FIELD OF INVENTION:
The present invention relates to enhancing capability of existing machine for highly productive cutting solution. It includes design, development and manufacturing of a special attachment (30) to enable mounting of coupling holder.
BACKGROUND OF THE INVENTION:
Coupling type tool holder & with tools as shown above at fig.1 & 2 can carry machining
at very high cutting parameters on a Horizontal Lathe. This tool holder can be mounted
on the lathe if they have provision made by the machine tool manufacturer. On existing
lathe this provision was not there. With earlier system, square shank tools are required
to be used which work at low cutting parameters like cutting speed of 60mm/min and
feed of 0.4mm/rev.
With coupling holder, these cutting parameters can be improved to a cutting speed of
120mm/min and feed upto 1mm/rev resulting in much faster machining.
These holders are available on new CNC lathe where provision has been made by the
machine tool manufacturer. But on old CNC machines this provision is not there. So it
was thought to develop this new capability in old machines to enhance productivity of
old machines.
In the present method standard cassettes of old design having provision for clamping of
square shank (40mmX40mm) tools are used.
These tools do not work with high performance parameters & achieve accuracies due to
vibrations at longer tool overhang
The machine tool mounting holder dovetail groove has length of 110mm whereas latest
tool holder require 135mm.

OBJECTS OF THE INVENTION:
There are three broad objectives of the present invention
The object of the invention is to enhance capability of old machine with productive & latest solution.
Another object of the invention is to cut down the machining cost of jobs by using developed special attachment (30), by which we can clamp different type of tools in the same holder as per requirement.
Other object of the invention is to provide a universal type arrangement for all Lathes having similar provision for tool holding for machining of rotor shafts where multiple type of tools are required.
Yet another object of the invention is to provide the rigidity of tool clamping, safe operation to achieve good surface finish and drawing accuracies on the job specifically in intricate profiles.
SUMMARY OF THE INVENTION:
By reverse engineering, mounting details of tool holding mechanism at old machine as
well as new latest holder, new drawings were developed.
Design of special attachment (30) having provision at one end to match with existing
machine mechanism & another end to match with new holder was envisaged &
developed.
Completely new drawings & 3D model was generated checking all possible limitations.
BRIEF DESCRIPTION OF THE ACCOMPANYING DRAWINGS:
Fig. 1 describes Coupling Tool Holder

Fig. 2 describes Rigid & high performance Cutting Tool to be used with the Holder of Fig. 1
Fig. 3 describes Machine Cassette Holder
Fig. 4 describes Machine Cassette
Fig. 5 describes Design before Iteration
Fig. 6 describes Design after Iteration to Reduce Weight
Fig. 6.1 describes Design after Iteration
Fig. 6.2 describes Design after Iteration with provision for Clamping Screw (10’)
Fig. 7 describes M10 Threaded Holes (15) in the Plate to hold smaller Plates
Fig. 8 describes small plates clamped to the M10 Threaded Holes (15)
Fig. 9 describes Final Assembly of the Special Attachment (30)
Fig. 10 describes the Special Attachment (30) firmly fixed on the Machine RAM
Fig. 11 describes the Special Attachment (30) firmly fixed on the Machine RAM and the high speed cutting holder (40) fixed with the help of small plates
Fig. 12 describes the Special Attachment (30) firmly fixed on the Machine RAM and the high speed cutting holder (40) fixed with the help of small plates.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT OF THE INVENTION:
Mounting system on old lathe has dimension 110mm as shown in fig. 3 whereas
matching dimension on mounting system on new lathe is 135mm as shown in fig. 1.
Due to above mentioned dimensional discrepancy the new holder cannot be fitted into
the tool holding system of machine.
There were two options to resolve this issue. First was to procure new customized
holder having the dimension holder redesigned for the dimension 110mm but that
would incur a huge cost to the company.
Second option was to innovate and design a special attachment (30) in-house which
can accommodate the sizes of 110mm on one end and 135mm on the other end and
can fit on the machine RAM with required rigidity.
The weight of the above (Fig. 5) Special Attachment (30) was coming out to be 15kg.
This weight becomes difficult to handle manually as the cassette has to be lifted by
hands and then it has to be placed in the machine RAM.
The weight of the new design (Fig. 6, 6.1) was found to be near 9.5kg which can be
managed by lifting and clamping it to the RAM of the machine. In the new design
length was also reduced to 45mm but the thickness of the plate was increased to
20mm which gives an additional strength to the Special Attachment (30).
Another constraint was that the clamping screw (10) for the machine needs to be
inserted in the clamping attachment after the attachment has been mounted on the
machine tool carrier. An extra space needs to be created for Allen Key and Screw which
would increase the total length of the attachment which in turn would render the
attachment unsafe as with the increase in total length the center of gravity is shifting
away from the machine RAM. The weight of the holder is nearly 35kg. So the design
should ensure that the center of gravity is not very far from the machine RAM because
if it is far it would increase the tendency of toppling.
Earlier the length was coming to be more to create space for the clamping screw (10) of the clamping plate (12). To overcome that, a provision for the same was made in the

