Modification of a Rotary Table with Sliding
Mechanism
This project focuses on modifying a standard manual rotary table by integrating a sliding mechanism. This
enhances the versatility of the rotary table, enabling complex machining operations that require both rotational
and linear adjustments. The sliding mechanism is designed with high precision linear guides and a robust
locking system to ensure stability and accuracy during operations.
Name of the Participants: Project Guide
Sarvesh Manoj Birar Anil. T. Karanjkar
Payal Hetesing Dingar
Vaishnavi Dattatray Hagawane
Uday Tushar Kashid
Introduction to the Rotary Table
The project modifies a traditional manual rotary table to integrate linear motion
functionality. The rotary table, typically restricted to rotary positioning, is
enhanced with a sliding table consisting of a lead screw and lead nut
arrangement. This allows the rotary table to displace linearly, expanding its
operational parameters for intricate machining procedures.
The main objective is to amplify the table's workability, decreasing setup
durations and minimizing the requirement for multiple machining
configurations. This incorporation of a linear sliding mechanism enables both
rotational and sliding adjustments of the workpiece simultaneously.
FIG: ROTARY TABLE
Rotational Motion Linear Motion Intricate Machining
Precise angular positioning Sliding mechanism for Enhanced workability for
of workpieces. linear displacement. complex tasks.
Rotary Table and Sliding Mechanism
Rotary tables are fundamental tools in metalworking and manufacturing, providing precise rotational positioning for workpieces. Their
core function centers on accurate angular displacement, enabling machining operations at specific intervals around a fixed axis. Control
mechanisms range from manual operation to integration with CNC systems.
A sliding mechanism incorporating a leadscrew and lead nut arrangement serves as a fundamental mechanical system for the precise
conversion of rotary motion into linear displacement. This arrangement offers exceptional control over linear movement, making it
suitable for applications demanding high accuracy.
Rotary Table Sliding Mechanism
Precise rotational positioning for workpieces. Conversion of rotary motion into linear displacement.
Detailed Design: Base Plate
The component, designed with dimensions of 600mm in length, 120mm in width, and 60mm in thickness, necessitates careful
material selection to ensure optimal performance. Cast iron is the preferred material due to its superior vibration damping
capabilities, high compressive strength, and cost-effectiveness, all of which contribute to a stable and durable platform.
Additionally, its ability to be cast into complex shapes offers manufacturing advantages. However, if cast iron is not feasible,
EN8 or EN9 steel can be considered. EN8 is particularly suitable for screws and jaws, where its strength and heat-treatability
provide crucial wear resistance. EN9, while offering a good balance of strength and machinability, is less ideal for the main
body of the component due to potential vibration concerns. The approximate raw material weight required is 42 kg, with an
estimated cost of 3800 INR.
Base Plate
600mm x 120mm x 60mm, cast iron for stability.
FIG: BASE PLATE
Detailed Design: Upper Head
The component, with dimensions of 300mm in length, 160mm in width, and 50mm in thickness, employs a strategic material
selection to optimize performance and cost-effectiveness. EN8 steel is utilized for screws and less critical structural elements,
chosen for its favorable balance of strength and machinability, particularly when heat-treated. This selection provides a cost-
efficient alternative to higher-grade steels, suitable for general engineering applications. Conversely, EN90 (EN 90MnCrV8) is
reserved for highly specialized, wear-resistant components, such as precision jaws, where its exceptional hardness and
durability are paramount. This material ensures superior performance in demanding applications requiring extreme wear
resistance. An estimated 25kg of raw material is required for this component, with an approximate cost of 2350 INR.
Upper Head
300mm x 160mm x 50mm, EN8 steel for strength.
FIG: UPPER HEAD
Detailed Design: Lead Screw, Lead Nut, and Slide Plate
The lead screw converts rotational motion into a sliding mechanism. It is 315mm long with a 20mm diameter, 250mm thread length,
and an 8mm pitch. EN8 is used for its strength, machinability, and wear resistance.
The lead nut is coupled with the lead screw, resulting in the movement of the upper head. It measures 50mm x 50mm x 30mm. The
slide plate locks the upper head in place, restricting upward movement and degrees of freedom. It measures 300mm x 30mm x 10mm
and is constructed from EN8 steel.
Lead Screw 1
315mm long, 20mm diameter, EN8 steel.
2 Lead Nut
50mm x 50mm x 30mm, coupled with lead screw.
Slide Plate 3
300mm x 30mm x 10mm, EN8 steel, locks upper head.
Literature Survey Highlights
Initial studies compare rotary tables driven by worm gears versus roller gear cam mechanisms, underscoring the superior motion
characteristics of roller drive systems. These studies emphasize the critical role of minimizing backlash and rotational fluctuations to
achieve optimal precision in advanced machining operations.
Research addresses the need for precise indexing systems, proposing solutions like curvic couplings and hydraulically driven clamping
mechanisms. Other studies focus on adjustable backlash in worm gear drives and the design of CNC rotary tables capable of supporting
heavy loads.
1 Roller Drive Systems 2 Precise Indexing Systems
Superior motion characteristics with Innovative solutions for enhanced
enhanced positioning accuracy. manufacturing precision.
3 Heavy Load Support
Importance of structural integrity and positional accuracy.
Working of the Assembly Mounting
The assembly's operation begins with the secure mounting and alignment of the Secure workpiece on rotary table.
workpiece on the rotary table, followed by establishing initial linear and
Linear Positioning
rotational positions using precise measurement tools. Linear positioning is Engage sliding mechanism, verify, and lock.
achieved by engaging the sliding mechanism, moving along linear guides to the
desired location, which is then verified and locked.
Rotational Positioning
Rotate to required angle, confirm, and secure.
Rotational positioning involves rotating the rotary table to the required angle,
confirmed by a graduated dial and subsequently secured. For combined motion
tasks, linear and rotational positions are adjusted sequentially, with continuous
verification using measurement tools during machining.
Results of the Modification
The original rotary table's restriction to rotational movement limited machining operations to a single circumferential point. The
integrated sliding mechanism, utilizing a leadscrew and lead nut, enables linear (X-axis) motion alongside rotation. This enhances the
table's functionality and reduces the necessity for highly skilled labor, lowering operational costs.
The modification allows for the substitution of a costly 4-axis VMC machine with a more economical bench drilling machine,
potentially decreasing manufacturing expenses by 8-10 times.
8-10x
Cost Reduction
Potential decrease in manufacturing expenses.
X-Axis
Linear Motion
Enabled by sliding mechanism.
Future Scope and Potential Developments
Potential future developments include integrating CNC compatibility and motorized controls to automate operations and enhance
precision. Exploring advanced materials like aluminum alloys or composites could reduce weight while maintaining strength.
Structural modifications to increase load capacity would broaden its application in heavy-duty scenarios.
Incorporating digital readouts and sensor feedback systems would provide real-time data and improve overall accuracy. Customizing
the design for specific industry needs, such as robotics, automotive, or aerospace, would tailor the table to unique application
requirements.
CNC Integration 1 Better Materials
2
4
Digital Readouts 3 Increased Load Capacity
Conclusion of the Project
This project successfully enhanced a manual rotary table by integrating a
sliding mechanism, enabling simultaneous rotational and linear motion. This
modification broadened workpiece compatibility, simplified operations, and
reduced manufacturing costs by 8-10 times. The project demonstrates a cost-
effective method to adapt traditional rotary tables for advanced industrial
applications.
The integration of sliding and rotational movements in a single unit
provides a valuable tool for manufacturers seeking to optimize their
machining processes and improve overall productivity.