The document describes experiments conducted to manufacture hardened barrel screws on a traditional lathe machine using different parameters. The researcher conducted machining operations like turning, spline cutting, spline milling and thread milling on an EN41B round bar. Experiments were performed with variations in parameters like depth of cut, feed rate and spindle speed. Three barrel screws were manufactured - one each on a lathe and CNC thread milling machine using the same parameters, and one on CNC milling machine varying the parameters. The screws were then tested and compared in terms of dimensions, surface finish, hardness, microstructure, cost of manufacturing etc. to determine the optimal manufacturing process.

1. IJSRD - International Journal for Scientific Research & Development| Vol. 3, Issue 10, 2015 | ISSN (online): 2321-0613
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The Experimental Approach of Manufacturing Hardened Barrel Screw
on Traditional Lathe Machine with Different Parameters
Dilip M Patel1
DR. Ashwin D patel2
1
PhD. Scholar 2
Principal
1,2
Department of Mechanical Engineering
1
Rai University, India 2
Ipcowala Institute of Engg and Technology, Anand, India
Abstract— Now a day manufacture has to think for most
economical, less time consuming, accurate and perfect
sequence of production process for manufacturing the
product. He has to adopt the various parameters focusing on
the above stated facts. The researcher has find out to control
the different parameters for optimum process based on
economical point of view by which the manufacturer can
save round above 30 % cost of product.
The Traditional lathe machine is used as machine tool
instead of (SPM) special purpose milling machine. He has
made three alterations.
1) Parameter – using milling attachment.
2) Parameter – using special profiled milling cutter.
3) Parameter – using indexing attachment with main
spindle.
For the above aspect the researcher has done number of
experiments to decide the optimal process and then by doing
the same process on SPM & lathe. He has concluded the
level of efficiency, economical & optimal process control.
Key words: Barrel Screw, Traditional Lathe machine
different parameter
I. INTRODUCTION
Barrel Screws are devices suitable for handling a wide
variety of materials that have good flow ability
characteristics. The screw feeder has a helicoidally surface
fitted on a shaft that rotates inside a fixed tube. The material
which comes out of the silo is pushed by the helicoids flight
along the base of the tube in the direction of transport. The
advantages of the screw feeder include the possibility of
having different openings, each with its own shut-off organ
for unloading the material.
A number of years ago Rexnord proposed a set of
selection guidelines, one for conveyors and the other for
elevators that are useful for an indicative choice of
conveyors on the basis of loading and unloading methods,
the course of transport and the features of the material (flow
ability, composition granulometry, temperature, friability,
abrasiveness and corrosivity.)
Manufacture screw on traditional lathe machine by
changing its different – drive viewing on the reduction of
cost process utility and easy methoding. When the screw
feeder, we are talking it’s use is wide and the profile is
somewhat complex on one shaft the pitch of screw may very
as well as start may be single, double or triple. The working
of screw feeder is in a hollow cylindrical cavity known as
barrel.
The simply target is generate the thread profile on
lathe machine and to harden it by biometric layer depletion
during the process profile different effecting parameters are
control and on one layer the optimal parameters are
achieved. The cutter to shape the screw profile is specially
designed the speed, depth of cut, the lost criteria and the
attached equipments is also sharply taken in to
consideration.
The working condition of screw inside the barrels
and other effecting parameters is taken into account wear &
tear, heating condition, temperature, speed of screw, the
screw feeder effected portion is harden by diametallic
deposition.
A. Barrel Screw:
A Screw to be shaped like an Archimedean spiral square
threaded profiled on shaft. It works in a closed chambered
Jacket known as Barrel Screw rotate according to required
speed in barrel and it feed plastic material from one side
located Hopper where the raw material is allowed to fall in a
Barrel on other side die consist of male & female to piece
receives the raw plastic material in a liquid form and it
shape the plastic material into required form.
