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ICMEMSCE IOP Publishing
IOP Conf. Series: Materials Science and Engineering 324 (2018) 012053 doi:10.1088/1757-899X/324/1/012053
1234567890‘’“”

Development of Semi-Automatic Lathe by using Intelligent

Soft Computing Technique

S Sakthi 1, J Niresh 2, K Vignesh 3, G Anand Raj 4

1,2,3,4
Department of Automobile Engineering, PSG College of Technology, India.

E-mail: sakthisenthilkumar.95@gmail.com

Abstract: This paper discusses the enhancement of conventional lathe machine to semi-
automated lathe machine by implementing a soft computing method. In the present scenario,
lathe machine plays a vital role in the engineering division of manufacturing industry. While
the manual lathe machines are economical, the accuracy and efficiency are not up to the mark.
On the other hand, CNC machine provide the desired accuracy and efficiency, but requires a
huge capital. In order to over come this situation, a semi-automated approach towards the
conventional lathe machine is developed by employing stepper motors to the horizontal and
vertical drive, that can be controlled by Arduino UNO -microcontroller. Based on the input
parameters of the lathe operation the arduino coding is been generated and transferred to the
UNO board. Thus upgrading from manual to semi-automatic lathe machines can significantly
increase the accuracy and efficiency while, at the same time, keeping a check on investment
cost and consequently provide a much needed escalation to the manufacturing industry.

1. Introduction
Lathe is a machine tool used principally for shaping articles of metal by causing the work piece to be
held and rotated by the chuck while a tool bit is advanced into the work causing the cutting action[1].
The basic lathe that was designed to cut cylindrical metal stock has been developed further to produce
screw threads, tapered work, drilled holes, knurled surfaces, and crankshafts as shown in Figure 1. The
typical lathe provides a variety of rotating speeds and a means to manually and automatically move the
cutting tool into the work piece. Some of the operations done by a lathe machines are tabulated below
in Table 1.

Figure 1. Conventional Lathe Machine [1]

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ICMEMSCE IOP Publishing
IOP Conf. Series: Materials Science and Engineering 324 (2018) 012053 doi:10.1088/1757-899X/324/1/012053
1234567890‘’“”

Table 1. Operations done by Lathe Machine[6]

Operation Description

Turning To produce straight, conical, curved, or grooved work pieces.

Facing To produce a flat surface at the end of the part or for making face grooves.

Boring To enlarge a hole or cylindrical cavity made by a previous process or to

produce circular internal grooves.

Drilling To produce a hole by fixing a drill in the tailstock

Threading To produce external or internal threads

Knurling To produce a regularly shaped roughness on cylindrical surfaces

2. Soft-Computing Technique used

Arduino is an open-source prototyping platform based on easy-to-use hardware and software. Arduino
boards are able to read inputs - light on a sensor or a finger on a button, and turn it into an output -
activating a motor, turning on an LED. The user can tell the board what to do by sending a set of
instructions to the microcontroller [4]. To do so the user should use the Arduino programming language
(based on Wiring), and the Arduino Software (IDE), based on Processing. The Uno is a
microcontroller board based on the ATmega328P [3].

2.1. Arduino UNO

The Uno differs from all preceding boards in that it does not use the FTDI USB-to-serial driver chip.
Instead, it features the Atmega16U2 (Atmega8U2 up to version R2) programmed as a USB-to-serial
converter. The Uno has a resettable poly-fuse that protects your computer's USB ports from shorts and
overcurrent [2]. Arduino board is shown in the Figure 2.

Figure 2. Arduino UNO[4]

3. Input Parameters
The specifications of micro-controller(Arduino UNO) & the lathe machine is tabulated in Table 2 &
Table 3.

2
ICMEMSCE IOP Publishing
IOP Conf. Series: Materials Science and Engineering 324 (2018) 012053 doi:10.1088/1757-899X/324/1/012053
1234567890‘’“”

[5]
Table 2. Arduino UNO- specifications[4] Table 3. Lathe Machine-Parameters

Microcontroller-Specification Lathe Machine

Microcontroller ATmega328P Swing over machine bed Min. 350mm

Operating Voltage 5V Swing over cross slide Min. 190mm
Input Voltage 7-12V Distance between centers 750-800mm
PWM Digital I/O Pins 6 Turning Length 700-750mm
Analog Input Pins 6 Width of bed Mini.260mm
DC Current per I/O Pin 20 mA Normal Chuck diameter 160mm
DC Current for 3.3V Pin 50 mA Guide Length of carriage 350-365
Flash Memory 32 KB(ATmega328P) Cross-slide travel 175-190
SRAM 2 KB(ATmega328P) Width of cross-slide 140mm
EEPROM 1KB(ATmega328P) Cross Travel += 10mm

4. Experimental Details
4.1 Principle Of Arduino Lathe :
Embedded System - is one that has hardware with software embedded in it as one of its important
components.

4.2 Construction Of Arduino Lathe

The essential electronics used in the construction of arduino lathe is tabulate in Table 4 .
Table 4. Essential electronic parts used in the construction of Arduino Lathe
Components Description
Motors are employed in both vertical & horizontal drive (i.e) Depth of cut & Lead
Motor
Screw Movement/Rotation.
Rectifiers Rectifiers are used to convert the AC into DC voltage.
Transformer Transformers are used to rise or lower the voltage for motors & arduino board.
Relay acts as a switch, that is controlled by a small electromagnet which can be
Relay Board activated by a small signal. In other words, the relay is used to power on -high
powered devices such as large motors with a signal from the Arduino.
Diode Diodes acts like a low value resistor and allows the current flow.
Microcontroller Microcontrollers are used to control the motor employed in feed & depth drive.

