along with premises of a world famous companies in the field of Machine Tools- M/s. New Bharat Engineering Works (Jamnagar) Pvt. Ltd., Establishing in 1951, collaborated with WMW- GERMANY for building NEW BHARAT horizontal Boring & Milling Machine, Hi-tech CNC machine & Lathe machine in Total 10,000 Machine are manufactured & supplied all over India & abroad. Atmiya Institute of Technology & Science Page 17

34 LITERATURE REVIEW Figure 2.1- Geeta Machine Tool Pvt. Ltd Existing Infrastructure Existing factory spread in 2.50 Lacks Square Feet land including foundry facilities Capacity of 10 MT single piece CI Casting Foundry In house Pattern shop & Fabrication shop In house Design & Drawing department Experience & skilled Manpower In house Gear Generator Machine [30] GEETA MACHINE TOOLS PVT. LTD. JAMNAGAR New Bharat Engineering Works, Pandit Nehru Marg, Jamnagar (Gujarat) INDIA Tel: /03, Website: Atmiya Institute of Technology & Science Page 18

35 LITERATURE REVIEW Fax: , Customers From Private Sector / Defence Industrial Training Institute (ITI S) Hindustan Aerospace Trivendrum Hindustan Aeronautics Limited (HAL)-Koraput L & T Relience Group ESSAR Group TATA Group BHEL [30] From Railway Workshop Using SPM/ Standard Machines Diesel Locomotive Works, Varanasi North West Railways-Jodhpur, Rajasthan Rail Wheel Factory, Yelahaka, Bangalore Integral Coach Factory, Channai [30] 2.3 Problem Statement After the analysis of Lathe Bed Manufacturing unit, it was found that Manufacturing Lead Time of Lathe Bed is long and Manufacturing Cost of Lathe Bed is high. 2.4 Objectives The main objective of my research work is given below: 1) Decrease the Manufacturing Lead Time of Lathe Bed 2) Reduce Manufacturing Cost with the use of Alternate Material for Lathe Bed. Atmiya Institute of Technology & Science Page 19

36 METHODOLOGY CHAPTER 3 METHODOLOGY 3.1 Introduction of Analytical Hierarchy Process (AHP) In daily life we are continuously passes through the decision making process. Whatever we do consciously or unconsciously that is a result of our decision. In generally we collect the information & with the use of it, we are taking judgement. All the information we collect, may not be useful for judgement or improving our decision. So first of all we understand the need and purpose of the decision. Then we can determine best from alternatives. Whatever the decision we are taking should be transparent in all the aspects. In many industries, final decision to be taken to select one among the number of criteria. The AHP method is effective approach in this kind of decision problem. It is developed by T.L.Satty in [26] In Analytical Hierarchy Process (AHP) pair-wise comparison is to be done for taking the priority decision. The comparison are done with the use of scale, how much more, one element dominates another with respect to a given attribute. After getting the solution, consistency is to be checked for satisfaction about decision. 3.2 Steps of AHP STEP 1) Define the problem and determine the information required for it. In this the problem that to be solved is defined and information required for the judgement is collected. STEP 2) Pair-wise comparison Each of judgement is assigned a number on a scale. One common scale adopted by Saaty is: Atmiya Institute of Technology & Science Page 20

37 METHODOLOGY Table 3.1 Intensity of Importance for AHP [26] Intensity of Definition Explanation importance 1 Equal importance Two factors contribute equally to the objective. 3 Somewhat more importance Experience and judgement slightly favour one over the other. 5 Much more importance Experience and judgement strongly favour one over the other. 7 Very much more importance Experience and judgement very strongly favour one over the other. 9 Absolute more importance The evidence favouring one over the other is of the highest possible validity. 2,4,6,8 Intermediate values Intermediate value of importance No of things No of comparison Table 3.2 Number of Comparison n n(n-1)/2 From this make a comparison matrix: For example: I like Apple (A) 7 times more than Grapes (G). Then A=7*G and G=A/7. I like Apple (A) 5 times more than Mango (M). A=5*M. and M=A/5. I likes Mango (M) 3 times more than Grapes (G). M=3*G. Atmiya Institute of Technology & Science Page 21

38 METHODOLOGY and G=M/3. A M G A M 1/5 1 3 G 1/7 1/3 1 SUM 47/35 19/3 11 STEP 3) Make a Normalized Matrix From comparison matrix, Find normalized matrix by (Each element /sum of its Column) A M G A 35/47 15/19 7/11 M 7/47 3/19 3/11 G 5/47 1/19 1/11 SUM STEP 4) Make a Priority Matrix From the Normalized matrix, find the Priority matrix by (sum of each row element/3) 35/47+15/19+7/ /47+3/19+3/11 W = /47+3/19+1/ W = Atmiya Institute of Technology & Science Page 22

39 METHODOLOGY So we can say Apple is 3.74(0.7235/0.1931) times more preferable than Mango. Apple is 6.11(0.7235/0.1183) times more preferable than Grapes. STEP 5) Find the value of λ max λ max = (sum of each column of comparison matrix)*(value % of that from priority matrix) = 47/35(0.7235) + 19/3(0.1931) + 11(0.1183) = = STEP 6) Find Consistency Index (C.I) Using the equation C.I = ( λ max -n)/ (n-1) Here n=3 So C.I = ( )/ (3-1) = Now Random Consistency Index (RI) Table 3.3 Value of RI for Different Value of n n RI Here for n= 3, RI = 0.5 STEP 7) Find Consistency Ratio (CR) By using the equation find consistency ratio (C.R) by using the equation CR= CI / RI. Here, CI= , RI=0.58 So CR=0.2474/0.58 = = 4.265% That is less than 10%. Atmiya Institute of Technology & Science Page 23