Fig. 1: Plastic Injection Molding Machine
In fact the screw work as a material conveyor to be feed in a
barrel from one side to another side outside the barrel
surface the heater are installed which maintain the required
heat for plastic raw material easily to flow in the barrel and
get to be shaped in a Die Cavity as per required shape and
size.
Barrel Screw is used for:
(1) Extrusion Plastic Machinery –
(2) Injection Moulding Machine
(3) Blow Moulding Machinery
The above three plastic plants are used for producing
different plastic parts they are generally used for Industrial
and Domestic purpose.
1) Use of Barrel Screw for Different Plastic Machinery
Plants:
- Injection Moulding
- Extrusion Moulding
- Laminatic Plant
- Blow Moulding
- Calendaring
- Vacuum Forming
- Plastics as Engineering Material

2. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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2) Different Types of Screw:
- Single Screw
- Barrier Screw
- Twin Screw and Barrel
- Parallel Twin Screw and Barrel
- Single Screw and Barrel
- Grooved Feed Barrel
- Barrier Screw
- Maddoc Barrier Screw
- Single Barrel
- Twin Hole Barrel Rear Barrel
- Twin Barrels
- Grooved Feed Bush
II. SCREW BARREL UTILITY
A. Pipe Plant:
- PVC Pipe Manufacturer (U PVC, R PVC, CPVC)
- HDPE Pipe Manufacturer
- PVC Braided Pipe Plant
- PVC Suction Hose Pipe
- PVC Soft Tubing Plant
B. Sheet Plant:
- Air Bubble Sheet Plant
- PP Sheet Plant
- HIPS Sheet Plant
- PVC Sheet Plant
- Thermo Forming
C. Film Plant:
- PVC Film Plant
- Lamination Film Plant
- Blown Film Plant
- Tape Plant
- Multi-Layer Film Plant
- Cable Manufacturer (Any Type of Materials)
- Compounding Plant
- Injection Moulding Machinery
- Blow Moulding Machinery
- Any type of Plastic Pallet Manufacturing
D. Barrier Screw (Double Thread):
- Single Thread Screw
E. Screw Manufacturing Different Method, Screw
Classification & Screw
- Application
- Production of Screw Threads – Possible Methods And
Their Characteristics:
The various methods, which are more or less widely
employed for producing screw threads, are:
1) Casting characteristics
- only a few threads over short length
- less accuracy and poor finish
- Example – threads at the mouth of glass bottles, spun
cast iron pipes etc.
2) Forming (Rolling) characteristics
- blanks of strong ductile metals like steels are rolled
between threaded dies
- large threads are hot rolled followed by finishing and
smaller threads are straight cold rolled to desired finish
- cold rolling attributes more strength and toughness to
the threaded parts
- Widely used for mass production of fasteners like
bolts, screws etc.
3) Removal process (Machining)
- accomplished by various cutting tools in different
machine tools like lathes, milling machines, drilling
machines (with tapping attachment) etc.
- widely used for high accuracy and finish
- Employed for wide ranges of threads and volume of
production; from piece to mass production.
4) Semi finishing and finishing (Grinding) characteristics
- usually done for finishing (accuracy and surface) after
performing by machining or hot rolling but are often
employed for direct threading on rods
- precision threads on hard or surface hardened
components are finished or directly produced by
grinding onlyemployed for wide ranges of type and
size of threads and volume of production
III. SIGNIFICANCE OF PROPOSED RESEARCH
Now a day plastic & relative product is hugely used in
Industries as well as domestic purposes. The process mainly
used to manufacture plastic is injection molding, blow
molding plastic, film making etc.
The raw materials are continuously feed in to the
barrel and long working life by certain heat treatment
process of metal deposition
IV. RESEARCH METHODOLOGY
This Project is based on an experimental research. It is
commonly used in sciences and engineering the number of
experiments are carried out considering different parameters
and how the parameters changes and causes to change other
are verified.
The Experimental method is a systematic and scientific
approach to researcher in which the researcher manipulates
one or more variables, controls and measures any change in
other variable.
