Second Operation Lathe

Along with three other team members, a second operation lathe was designed and manufactured for Cooper Union’s Student Machine Shop during academic year 2014-2015. With only one lathe in the Student Machine Shop, it was decided that creating a second operation lathe would decrease the long line of students waiting for that machine by providing one capable of turning less complex parts, such as pieces not requiring thread cutting or the use of a tailstock. Working under budget constraints from the Department of Mechanical Engineering, as well as turning and safety requirements established by shop technicians, faculty, and staff, a second operation lathe was designed in SolidWorks. Sufficient strength and deformation requirements were validated using finite element analysis (FEA) and parametric hand calculations. Once the design was successfully vetted after multiple concepts and iterations, 2D drawings for manufacturing were produced. The majority of parts were machined from stock by my teammates and I using the manual mill and lathe, with assembly occuring as parts were completed.

The resulting lathe has an efficient footprint of roughly 30 inches by 20 inches to save valuable floorspace. Its translation system is comprised of a main carriage, cross slide, compound rest, and swivel vice. A Dunham headstock accepts the school’s collection of 5C collet hardware. And its continously variable transmission augements a 1795 RPM motor to create a spindle speed range of roughly 800 - 4500 RPM. This design permits the lathe to turn steel and aluminum workpieces that are up to 12 inches in length and 6 inches in diameter with a precision of 0.001 inches. The lathe also has mounting locations for encoders so that a digital readout of tool position and spindle speed can be implemented by other students. I was responsible for the design of the continuously variable transmission (CVT), frame, safety shield, compounds rest, and swivel vice. As for manufacturing, I fabricated the CVT, the safety shield, cut and drilled frame tubing in preperation for welding, and machined a few parts for the translation system.

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