40 METHODOLOGY If the value of consistency ratio is smaller than or equal to 10%, the inconsistency is acceptable. If the consistency ratio is greater than 10%, we need to revise the subjective judgment. Here we are getting the value of CR is less than 10%, so the consistency is acceptable. [31] 3.3 Application of AHP for Material Selection for Lathe Bed STEP 1) Define the problem and determine the information required for it.. The two functional requirement of the machine tool bed for the machine tool are: High damping High structural stiffness [1] The goal is to find out the best material from the alternative. It is to be taken three alternative materials for lathe bed: Cement Concrete Polymer Concrete Epoxy Granite Table 3.4 Comparison of Mechanical Properties of Alternative Materials Used in Machine Tool Structures [2] Property Cement Concrete Polymer Concrete Epoxy Granite E( GPa) σ F.S (MPa) σ c.s (MPa) α (10-6 /k) ρ(kg/m 3 ) ξ Atmiya Institute of Technology & Science Page 24

41 METHODOLOGY Table 3.5 Parameters for Analyzing Structure Material for Lathe Bed Sr No Material Properties Status Influence on the Behaviour of the Machine Value Tool 1 Material and High Positive influence on the dynamic properties structural damping 2 Density Low Positive influence on the dynamic properties 3 Thermal expansion co Low Positive effect on geometric accuracy efficient 4 Young s modulus High Positive influence on the static and dynamic stiffness 5 Poisson ratio High Positive influence on the machine tool torsion stiffness 6 Thermal conductivity Low or Does not effect. high Table 3.6 Intensity of Importance for AHP Intensity of Definition Explanation importance 1 Equal importance Two factors contribute equally to the objective. 3 Somewhat more importance Experience and judgement slightly favour one over the other. 5 Much more importance Experience and judgement strongly favour one over the other. 7 Very much more importance Experience and judgement very strongly favour one over the other. 9 Absolute more importance The evidence favouring one over the other is of the highest possible validity. 2,4,6,8 Intermediate values Intermediate value of importance. Atmiya Institute of Technology & Science Page 25

42 METHODOLOGY STEP 2) Pair-wise Comparison Table 3.7 Number of Comparison No of Items n No of Comparison n(n-1)/2 From this make a comparison matrix: The Epoxy Granite (EG) is 5 times more important than Polymer Concrete (PC). Then EG=5*PC PC=1/5 EG The Epoxy Granite (EG) is 9 times more important than Cement Concrete (CC). Then EG=9*CC CC=1/9 EG The Polymer Concrete (PC) is 3 times more important Cement Concrete (CC) Then PC=3*CC CC=1/3 PC Comparison Matrix: EG PC CC EG PC 1/5 1 3 CC 1/9 1/3 1 SUM 59/45 19/3 13 STEP 3) Make a Normalized Matrix Column) From comparison matrix, Find normalized matrix by (Each element /sum of its Atmiya Institute of Technology & Science Page 26

43 METHODOLOGY EG PC CC EG 45/59 15/19 9/13 PC 9/59 3/19 3/13 CC 5/59 1/19 1/13 SUM STEP 4) Make a Priority Matrix From the Normalized matrix, find the Priority matrix by (sum of each row element/3) 45/59+15/19+9/ W = 9/59+3/19+3/ /59+1/19+1/ W = It indicates Epoxy Granite (EG): 74.81% Polymer Concrete (PC): 18.04% Cement Concrete (CC): 7.14% Atmiya Institute of Technology & Science Page 27

44 METHODOLOGY So we can say Epoxy Granite (EG) is 4.14(74.18/18.04) times more preferable than Polymer Concrete (PC). Epoxy Granite (EG) is 10.4(74.81/7.14) times more preferable than Cement Concrete (CC). STEP 5) Find the value of λ max λ max = (sum of each column of comparison matrix)*(value % of that from priority matrix). = 59/45(0.7481) + 19/3(0.1804) +13(0.0714) = = STEP 6) Find Consistency Index (C.I) Using the equation C.I = (λmax -n)/ (n-1) Here n=3 So C.I = ( )/ (3-1) = Now Random Consistency Index (RI) Table 3.8 Value of RI for Different Value of n n RI Here for n=3, RI=0.58 STEP 7) Find Consistency Ratio (CR) By using the equation find consistency ratio (C.R) by using the equation CR= CI / RI. Here, CI= RI=0.58 So CR= /0.58 = = 4.436% Atmiya Institute of Technology & Science Page 28

45 METHODOLOGY That is less than 10%. If the value of consistency ratio is smaller than or equal to 10%, the inconsistency is acceptable. If the consistency ratio is greater than 10%, we need to revise the subjective judgment. Here we are getting the value of CR is less than 10% so the consistency is acceptable. [31] So we choose the Epoxy Granite (EG) material for lathe bed among all alternatives. 3.4 Manufacturing Process of Epoxy Granite Lathe Bed For Manufacturing the Lathe Bed, following processes is to be followed. First of all waste Granite cut pieces are collected. Then it is crushed in the crusher. Then the crushed Granite is sieving in different size. Then the mould of Lathe Bed is prepared and the mixture of the crushed Granite, resin and hardener is filled in the mould. After 24 hours it is de moulded and finished by Grinding Machine. COLLECTION OF WASTE GRANITE CUT PIECES CRUSH THE GRANITE SIEVING IN DIFFERNT SIZE MOULD PREPARATION COLLECTION OF RESIN & HARDENER FILL THE MOULD WITH EPOXY GRANITE CURING FOR 24 HOURS AND DEMOULDING FINISHING BY GRINDING MACHINE Figure 3.1 Manufacturing Process of Epoxy Granite Atmiya Institute of Technology & Science Page 29

46 METHODOLOGY Methodology followed to manufacture the Epoxy Granite Lathe Bed is discussed below: MEASUREMENT OF CAST IRON LATHE BED CALCULATE THE DIMENSIONS FOR EPOXY GRANITE LATHE BED MAKING THE SAMPLE OF 150 GRAM MAKING THE SAMPLE OF 1 KG PREPARATION OF MOULD, CRUSH THE GRANITE AND SIEVING FABRICATION OF EPOXY GRANITE LATHE BED MODEL ANALYSIS USING ANSYS 14.5 COMPARTIVE STUDY OF CAST IRON BED AND EPOXY GRANITE LATHE BED Figure 3.2 Methodology 3.5 Design of Epoxy Granite Lathe Bed for Equal Stiffness Figure 3.3 Existing C.I Lathe Bed Atmiya Institute of Technology & Science Page 30