The experiment has been carried out on conventional
lathe machine and CNC Thread Milling Machine. In order
to perform different machining operations on a lathe and
CNC Thread Milling Machine. The raw material of barrel
screw that is EN41B Round Bar of ∅110 mm is taken and it
is to be holding on lathe chuck and it is machined by HSS
Single Point cutting tool and milling cutter. The number of
machining operation is performed considering the following
parameters.
- Job Speed
- Feed
- Depth of Cut
The six machining operation is carried out on EN41B
material round bar on lathe machine and CNC Thread
Milling Machine in order to manufacture barrel screw with
the same parameters and by changing some of parameters.

3. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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The three machined barrel screws are Screw No. 1
manufactured on lathe machine and Screw No. 2
manufactured on CNC Thread Milling Machine with same
feed and job speed and Screw No. 3 is manufactured on
CNC Thread Milling Machine with varying job speed and
Feed.
Screw No. 1, Screw No. 2 and Screw No. 3 are
tested in laboratory and considering the following tests.
- Dimension Check – Up
- Surface Finish
- Hardness
- Micro Structure
- Chemical Analysis
And also comparison in terms of manufacturing cost.
V. EXPERIMENTAL SET-UP & DESCRIPTION
A. Lathe Machine specification:
The length between centers =10’’
= 3048 MM
The overall length of machine =14’’
= 4267 MM
The centre weight of measured =14’
= 355.6 MM
the swing diameter over bed =16’
= 406.4 MM
The length of bed = 12’’
= 3662 MM
Fig. 1: Lathe Machine
Fig. 2: Lathe Machine
VI. PARAMETRIC CHANGES
A. Milling Attachment:
Milling attachment as shown in figure is developed for
threading the barrel screw. A separate AC variable drive
motor is installed via V. Pulley block a central shaft with
taper shank sleeve and collect chuck is fixed with box type
fabricated structure both end of shaft is supported by Ball
Bearing. The attachment is installed on cross slide of lathe
machine with front support live rest.
Fig. 3: Milling Attachment
End mill cutter ∅ 25 mm and specially profiled taper round
nose cutter is installed in collect chuck.
VII. OBSERVATION TABLE AND GRAPHS
A. Lathe Machine:
Process :-
1
Turning
Material:-
EN41 Φ 110 mm Length: 3360 mm
Round Bar
Machinin
g:-
From Φ 110 mm to Φ 100.5 mm
length:3360 mm
Tool: P20 Carbide Tipped Turning tool
Observation Table 5.2.1.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of tool
(mm /
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job
Speed
(R.P.M.)
1 5 7 34.54 480 100
2 3 5 33.97 672 100
3 1.5 3 32.02 1120 100
Observation Table 5.1.1.2
Sr.
No
Total
Depth
of cut
(mm)
Feed
of tool
(mm /
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job
Speed
(R.P.M.)
1 5 15 51.81 224 150
2 3 10 49.45 336 150
3 1.5 5 48.04 672 150
Observation Table 5.1.1.3
Sr.
No
Total
Depth
of cut
(mm)
Feed
of tool
(mm /
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job
Speed
(R.P.M.)
1 5 20 69.08 168 200

4. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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2 3 15 65.94 224 200
3 1.5 10 64.05 336 200
Process :-
1
Turning
Material:-
EN41 Φ 110 mm Length : 3360 mm
Round Bar
Machinin
g:-
From Φ 110 mm to Φ 100.5 mm
length:3360 mm
Tool: P20 Carbide Tipped Turning tool
Observation Table 5.2.1.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of tool
(mm /
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job
Speed
(R.P.M.)
1 5 7 34.54 480 100
2 3 5 33.97 672 100
3 1.5 3 32.02 1120 100
Fig. 4: Feed of tool vs. Cutting Time
Fig. 5: Depth of Cut vs. Cutting Speed
Process :-
2
Turning (Spline)
Material:-
EN41 Φ 110 mm Length : 3360 mm Round
Bar
Machining
:-
From Φ 100.5 mm to Φ 89.7 mm length:200
mm
Observation Table 5.2.2.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of tool
(mm /
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job
Speed
(R.P.M.)
