"Optimizing Lathe Process Capability Using Non-Metallic Gears: A Comparative Analysis of Machining Performance"

This paper presents the effects of non-metallic gears (cast nylon, nylon, and Hylam) in the process capability performance of a lathe machine in turning operations in comparison with metallic gears. Machining of 216 shafts has been carried out under different setups of spindle speed, feed rate, and depth of cut. Process capability indices in terms of (Cp, Cpk) have been calculated and control charts - X-bar and R-charts were used to analyze the performance. The results also reveal that the Hylam gear outperforms the other gears, with higher process capability due to its superior density and flexural strength. This analysis reveals there is considerable scope for the application of non-metallic gears to develop surfaces that can achieve better surface finish by taking up process control and machining precision at lesser cost than metallic gears in modern lathe machining.