This thesis deal with design development and fabrication of “MULTI PURPOSE MECHANICAL MACHINE”. This machine is designed for the purpose of MULTI-OPERATIONs i.e. BLANKING, CUTTING, SHAPING, HAMMERING & GRINDING. This machine perform multipurpose operation at same time with required speed & this machine is automatic which is controlled or operated by motor which is run with the help of current. This machine is based on the mechanism of whit worth return. This model of the multi operational machine is may be used in industries and domestic operation which can perform mechanical operation like drilling, cutting & shaping of a thin metallic as well as wooden model or body
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Multi
1. ABSTRACT
This thesis deal with design development and fabrication of “MULTI PURPOSE
MECHANICAL MACHINE”. This machine is designed for the purpose of MULTI-
OPERATIONs i.e. BLANKING, CUTTING, SHAPING, HAMMERING & GRINDING.
This machine perform multipurpose operation at same time with required speed & this machine
is automatic which is controlled or operated by motor which is run with the help of current. This
machine is based on the mechanism of whit worth return. This model of the multi operational
machine is may be used in industries and domestic operation which can perform mechanical
operation like drilling, cutting & shaping of a thin metallic as well as wooden model or body.
2. CHAPTER 1
INTRODUCTION
Industries are basically meant for Production of useful goods and services at low production cost,
machinery cost and low inventory cost. Today in this world every task have been made quicker
and fast due to technology advancement but this advancement also demands huge investments
and expenditure, every industry desires to make high productivity rate maintaining the quality
and standard of the product at low average cost
In an industry a considerable portion of investment is being made for machinery installation. So
in this paper we have a proposed a machine which can perform operations like drilling, sawing,
shaping, some lathe operations at different working centers simultaneously which implies that
industrialist have not to pay for machine performing above tasks individually for operating
operation simultaneously.
Economics of manufacturing: According to some economists, manufacturing is a wealth-
producing sector of an economy, whereas a service sector tends to be wealth-consuming.
Emerging technologies have provided some new growth in advanced manufacturing employment
opportunities in the Manufacturing Belt in the United States. Manufacturing provides important
material support for national infrastructure and for national defense.
3. CHAPTER 2
LITERATURE REVIEW
Before starting our work we have undergone through many research papers which
indicates that for a production based industries machine installation is a tricky task as many
factor being associated with it such as power consumption (electricity bill per machine),
maintenance cost, no of units produced per machine i.e. capacity of machine, time consumption
and many more….
Some research papers which have led us to approach to the idea of a machine which may give
solution to all these factors are as follows:
Heinrich Arnold1 November 2001: Rather long re-investment cycles of about 15 years
have created the notion that innovation in the machine tool industry happens incrementally. But
looking at its recent history, the integration of digital controls technology and computers into
machine tools have hit the industry in three waves of technology shocks. Most companies
underestimated the impact of this new technology. This article gives an overview of the history
of the machine tool industry since numerical controls were invented and introduced and analyzes
the disruptive character of this new technology on the market. About 100 interviews were
conducted with decision-makers and industry experts who witnessed the development of the
industry over the last forty years. The study establishes a connection between radical
technological change, industry structure, and competitive environment. It reveals a number of
important occurrences and interrelations that have so far gone unnoticed.
Dr. ToshimichiMoriwaki (2006): Recent trends in the machine tool technologies are
surveyed from the view points of high speed and high performance machine tools, combined
multifunctional machine tools, ultra precision machine tools and advanced and intelligent control
technologies.
4. Frankfurt-am Main, 10 January 2011. : The crisis is over, but selling machinery
remains a tough business. Machine tools nowadays have to be veritable “jack of all trades”, able
to handle all kinds of materials, to manage without any process materials as far as possible, and
be capable of adapting to new job profiles with maximized flexibility. Two highly respected
experts on machining and forming from Dortmund and Chemnitz report on what’s in store for
machine tool manufacturers and users.