47 METHODOLOGY EXISTING CAST IRON LATHE BED Figure 3.4 Existing Cast Iron Bed with Dimension Atmiya Institute of Technology & Science Page 31

48 METHODOLOGY Figure shows the dimensions of the existing Cast Iron Lathe Bed. To change the material of the lathe bed it requires to design at equal stiffness. For analysis of the Machine Tool component such as the bed the rectangle beam is considered. For the beam subjected to the bending load, the deflection (y) is proportional to the applied load (F) and length cube (L) and inversely proportional to flexural rigidity y α FL 3 / EI Where F= Load applied L=Length of cube E=young s modulus EI= Flexural rigidity I= Moment of inertia K= stiffness [21] K= F/y For equal stiffness their flexure rigidity EI will be constant. Length for the beam is considered constant. Aspect ratio d/b is taken constant. K= F/y α EI K C.I α E C.I I C.I α E C.I (b C.I d 3 C.I /12) K E.G α E E.G I E.G α E E.G (b E.G d 3 E.G /12) Here aspect ratio (d/b) is considered constant. K C.I α E C.I (d 4 C.I /24) K E.G α E E.G (d 4 E.G /24) For designing for equal stiffness we are taken K C.I = K E.G E C.I (d 4 C.I /24) = E E.G (d 4 E.G /24) Atmiya Institute of Technology & Science Page 32

49 METHODOLOGY d 4 E.G/ d 4 C.I = E C.I/ E E E.G d E.G / d C.I E EG =30 MPa d EG / d C.I = (100/30) d EG / d C.I = (3.33) ¼ = (E C.I/ E E.G) 1/4 E C.I = 100 MPa ) 1/4 d EG = 1.35 d d C.I This indicates that the depth of the epoxy granite bed should be 35% higher than the cast iron bed for equal stiffness. [21] Figure 3.5 Dimensions for Steel, Cast Iron and Epoxy Granite for equal Stiffness For equal stiffness design we have to maintain equal aspect ratio (d/b). In this figure the aspect ratio 2 is maintained constant. If we increase the depth, to maintain the aspect ratio we have to increase the width as shown in figure. Figure indicates the size of Steel, Cast Iron and Epoxy Granite for equal stiffness. [21] Atmiya Institute of Technology & Science Page 33

50 METHODOLOGY PROPOSED EPOXY GRANITE LATHE BED Figure 3.6 Proposed Epoxy Granite Lathe Bed with Dimension Atmiya Institute of Technology & Science Page 34

51 METHODOLOGY 3.6 Introduction of Granite, Epoxy Resin and Hardener 3.6.1) Granite Granite is a very hard natural igneous rock formation of visibly crystalline texture formed essentially of quartz and orthoclase or microcline. [27] Figure 3.7 Black Granite as an Industrial Waste Granite used in this project is Industrial waste. It has high strength, stiffness and better wear resistance properties. It is found in Assam, Bihar, Andhra pradesh. Chemical composition: Silica 70-77% Alumina 11-13% Soda 3-5% Lime 1% [32] Physical Properties: Density g/ cm 3 Tensile Strength 7-25 Mpa Modulus of Elasticity Gpa Compressive Strength Mpa [33] Thermal conductivity w/mk Crushing strength Kg/ cm 2 Atmiya Institute of Technology & Science Page 35

52 METHODOLOGY Appearance - black and white spackled rock Solubility- insoluble Odourless [32] 3.6.2) Resin & Hardener Epoxy Resin LY 556 is a synthetic resin. It is made from Epichlorohydrin and Bisphenol-A. [29] It is from the epoxide family. It is used as matrix material. Epoxy resin comes under the class of thermo set alongside silicones and polyester. HY-951 is used as a Hardener. It contains active hydrogen. The proportion of Epoxy Resin LY- 556 and Hardener HY-951 is taken in proportion 10:1 by weight. To get the best result the proportion of crushed Granite and Resin is 80:20 by weight [2]. Figure 3.8 Resins and Hardener 3.7 Manufacturing of Sample of 150 gm To check the feasibility of Epoxy Granite, first of all the sample of 150 gm is made. The waste cut piece of black Granite is collected from Shivam Marbles, GIDC Phase III, Jamnagar Atmiya Institute of Technology & Science Page 36

53 METHODOLOGY Figure 3.9 Waste cut piece of Black Granite Then it is hammered to get small grains as shown in figure. Because of unavailability of a machine to crush such a small quantity, this work is done by hammering. After hammering the granite, grains of the small granite got as shown in figure. Figure 3.10 Hammering the Granite to get Crushed Granite After collecting the crushed Granite, sieving of Granite in different size is required. For this different size of sieves are required. This work is done in Material Lab of Civil department in our college. Atmiya Institute of Technology & Science Page 37

54 METHODOLOGY Figure 3.11 Sieving in Different Size of 0.5, 1.7, 2.36 mm After collecting the crushed Granite with different size, it mixes with the resin and hardener in proportion 80:20 by weight and moulding it as shown in figure. The proportion of resin: hardener is 10:1 by weight [2]. Figure 3.12 Moulding of the Sample 1 After 24 hours, it gets the Epoxy Granite sample as shown in figure. Figure 3.13 Epoxy Granite Sample - 1 Atmiya Institute of Technology & Science Page 38

55 METHODOLOGY 3.8 Manufacturing of Sample of 1 Kg In this, the sample of 1 Kg having 15 mm thick, the proportion of Granite is 800 gm, 180 gm resin and 20 gm hardener is mixed. The mould is made of thermocol as shown in figure. The mixture is fed in the mould. Figure 3.14 Moulding of the Sample - 2 After 24 hours, it gives the Epoxy Granite sample as shown in figure. Figure 3.15 Epoxy Granite Sample - 2 Atmiya Institute of Technology & Science Page 39