1 5 7 31.55 28.57 100
2 4 5 29.98 40 100
3 1.8 3 28.73 66.66 100
Fig. 6: Feed of tool vs. Cutting Time
Fig. 7: Depth of Cut vs. Cutting Speed
Process :-
3
Spline Milling
Material:-
EN41 Φ 110 mm Length : 3360 mm
Round Bar
Machining
:-
Spline Milling 6 slot size: 89.7 mm to
77.9 mm
Width 16 mm, Depth 11.5 mm Slot
length 170 mm
Tool:
Hss milling cutter Dia 16 mm 4 flute
Initial slot is generate by 16 MM
Diameter End Mill Cutter then the taper
cut is generated by radius End Mill Form
Cutter
Observation Table 5.2.3.1
Sr.
No
Total
Depth of
cut (mm)
Feed of
tool (mm
/ min)
Cutting
speed (mm/
min)
cutting
time
(min)
1 5 10 70.41 17
2 4 15 66.48 11.33
3 1.8 20 66.34 8.5
4 1 20 61.93 8.5
480
672
1120
0
500
1000
1500
7 5 3
CuttingTime(min)
Feed of Tool (mm/min)
Feed of tool vs. Cutting Time
34.54 33.97 32.02
51.81 49.45 48.04
69.08 65.94 64.05
0
10
20
30
40
50
60
70
80
5 3 1.5
CiuttingSpeed(mm/min)
Depth of Cut (mm)
Depth of Cut vs. Cutting Speed
100 R.P.M
150 R.P.M
200 R.P.M
28.57 40
66.66
0
50
100
7 5 3
CuttingTime(min)
Feed of Tool(mm/min)
Feed of tool vs. Cutting Time
34.54
33.97
32.02
34.54
33.97
32.02
30.5
31
31.5
32
32.5
33
33.5
34
34.5
35
5 3 1.5
CuttingSpeed(mm/min)
Depth of cut (mm)
Depth of cut vs. Cutting Speed

5. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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Fig. 8: Feed of tool vs. Cutting Time
Fig. 9: Depth of Cut vs. Cutting Speed
Process
:- 4
Thread Milling
Material
:-
EN41 Φ 110 mm Length : 3360 mm Round
Bar
Machini
ng:-
Helix machining of 100 mm pitch Length:
2735 mm
and machining from Φ 100.5 mm to Φ 92.5
mm Parallel core
assuming cutting speed of screw dia
considering cutter RPM
Tool:
HSS Milling cutter 4 flute Φ 25 mm Cutter
Speed: 250 R.P.M.
Observation Table 5.2.4.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of
tool
(mm
/
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job Speed
(Min per
Revolution)
1 4 6 78.89 455.83 16.66
2 3 8 74.18 341.87 12.5
3 1 10 71.82 273.5 10
Fig. 9: Depth of Cut vs. Cutting Speed
Process
:- 5
Thread Milling
Material
:-
EN41 Φ 110 mm Length : 3360 mm Round
Bar
Machini
ng:-
Helix machining of 100 mm pitch Length:
1350 mm
and machining from Φ 92.5 mm to Φ 75.5
mm Parallel core
Tool:
Hss Milling cutter 4 flute Φ 25 mm Cutter
Speed: 250 R.P.M.
Observation Table 5.2.5.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of
tool
(mm
/
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job Speed
(Min per
Revolution)
1 5 6 72.61 225 16.66
2 5 7 68.68 192.85 14.28
3 5 8 64.76 168.75 12.5
4 2 9 60.83 150 11.11
Fig. 10: Feed of tool vs. Cutting Time
Process
:- 6
Thread Milling
Material
:-
EN41 Φ 110 mm Length : 3360 mm Round
Bar
Machini
ng:-
Helix machining of 100 mm pitch Length:
1000 mm
and machining from Φ 92.5 mm to Φ 75.5
mm Tapper core
Tool:
Hss Milling cutter 4 flute Φ 25 mm Cutter
Speed: 250 R.P.M.