4.3 Working- Algorithm of Arduino lathe

The design phase of arduino lathe is developed using Solid Works software as shown in Figure 3. The
coding is generated and compiled using Arduino IDE software as shown in Figure 4.The step by step
working procedure of arduino lathe is tabulated in the Table 5.

3
ICMEMSCE IOP Publishing
IOP Conf. Series: Materials Science and Engineering 324 (2018) 012053 doi:10.1088/1757-899X/324/1/012053
1234567890‘’“”

Figure 3. Design of Arduino Lathe Figure 4. Arduino IDE software –Coding

Table 5. Working Algorithm for Arduino Lathe

Steps Function
Step 1 The “Arduino Software IDE” is Initialized as shown in Figure 4.
Step 2 Based on the input parameters, the calculations are done for the required machining Process.
With these results, the Arduino coding are generated for required Profile/Operation with
Step 3
specified Definition, Void Setup and Void Loop.
Step 4 Now the coding is compiled. So that, it ensures the coding generated is error free.
These Coding are transmitted to the Arduino board by means of USB cable or accessed by
Step 5
means of its IP address.
Step 6 Mean while , the Work piece is mounted on the chuck of arduino lathe as shown in Figure 3.
Now, the arduino reads the program and based on the coding generated it initiate the
Step 7
manufacturing process/operation.
After the process gets over, if necessary the arduino can be reset for the new
Step 8
process/operation.

5. Formula used for Calculation :

The optimum cutting conditions (i.e. speeds, feed and depths of cut) depended upon the tool & work
material for the required surface finish and the dimensional accuracy. The optimum cutting conditions
used to determine the required spindle speeds for the proposed dimensional information about the
work pieces to be machined .From the equation (1), (2),…(7), the formula required for calculation is
achieved[6]. So that these results can be incorporated while generating Coding for desired lathe
operation.

5.1 Determination of Power Requirements

The drive power required for the cutting motion depends upon the cutting speed and the cutting force.
The power needed for the feed drive is also dependent upon the feed force and the feed rate. The
cutting forces mainly depended upon the work material, the size of cut, tool geometry, and cutting
speed and to extend the tool material. From the analysis of the forces in turning, it was found that the
cutting forces in turning could be resolved into three components namely:

4
ICMEMSCE IOP Publishing
IOP Conf. Series: Materials Science and Engineering 324 (2018) 012053 doi:10.1088/1757-899X/324/1/012053
1234567890‘’“”

The tangential component : Ft-it is in the direction of the cutting velocity vector.
Ft = R1.(Fx)1.(dy)1 kgf (1)
The radial component : Fr-is in the direction of the radius of the job.
Fr = R2.(Fx)2.(dy)2 kgf (2)
The axial component : Fa-is in the direction of the longitudinal feed
Fa = R3.(Fx)3.(dy)3 kgf (3)
Therefore the rate of work needed in turning approximately equals to the product of tangential force
component and the cutting velocity.
The horsepower, needed for turning : P = (Ft x Vmax)/4500 hp (4)
The power rating, of the cutting drive : PRC = P / ηC hp (5)
The power rating, of the feed drive : PRF = (Q x F) / f (6)
The feed force, for lathe operations : Q = k.Fa + ( Fc + Fr +Wd ) (7)

Where, ηC is the mechanical efficiency, β is the coefficient of friction between the carriage and the
guide ways, k is a recommended factor, Wd is the weight of the parts being traversed, Fa,Fc and Fv are
the components of the cutting force in the feed, cutting and radial directions respectively.

6. Conclusion
Therefore, the design of Semi-automatic lathe is successfully developed by the Solid Works Software.
Which has the communion of both hardware(Arduino UNO) & software(Arduino IDE) resulting in the
development of semi-automated approach towards the conventional lathe machine. As automation
newly developed Arduino lathe is done by implementing some new features to the standard lathe,
therefore the setup cost is increased, but when compared to the fully automated/CNC machine the
setup cost is much low. The accuracy of the job manufactured in semi-automated lathe is high
relatively, so the repeatability and dimensional stability of the manufactured part is achieved. Since the
production rate is high, the semi-automated lathe machines will be very useful in mass production.

7. References
[1] Prakash N. Parmar , Prof. N. C. Mehta , Prof. Manish V. Trivedi, “Investigation on Automation
of Lathe Machine”, International Journal of Emerging Technology and Advanced Engineering-
IJETAE, ISSN 2250-2459, Vol.4, Issue 5, May 2014, page no. 524-529.
[2] Akshay R Sonawane, Arun Bhiva Rane and D. S. S. Sudhakar, “Development Of A3-Axis Cnc
Milling Machine With An Open Source Controller”, IJRET, eISSN: 2319-1163 | pISSN: 2321,
Aug-2017.
[3] S.Vigneshrao, “Design Of 3-Axis Computer Numerical Control (Cnc) Router Using Stepper
Motor”, International Journal of Global Engineering (IJGE), E-ISSN: 2456-3099, Vol.1, Issue 3,
March-2017.
[4] Kulkarni Bharat P, “Arduino Based 3 axis PCB Drilling Machine”, International Journal of
Emerging Technologies in Engineering Research (IJETER). Vol. 4, Issue 6, June (2016).
[5] Jahnavi Madireddy, "Importance of Lathe Machine in Engineering Field and its usage", Global
Journal of Researches in Engineering: A Mechanical and Mechanics Engineering, Vol.14, Issue
6, Year 2014, ISSN: 2249-4596 , Print ISSN: 0975-5861
[6] Sundar Pandian and S. Raj Pandian, “A Low-Cost Build-Your-Own Three Axis Cnc Mill
Prototype”, International Journal on Mechanical Engineering and Robotics (IJMER), ISSN
(Print): 2321-5747, Vol.2, Issue-1, 2014.