56 METHODOLOGY 3.9 Comparison of Properties for varying Resin Content For checking the strength a specimen having dimensions 60*60*18 mm in the grip and 150*50*18 mm in test area are prepared according to the ASTM D 3039 standard. For making the specimen the wooden mould is prepared as shown in figure and specimens are prepared. To compare the properties for varying Resin Content, 3 specimens are prepared with varying Resin Proportion of 17%, 20 % and 23%. Figure 3.16 Mould for Making the Specimen Figure 3.17 Specimen with Varying Resin Content 17%, 20 % and 23% After making the Specimens, tensile test are conducted as shown in figure. Atmiya Institute of Technology & Science Page 40

57 METHODOLOGY Figure 3.18 Specimen before Test Figure 3.19 Specimen after Test Resin 17% Resin 20% Resin 23% Strenth ( Mpa) Figure 3.20 Comparisons of Properties for Varying Resin Content Atmiya Institute of Technology & Science Page 41

58 METHODOLOGY The chart shows that the resin with 20% proportion gives maximum strength. So this proportion is used for Manufacturing of Lathe Bed Manufacturing of Lathe Bed ) Collection of Black Granite as raw material I have visited various Granite cutting factories like 1) Shivam Marbles 2) Shriji Granite. I have collected about 100 Kg from these factories. It is industrial waste so it can get free of cost. Figure 3.21 Site scene of Shivam Marbles - A Figure 3.22 Site scene of Shivam Marbles-B Atmiya Institute of Technology & Science Page 42

59 METHODOLOGY Figure 3.23 Collection of about 100 Kg waste Cut Pieces of Granite ) Resources for Crushing the Granite cut pieces a) Visit of Mill The visit was made in the following milling unit. Mansi Minerals, Plot No 268, street c Rafadeshwar GIDC, Vakaner Road, Morbi. Contact No: Figure 3.24 Miller at Mansi Minerals Atmiya Institute of Technology & Science Page 43

60 METHODOLOGY In my visit, I saw process of conversion of vitrified and glass in Powder form. But due to high capacity of miller, it requires minimum 5000 Kg raw material. I want to crush the material about 100 Kg. So it is not useful for my Project. b) Visit of Stone Crusher The visit was made in the following crushing unit. Dared Jamnagar Bypass road, Jamnagar Figure 3.25 Stone Crusher In my visit, I saw the process of crushing the stone in grain of different size as shown in fig. But it requires minimum 2 to 3 Ton raw material to crush. I want to crush the material about 100 Kg. So it is not useful for my Project. c) Visit of Small Capacity Crusher The visit was made in the following crushing unit. Dipen Trading, Gokul Nagar GIDC Phase I, Jamnagar Contact No: Atmiya Institute of Technology & Science Page 44

61 METHODOLOGY Figure 3.26 Small Size Crusher at Dipen Trading In my visit, it is found that this machine fulfils my requirement to crush 100 Kg Granite cut pieces. The 100 kg material is crushed within 20 Minutes. The rate of crush the material is 1.5 Rs/ Kg. After crushing, I got the material as shown in figure. Figure 3.27 Crushed Granite after Crushing ) Sieving in Different Size Coarse Grain particles in higher proportion give strength the structure and medium and fine particles reduce the void formation in the structure. So the mixture in the ratio 50:25:25 (Coarse: Medium: Fine) is selected for the structure. Powder form of Granite gives good surface finish of the Lathe Bed and Coarse grain size of granite is required for strength. So powder less than 0.5 mm is used when surface finishing is required and rest of all is made from the mixture of grains 50:25:25 (Coarse: Medium: Fine). Atmiya Institute of Technology & Science Page 45

62 METHODOLOGY For sieving the granite in different sizes, different sizes of sieves are required. This work is done in Material Lab of Civil department in our College. Figure 3.28 Sieving in Different Size 0.5, mm (Fine, Medium, Coarse) Figure 3.29 Sieving in Different Size 0.5, mm (Fine, Medium, Coarse) ) Sources for Resin and Hardener For binding the granite particles, according to research paper Resin LY- 556 and HY- 951 is required to use. The proportion of Granite: Resin: Hardener is 80:18:2. For checking feasibility, I will take sample quantity of Resin and Hardener. The visit was made in the following unit. D-Fix Enterprise, 506, Parshwanath Business Park, Prahaladnagar, Ahmedabad. Atmiya Institute of Technology & Science Page 46

63 METHODOLOGY Contact No: Figure 3.30 Samples of Resin & Hardener To check feasibility, I made sample of 150 gm. After success of it for sample I asked for market price of Resin & Hardener. This is 225 Rs/Kg for Resin and 437 Rs/Kg for Hardener. So for making 36 Kg of material, it requires 6.48 Kg Resin and 0.72 Kg Hardener. So its total cost is 1768 Rs for 36 Kg of Lathe Bed. So approximately manufacturing cost Rs/kg so it is possible to use. So I purchase it. Figure 3.31 Resin and Hardener for Manufacturing of Lathe Bed ) Resources for Moulding material for good Finishing a) Use of Plastic Plate Atmiya Institute of Technology & Science Page 47

64 METHODOLOGY To check feasibility of use of Plastic Plate for Mould, sample of 150 gm is mould in Plastic Plate. It shows good finishing but it is difficult to make the Plastic mould of Lathe Bed. Figure 3.32 Use of Plastic Plate for Mould b) Use of Thermocol I made a sample with thermocol mould and burnt the thermo coal after use. But due to burning and material enters small holes of thermocol, it gives very bed finishing. Figure 3.33 Use of Thermocol Mould c) Use Thermocol with plastic Cover In this Thermocol with plastic wrapper as mould is used and remove it after curing. It gives good surface finish and mould is easily removed. Wooden mould can also use for a large production. Here I use Thermocol as a mould because it is cheap than wood and requires less time for manufacturing. Atmiya Institute of Technology & Science Page 48