Observation Table 5.2.6.1
Sr.
No
Total
Depth
of cut
(mm)
Feed
of
tool
(mm
/
min)
Cutting
speed
(mm/
min)
cutting
time
(min)
Job Speed
(Min per
Revolution)
1 5 6 72.61 166.66 16.66
2 5 7 68.68 142.85 14.28
3 5 8 64.76 125 12.5
4 2 9 60.83 111.11 11.11
17
11.33 8.5 8.5
0
20
10 15 20 20
CuttingTIme
(min)
Feed of Tool (mm/min)
Feed of tool vs. Cutting Time
70.41
66.48 66.34
61.93
70.41
66.48 66.34
61.93
55
60
65
70
75
5 4 1.8 1
CuttingSpeed(mm/min)
Depth of cut (mm)
Depth of cut vs. Cutting
Speed
31.55 29.98 28.73
31.55 29.98 28.73
25
30
35
5 4 1.8
CuttingSpeed(mm/
min)
Depth of cut (mm)
Depth of cut vs. Cutting
Speed
225
192.85 168.75 150
0
100
200
300
6 7 8 9
CuttingTime(min)
Feed of tool (mm/min)
Feed of tool vs. Cutting Time

6. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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Fig. 11: Feed of tool vs. Cutting Time
B. CNC Milling Machine Observation Table with varying
feed:
Fig. 12: Depth of Cut vs. Cutting Speed
Fig. 13: Feed of tool vs. Cutting Time
Fig. 14: Depth of Cut vs. Cutting Speed
Fig. 15: Feed of tool vs. Cutting Time
Fig. 16: Depth of Cut vs. Cutting Speed
Fig. 17: Feed of tool vs. Cutting Time
166.66
142.85 125 111.11
0
50
100
150
200
6 7 8 9
CuttingTime(min)
Feed of Tool (mm/min)
Feed of tool vs. Cutting Time

7. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
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Fig. 18: Feed of tool vs. Cutting Time
Fig. 19: Feed of tool vs. Cutting Time
Fig. 20: Feed of tool vs. Cutting Time
VIII. CONCLUSION
The three screws are manufactured on final stage Screw No.
1 on lathe machine with different parameter Screw No. 2 on
CNC Milling machine with same3 observation as per Screw
No. 1 and Screw No. 3 on CNC Milling by taking the
different feed and different job speed.
A. Comparing these three screws. The following
conclusions have been drawn.:
- The manufacturing process sequence is finalised
- There is no change in machining time for Screw -1 and
Screw -2 and the machining time is less for Screw – 3.
- The all three screw are inspected dimensionally and
find the accuracy is as per drawing.
- The cost consideration has been calculated and per
hour machining cost is 300 Rs. / hr for lathe and 850
Rs./hr for CNC Milling Machine
- The initial investment of lathe and different parameter
accessories are less than thread milling CNC Machine.
- The maintenance is easy for lathe machine with
different parameters & accessories.
- The manufacturing process is easy and simple in the
case of lathe machine.
- In CNC Thread Milling Machine the complication of
operation may be occurring.
- This research work opens new door in the field of
manufacturing.

8. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
(IJSRD/Vol. 3/Issue 10/2015/086)
All rights reserved by www.ijsrd.com 430
- Productivity is more because the ultimate cost of
production is less in case of lathe machine.
- The three parameters to be changed on lathe machine
is a new trend of manufacturing barrel screw.
B. Limitation:
The rate of production on CNC Milling Machine is more
than lathe machine with different parameters.
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9. The Experimental Approach of Manufacturing Hardened Barrel Screw on Traditional Lathe Machine with Different Parameters
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