design without increasing the length by making holes exactly opposite to the clamping plate (12) which would satisfy the requirement of putting a screw and Allen key for tight clamping on the machine. The above concept is demonstrated in the below figure 6.2.
The M10 bolt can pass through the hole as shown in the figure 6.2. This solves the problem of increased length of the attachment. The Allen key can be inserted through this hole and machine clamping plate (12) can be tightened on the RAM by the M10 bolts.
Another constraint was manufacturing the integrated taper (as shown in Fig. 5) which would have required a special profile disc cutter. A profiled disc cutter would have increased the cost of manufacturing and also the finish at the included taper would not be as per the requirement.
The problem of manufacturing integrated taper was solved by the making two small plates of the required taper and then bolting them with adequate number of bolts to the plate of attachment. As shown in the above Fig. 7 M10 threads were created and more number of holes was done for the lower plate as this surface will bear the maximum weight of the high speed holder. Small plates were then bolted on these threads to generate the required taper for the high speed cutting holder (40). Manufacturing these plates was easier and at no additional cost for new cutter as compared to the integrated taper which was envisaged earlier. With more number of M10 bolts strength is also increased.
After taking all these constraints into consideration a new design was developed. In the new design provisions were made for easier clamping without increasing weight and total length and easier manufacturing.
As shown in the fig. 8 final assembly of the special attachment (30) is done after properly tightening the bolts of the small plate and also tightening the bolts of the clamping plate (12).

The following are the benefits accrued after changing the process of machining and the use of an improved tool.
1) Capability Enhancement: Capability of existing machine enhanced.
2) Productivity: Total machining time of Rotors on Horizontal Lathe is reduced
3) Quality: By using above clamping device required drawing accuracies and surface finish are achieved that’s why quality of machined component is improved.
4) Financial Benefit: As cycle time is reduced critical CNC machine availability is increased to take up more nos. of components
5) Power Saving: Overall Productivity & Utilization of machine is increased hence power consumption was reduced.
6) Health and working condition: As clamping and unclamping is reduced, so machine operators will face less fatigue.
7) Tool Safety: Less tool breakages as working length is optimum which does not put any additional stress on the tool.
8) Personal Safety: Frequent handling of tool is reduced. Tool change has become simplified since now there is no need of changing the entire holder. There is no chance of collision also.

WE CLAIM:
1. An attachment to hold cutting parameters (generally for CNC Lathe machine), the attachment having a base of reduced length of Special Attachment (30) and increased thickness, wherein a dovetail groove has length of about 130 mm-135
mm;
wherein provision to receive a clamping screw (10) is in alignment with a
clamping plate (12) on a front face of the attachment;
provision for positioning and fastening of smaller plates on the said front face of
the attachment to which the said small plates are clamped to selectively taper
the holder.
2. An attachment to hold cutting parameters as claimed in claim 1, wherein the total weight of the holder is about 10 kg.
3. An attachment to hold cutting parameters as claimed in claim 1, wherein the total holder dovetail groove has length of about 135 mm.