65 METHODOLOGY Figure 3.34 Use of Thermocol with Plastic Cover ) Resources for Finishing For smooth movement of carriage and tail stock in the Lathe Machine, it requires to avoid uneven surface on the guide ways. a) Use milling cutter Because of high hardness of Epoxy Granite, Milling Cutter cannot capable to cut the Epoxy granite. So Milling Cutter cannot use. b) Use of different grits of hand grinding wheel Hand grinding wheel with varying grit size from 100 to 8000 is used for finishing in Granite stones for glassy finishing. The grinding wheel of 1500, 2000 and 3000 grits is used respectively. It gives average finishing but cannot avoid uneven surfaces because of variation of pressure applied by hand. For smooth movement of carriage and tail stock, it requires to avoid uneven surface on the guide ways. So Hand grinding wheels not fulfil the requirement. To avoid the uneven surfaces, it requires machine grinding. Atmiya Institute of Technology & Science Page 49

66 METHODOLOGY Figure 3.35 Hand Grinding Wheel C) Use of Surface Grinding Machine with Amery wheel AA-46/54 For smooth movement of carriage and tail stock, it requires to avoid uneven surface on the guide ways. The use of Surface Grinding Machine with Amery wheel AA-46/54 gives good surface finish up to 2.59 μ and fulfils the requirement. Figure 3.36 Surface Roughness Measurement ) Making of Mould from Thermocol Because of low cost and less time to get desired shape, thermocol is used to make mould for Lathe Bed. First of all impression of the section of the Lathe Bed on the wooden Sheet is made for easy understanding as shown in fig. For that primer is pasted on the wooden sheet to get clear drawing on sheet. It will dry in minutes. Then drawing of the cross section of Lathe Bed is made on it as shown in figure. Atmiya Institute of Technology & Science Page 50

67 METHODOLOGY Figure 3.37 Cross section of the Lathe Bed made on Wooden Sheet After getting the cross section view of the Lathe Bed on wooden sheet, the process of manufacturing of thermocol mould is done. First of all, the thermocol sheet is cut according to the requirement. Figure 3.38 Measurement and Cutting of the Sheet according to Requirement After the measurement and cutting of the sheet, it is joined by fevicoal as shown in figure below. First of all the mould of upper side of the Lathe Bed is prepared. Atmiya Institute of Technology & Science Page 51

68 METHODOLOGY Figure 3.39 Preparation of the Mould of the Lathe Bed with Thermocol step 1 After making the upper side of the Lathe Bed, mould of side of the lathe Bed and Legs are prepared. Figure 3.40 Preparation of the Mould of the Lathe Bed with Thermocol step 2 After making of the mould of the side of Lathe Bed, it is joined by nails as shown in figure. Figure 3.41 Preparation of the Mould of the Lathe Bed with Thermocol step 3 Atmiya Institute of Technology & Science Page 52

69 METHODOLOGY The gap between the sheets gives wall thickness of the Lathe Bed. The figure shows the final shape of the mould for Lathe Bed. By filling the Epoxy Granite Material within the gap we get the Epoxy Granite Lathe Bed. Figure 3.42 Preparation of the Mould of the Lathe Bed with Thermocol step ) Filling the Mould with Epoxy Granite Material After making the Lathe Bed Mould the Epoxy Granite is filled in the mould as shown in figure. Figure 3.43 Filling the Mould with Epoxy Granite Material Atmiya Institute of Technology & Science Page 53

70 METHODOLOGY ) De moulding the Mould After 24 hours it is de moulded and the Epoxy Granite Lathe Bed is ready. Figure 3.44 De moulding the Mould Figure 3.45 Epoxy Granite Lathe Bed Atmiya Institute of Technology & Science Page 54

71 METHODOLOGY 3.11 Summary of Sources of Different Activity Table 3.9 Summary of Sources of Different Activity Sr No Activity Address Contact No 1 Collect Granite cut Shivam Marbles, pieces GIDC Phase III, Jamnagar 2 Crush the Granite cut Dipen Trading, Gokul Nagar pieces GIDC Phase I, jamnagar 3 Sieving in different Material Lab of Atmiya College size of Engg & Tech, Rajkot 4 Collect Resin & D-Fix Enterprise, Hardner 506, Parshwanath Business Park, Prahaladnagar, Ahmedabad. 5 Manufacturing of Geeta Machine Tool, Lathe Bed P N Marg, Jamnagar Atmiya Institute of Technology & Science Page 55

72 ANALYSIS OF EPOXY GRANITE LATHE BED CHAPTER 4 ANALYSIS OF EPOXY GRANITE LATHE BED 4.1 Measurement of Forces on the Lathe Bed For measuring the forces on the Lathe Bed, the MS bright bar of 43 mm having 300 mm length is purchased. Weight of this bar is approximately 3.75 Kg. Figure 4.1 M.S Bright Bar of 43 mm Diameter & 300 mm Length The forces on the Lathe Bed are measured by Lathe Tool Dynamometer as shown in figure in our college workshop. Figure 4.2 Force Measurements on the Lathe Bed by Lathe Tool Dynamometer-A Atmiya Institute of Technology & Science Page 56

73 ANALYSIS OF EPOXY GRANITE LATHE BED Figure 4.3 Force Measurements on the Lathe Bed by Lathe Tool Dynamometer-B Reading of the lathe tool dynamometer Thrust force: 50 kgf = N Feed force : 25 kgf = N Radial force: 3 kgf = N Parameters used: Depth of cut : 2.5 mmm Diameter of work piece: 43 mm Feed: 40mm /Min Spindle speed: 100 RPM Figure 4.4 Forces on the Lathe Bed Atmiya Institute of Technology & Science Page 57

74 ANALYSIS OF EPOXY GRANITE LATHE BED P I = P 1 (B + d)/ 2 B + P 3 h/ B P II = P 1 (B - d)/ 2 B + P 3 h/ B P 1 =Tangential/ Thrust force = N P 3 =Feed force = N B= Centre distance between the flat and V guide = 154 MM h= Height between the flat guide and the centre of the work piece = 140 MM PI = P1 (B + d)/ 2 B + P3h/ B PI = ( )/ 2 (154) (140)/ 154 = = N P II = P 1 (B - d)/ 2 B + P 3 h/ B P II = (154-43)/ 2 (154) (140)/ 154 = = N Forces considered on the lathe bed: P I = N P II = N P 3 = Feed force = N Weight of the head stock = 40 Kg = N Weight of carriage = 30 Kg = 294 N Table 4.1 Forces considered on the lathe bed Forces Value P I P II N N P N Weight of the head stock N Weight of carriage 294 N Atmiya Institute of Technology & Science Page 58

75 ANALYSIS OF EPOXY GRANITE LATHE BED 4.2 Analysis of Cast Iron Lathe Bed Forces on Cast Iron Lathe Bed Figure 4.5 Forces on the Cast iron Lathe Bed Atmiya Institute of Technology & Science Page 59

76 ANALYSIS OF EPOXY GRANITE LATHE BED Deformation Analysis of Cast Iron Lathe Bed Figure 4.6 Deformation Analysis of Cast Iron Lathe Bed Atmiya Institute of Technology & Science Page 60

77 ANALYSIS OF EPOXY GRANITE LATHE BED Stress Analysis of Cast Iron Lathe Bed Figure 4.7 Stress Analysis of Cast Iron Lathe Bed Atmiya Institute of Technology & Science Page 61

78 ANALYSIS OF EPOXY GRANITE LATHE BED Stain Analysis of Cast Iron Lathe Bed Figure 4.8 Stain Analysis of Cast Iron Lathe Bed Atmiya Institute of Technology & Science Page 62

79 ANALYSIS OF EPOXY GRANITE LATHE BED 4.3 Analysis of Epoxy Granite Lathe Bed Consideration of Forces on Epoxy Granite Lathe Bed Figure 4.9 Forces on Epoxy Granite Lathe Bed Atmiya Institute of Technology & Science Page 63

80 ANALYSIS OF EPOXY GRANITE LATHE BED Deformation Analysis for Epoxy Granite Lathe Bed Figure 4.10 Deformation Analysis for Epoxy Granite Lathe Bed Atmiya Institute of Technology & Science Page 64

81 ANALYSIS OF EPOXY GRANITE LATHE BED Stress Analysis for Epoxy Granite Lathe Bed Figure 4.11 Stress Analysis for Epoxy Granite Lathe Bed Atmiya Institute of Technology & Science Page 65

82 ANALYSIS OF EPOXY GRANITE LATHE BED Stain Analysis for Epoxy Granite Lathe Bed Figure 4.12 Strain Analysis for Epoxy Granite Lathe Bed Atmiya Institute of Technology & Science Page 66

83 ANALYSIS OF EPOXY GRANITE LATHE BED 4.4 Summary of Analysis Table 4.2 Comparison of Cast iron Lathe Bed and Epoxy Granite Lathe Bed Sr No Property Unit Cast Iron Lathe Bed Epoxy Granite Lathe Bed 1 Deformation Meter 4.34* * Stress Pa 3.84* * Strain * *10-5 Atmiya Institute of Technology & Science Page 67

84 RESULTS AND DISCUSSION CHAPTER 5 RESULTS AND DISCUSSION 5.1 Manufacturing Lead Time Comparison Table 5.1 Manufacturing Lead Time of Cast Iron Lathe Bed Sr No Process Time 1 Core making, Mould making 1 day 2 Core drying, Mould drying 1 day 3 Colour spraying on core, drying of core 1 day 4 Core setting in a mould & pouring the molten metal 1 day 5 Atmospheric cooling 1 day 6 Machining on Milling Machine 1 day 7 Finishing on Grinding Machine 1 day Total 7 days Table 5.2 Manufacturing Lead Time of Epoxy Granite Lathe Bed Sr No Process Time 1 Crushing the Granite 20 Min per 100 Kg 2 Mould making and mould filling 1 day 3 Curing time 1 day 4 Finishing on Grinding Machine 1 day Total 3 days Moulding of Epoxy Granite gives good surface finishing than Casting of the Cast iron. So moulding of the Epoxy Granite Lathe Bed does not require machining. It requires only the surface finishing. So Manufacturing Lead Time can reduce by eliminating the machining. After moulding one Lathe Bed, same mould can use for mould the other Lathe Bed if the wooden mould is used. So if the mould is ready for the Lathe Bed, Manufacturing Lead time for Epoxy Granite Lathe Bed is only 48 hours. Atmiya Institute of Technology & Science Page 68

85 RESULTS AND DISCUSSION In this day, Less Manufacturing Lead time and cost are most important factors for any product. Manufacturing Lead Time of Cast iron Lathe Bed is 7 days. With the use of Epoxy Granite material as the Lathe Bed Manufacturing Lead time can be reduced to 3 days. So it is possible to fulfil the urgent requirement of the customer. 5.2 Cost Comparison Table 5.3 Cost of Epoxy Granite Sr No Parameter Cost/unit Required Cost 1 Epoxy Resin LY Rs/kg 6.48 Kg Hardener HY Rs/Kg 0.72 Kg Waste cut pieces of Granite Kg Crushing of waste cut pieces 1.5 Rs/ Kg Kg 43 5 Cost of mould 40 Rs per 1 mt *1 5 sheet 200 mt*20mm 6 Labour cost 300 Rs/day 2 day 600 Total 2615 Cost Per unit weight of Epoxy Granite = 2615/36.4 = Rs/Kg Since density of the Epoxy Granite is 2850 Kg/m 3 and Density of Cast Iron is 7150 Kg/ m 3. So weight of the Epoxy Granite is less than Cast iron. Table 5.4 Cost Comparison of Cast Iron Lathe Bed and Epoxy Granite Lathe Bed Sr No Parameter Cast Iron Lathe Bed Epoxy Granite Lathe Bed 1 Density 7150 Kg/ m Kg/m 3 2 Weight Kg Kg 3 Cost per unit weight 54 Rs/Kg Rs/ Kg 4 Total cost of Lathe Bed 54.40*54 = *71.84 = 2615 Remarks 89.03% cost of Cast Iron Lathe Bed Atmiya Institute of Technology & Science Page 69

86 RESULTS AND DISCUSSION Table 5.5 Initial Cost Comparison Cast Iron Lathe Bed Epoxy Granite Lathe Bed Operation Equipment Cost Operation Equipment Cost Melting the scarp Cupola Furnace ( 30Tons) 2 to 3 Lakh Crushing the Granite Crusher 50,000( 75% less than Cast Iron Lathe Bed So the Initial Cost of the Lathe Bed of the Epoxy Granite is less than the Cast Iron Lathe Bed. 5.3 Wear Test A Pin-on Disc test is done to compare the wear of Epoxy Granite and Cast Iron. According to ASTM G standard, the size of pin is 8 mm in diameter and 40 mm in height. The top surface of the Lathe Bed is manufactured from the fine Granite grains. So here the pin is made from the fine Granite grains having the size less than 0.5 mm. The diameter of the disk is 140 mm. Figure 5.1 Wear Testing Machine Table 5.6 Comparison of Cast Iron and Epoxy Granite for Wear Test Sr No Load (N) Speed (rpm) Time (min) Wear (μm) Cast Iron Epoxy Granite Atmiya Institute of Technology & Science Page 70

87 RESULTS AND DISCUSSION 5.4 Comparison of Cast Iron Lathe Bed and Epoxy Granite Lathe Bed 1) Surface roughness of the Lathe Bed is improved with the use of Epoxy Granite. Surface roughness in the Cast iron is achieved up to 10 μ. Surface roughness in the Epoxy Granite is achieved up to 2.59 μ. 2) Wear rate is reduced with the use of Epoxy Granite material as Lathe Bed. Wear for Cast Iron is 32 μ and for Epoxy Granite is 20 μ for the same load and same time. 3) With the use of Epoxy Granite weight of the Bed can decrease. The density of the Cast Iron and Epoxy Granite is 1750 Kg/m 3 and 2850 Kg/m 3 respectively. So the weight of the Cast Iron Lathe Bed is Kg and Weight of the Epoxy Granite Lathe Bed is Kg. This is beneficial for transportation. 4) In casting of the Cast Iron Lathe Bed, due to heating, cooling heat treatment residual stress are present. In Epoxy Granite Lathe Bed, it is free from residual stress because of there is no heating and cooling. 5) In Cast Iron Lathe Bed, with the use of Cupola furnace during Casting, it pollutes the atmosphere due to generation of harmful fumes. In Epoxy Granite Lathe Bed, there is no harmful fumes are generated. 6) In Cast Iron Lathe Bed, workstation is dirty due to sand casting, making and breaking of sand cores, spread of molten metal during pouring, de mounding the casting from the mould. With the use of Epoxy Granite the workstation becomes less dirty. 7) Epoxy Granite has good damping than Cast Iron. So due to less vibration in Epoxy Granite Lathe Bed, the life of the tool can increased [12][22]. 8) Because of good damping and no rusting problem, the life of the Lathe Bed can increased with use of Epoxy Granite [21]. 9) In Casting, there is no use of 100% raw material because of runner; risers are not a part of the desired casting. In manufacturing of Epoxy Granite Lathe Bed use of 100% raw material is possible. 10) Due to use of Cupola furnace and storage of coal, more working space is required in manufacturing in Cast Iron Lathe Bed. Due to use of Crusher, less working space is required in manufacturing in Epoxy Granite Lathe Bed. 11) Distortion and shrinkage problem during Casting is avoided with the use of Epoxy Granite material. 12) With the use of wastage of Granite cut pieces, it makes possible to use of wastage of Granite factories. It solves the problem of disposal of wastage. With the use of Granite as Lathe Bed, use of other resources like Cast Iron can reduce. Atmiya Institute of Technology & Science Page 71

88 RESULTS AND DISCUSSION 13) In Casting, variety of skilled workers is required for Casting, Machining etc. In manufacturing of Epoxy Granite Lathe Bed, no such skilled workers are required. 14) Due to the effect of environment, it creates corrosion in Cast Iron. The Epoxy Granite is unaffected to Environment. 15) Cast Iron is affected to Thermal effect. Epoxy Granite is unaffected to Thermal effect. Table 5.7 Comparison of Cast Iron Lathe Bed and Epoxy Granite Lathe Bed performance Sr No Parameter Cast Iron Lathe Bed Epoxy Granite Lathe Bed 1 Surface roughness in μ Wear rate in μ Table 5.8 Other Comparison of Cast Iron Lathe Bed and Epoxy Granite Lathe Bed Sr No Parameter Cast Iron Lathe Bed Epoxy Granite Lathe Bed 1 Weight Kg Kg 2 Residual stress Presence of Residual stress Free from Residual stress 3 Effect of Environment Creates corrosion Not affected 4 Thermal effect Affected Not affected 5 Pollution It pollutes the atmosphere It does not pollute the atmosphere 6 Workstation Dirty Less dirty 7 Tool life Less More 8 Life of Lathe Bed Less More 9 100% Utilization of Not possible Possible raw material 10 Working space More Less 11 Shrinkage and Presence Not presence distortion 12 Saving of raw material resources Not possible Possible Atmiya Institute of Technology & Science Page 72

89 CONCLUSION CHAPTER 6 CONCLUSION 6.1 Conclusion With use of Epoxy Granite as alternate material for Lathe Bed, it decreases Manufacturing Lead Time of Lathe Bed from 7 days to 3 days. So it reduces the Manufacturing Lead Time by 52.14%. It also reduces the Manufacturing cost of existing Lathe Bed from 2937 to 2615 Rs. So it reduces Manufacturing Cost by %.Wear rate of the Epoxy Granite is also less than Cast Iron. Epoxy Granite is also unaffected by Environment and Thermal effect. 6.2 Future Scope 1) The analysis is also possible by varying the proportion of Grain size of coarse, medium and fine. 2) The analysis is also possible by varying Grain size of coarse, medium and fine. 3) The study is also extended to thermal analysis. 4) The Epoxy Granite Bed is manufactured for CNC Machine tool and analysis can compared. Atmiya Institute of Technology & Science Page 73

90 REFERENCES PAPERS REFERNCES [1] S.S. Abuthakeer, et.al, Static and Dynamic Performance Improvement of Conventional Computer Numerical Control Machine Tool Bed with Hybrid Welded Steel, American Journal of Applied Sciences, 2011 [2] N.Mahendrakumar, et.al, Study of Alternative Structural Materials for Machine Tools, All India Manufacturing Technology, Design and Research Conference (AIMTDR), 2014 [3] Vitor A. Ducatti, et.al, Comparative Study with Alternative Materials for Manufacture of Machine Tool Structures UNICAMP, Brasil [4] S.B.Chandgude, et.al, Material Selection in Structural Design of Mini Milling Machine, International Journal of Research in Advent Technology, 2014 [5] D. Li, et.al, Optimization Design of Lathe-beds Based on FEA, IEEE, 2009 [6] A M Joshi, et.al, Finite Element Analysis of CNC Lathe Head Stock, Journal of Information Knowledge and Research in Mechanical Engineering,Vol-2, Issue-1, 2009 [7] Ding Jiangmin, et.al, Composite Concrete Bed for CNC Machine Tool, IEEE, 2010 [8] Tian Yaogang, et.al, Mechanical and Dynamic Properties of high Strength Concrete modified with Lightweight Aggregates pre saturated Polymer Emulsion, Elsevier, 2015 [9] Jaimon Dennis Quadros, et.al, Analysis of variance and response Surface Analysis of Thrust Force and Torque in Drilling Granite Fiber Reinforced Epoxy Composite by using Multi Facet HSS Twist Drill. Elsevier, 2015 [10] Dai Gil Lee, et.al, Damping Improvement of Machine Tool Columns with Polymer Matrix Fiber Composite Material, Elsevier, 1998 [11] M. Rahman, et.al, Development of a polymer impregnated concrete damping carriage for linear guide ways for machine tools, Elsevier, 2001 Atmiya Institute of Technology & Science Page 74

91 REFERENCES [12] C. Bruni, et.al, Hard turning of an alloy steel on a machine tool with a polymer concrete bed, Elsevier, 2001 [13] Dai Gil Lee et.al, Design and Manufacture of Composite high speed Machine Tool Structures, Elsevier, 2007 [14] Jung Do Shu et.al, Damping Characteristics of Composite hybrid spindle covers for high speed machine tools, Elsevier, 2001 [15] Vinay Babu Gada et.al, The Impact of Cutting Conditions on Cutting Forces and Chatter Length for Steel and Aluminium, International Journal of Engineering and Advanced Technology, Vol-2, Issue-4, 2013 [16] Hyun Surk Kim et.al, A Study on Epoxy Resin Concrete for the Ultra-precision Machine Tool Bed, Elsevier, 2013 [17] Aguinaldo dos Santos et.al, Cascade approach on Recycling for Marble and Granite Product Design, Elsevier, 2008 [18] Shiqun Li et.al, Influence of Interface Modification and Phase Separation on Damping Properties of Epoxy Concrete, Elsevier, 1996 [19] K.P. Roysarkar et.al, Designing Machine Tool Structures with Epoxy Concrete, Centre Mechanical Engineering Research Institute (CEMRI), Durgapur [20] Deepak D. Ubale et.al, Experimental Investigation of Material Properties of Epoxy Granite, International Journal of Mechanical and Production Engineering, Volume - 1, Issue-3, 2013 [21] A.Selvakumar et.al, Analysis of Alternative Composite Material for High speed precision Machine Tool Structures, Annals International Journal of Engineering, 2012 [22] Antonio Piratelli-Filho, Behaviour of Granite-Epoxy Composite Beams Subjected to Mechanical Vibrations, Department of Mechanical Engineering, University of Brazil, 2010 Atmiya Institute of Technology & Science Page 75

92 REFERENCES [23] Sandesh Kamath et.al, Experimental study on Mechanical Properties of Red Granite-Epoxy particulate Composites, International Journal of Mechanical Engineering and Robotics Research, Volume 3, 2014 [24] M rahman et.al, Tool wear study in lathe bed of cementitious material, Elsevier, 2001 [25] Norbert kepczak et.al, Application of mineral casting for machine tool bed, Lodz university, Poland, 2013 [26] Evangelos triantaphyllou et.al, Using the analytic hierarchy process for decision making in engineering in engineering application: some challenges, International journal of Industrial Engineering Application and Practice, Vol-2, No-2, 1995 BOOKS [27] Merriam-Webster s dictionary, 2013 [28] Workshop Technology- Volume-2, S.K. Hajra Choudhur, pn-83, 88, [29] Material Science & Technology, Dhanpat Rai Publication, O P Khannna, pn-5.5, OTHERS [30] Brochure of Geeta Machine Tool Pvt Ltd [31] Decision making with the analytic hierarchy process-thomas L saaty THESIS [32] Project report on Composites for Machine Tool Beds of NIT, Rourkera WEBSITE [33] Atmiya Institute of Technology & Science Page 76

93 Appendix A: Review Card Atmiya Institute of Technology & Science Page 77

94 XXX Atmiya Institute of Technology & Science Page 78

95 Atmiya Institute of Technology & Science Page 79

96 Atmiya Institute of Technology & Science Page 80

97 Atmiya Institute of Technology & Science Page 81

98 Atmiya Institute of Technology & Science Page 82

99 Appendix B: Compliance Following comments are suggested by external examiners during the period of Dissertation Phase-1. These comments are fulfilled by me in Mid Semester Thesis Progress Review. Sr. No Comment Given By External Examiner Modification done based on Comment 1 Check the feasibility of the work with respect to the relative motion of Epoxy Granite and Cast Iron parts. Carriage & Lathe bed is made up of same Epoxy Granite material, as movement/motion of carriage with Cast Iron and bed with Epoxy Granite is not expected in this research work. The research work focused on relative movement of same epoxy Granite material. 2 Compare the cost aspects Cost comparison done by student Following comments are suggested by external examiners during the period of Mid Semester Thesis Progress Review. These comments are fulfilled by me in my project work. Sr. No 1 Comment Given By External Examiner Actual setup can be created using Granite bed Lathe machine for study of variables and its comparison with C.I bed Modification done based on Comment Wear test performed by student. Surface roughness measured. The surface roughness is better than C.I. bed. 2 Excellent work - Atmiya Institute of Technology & Science Page 83

100 Appendix C: Paper Publication Certificate Atmiya Institute of Technology & Science Page 84