Multi-purpose machines are the declarations of independence. The trend towards the kind of
multi-purpose machining centers that are able to cost efficiently handle a broad portfolio of
products with small batch sizes accelerated significantly during the crisis. “With a multi-purpose
machine, you’re less dependent on particular products and sectors”, explains Biermann.
2.1. WHITWORTH’S QUICK RETURN MECHANISM
The objective of this experiment is to investigate the performance of a whit worth quick return
motion and to verify that the motion does have a quick return stroke and a slow cutting or
forward stroke.
Mechanism is a simplified model, usually in the form of a line diagram, which is used to
reproduce exactly the motion occurring in a machine. The purpose if this reproduction is to
enable the nature of the motion to be investigated without the encumbrance of the various solid
bodies which forms the machine elements.
WHITWORTH QUICK RETURN MECHANISM
5. The above diagram shows the mechanism as used on the apparatus. Link 1 on the top diagram is
extended to point A. Attach to point A is another link with pivot. The other end of this link
terminated in a slider. In a machine tool where this mechanism is used the cutting tool is attached
to this slider.
The link POA rotates about a O. The mechanism is driven by crank PC which rotates about C
with constant velocity. The slider at P slides along POA as the crank is turned. Its path is shown
by the dashed circle, centered on C and through P. Clearly when P is at P1 the slider S is at the
outer extremely of its travel. When P is at P2 the slider S is at the inner extremely of its travel.
Now as PC rotates with constant velocity the time taken to go from P1 to P2 is less than that
taken to go from P2 to P1. However during both those time intervals the slider as moving the
same distance. Therefore the speed of S is different during the different parts of cycle. During the
shorter time intervals P1 to P2 the slider as has the greater speed and during the interval P2 to P1
it has slower speed. Thus P1 to P2 is quick return and P2 to P1.
When applied to metal cutting machine the other advantage is variable power distribution during
the cycle. When S is on the return stroke the slider at P is nearer O and simple moment shows
that the torque applied is low. Hence, the return stroke uses less power as P=T.W. During the
cutting stroke the slider at P is at greater radius from O and thus more power is available to
perform useful work in the cutting metal.
Thus the overall performance is to provide high power forward cutting stroke with a low
power and higher speed quick return in preparation for the next cut.
2.2. SCOTCH YOKE MECHANISM
6. The Scotch yoke is a mechanism for converting the linear motion of a slider into rotational
motion or vice-versa. The piston or other reciprocating part is directly coupled to a sliding yoke
with a slot that engages a pin on the rotating part. The shape of the motion of the piston is a pure
sine wave over time given a constant rotational speed.
This mechanism is an inversion of the double slider crank mechanism. The inversion is
obtained by fixing either the link 1 or link 3. In Fig, link 1 is fixed. In this mechanism, when
the link 2 (which corresponds to crank) rotates about B as centre, the link 4 (which corresponds
to a frame) reciprocates. The fixed link 1 guides the frame.
Other inversions of the double slider crank mechanism include Oldham coupling and elliptical
trammel.
History
This linkage is being called by a Scotsman in 1869 a "crank and slot-headed sliding rod“
But now it is known as a Scotch yoke because, in America at least, a "Scotch" was a
slotted bar that was slipped under a collar on a string of well-drilling tools to support
them while a section was being added
In 1940 Russell Bourke applied this mechanism to the internal combustion engine called
Bourke 30 engine
7. SIMPLE HARMONIC MOTION
Suppose crankshaft is rotating at an angular velocity
‘Ω’. If r is the radius of the crank then,
Tangential velocity, v= ‘rΩ’.
From the mechanism we have the following relation;
Component of tangential velocity in Y-direction is
given by;
u = Reciprocating velocity of U-Slot.
If α is the angle made by the tangential velocity with
X-Axis at any point of time,
Component of tangential velocity in Y direction is u = rΩsinα.
u = v.sinα
So, velocity of U-Slot= rΩsinα.
As a result, Velocity of U-Slot is a sine function of α.
Now as we know,α is directly proportional to time. Thisimplies velocity of U-Slot is a sine
function of time. Hence, the motion of U-Slot is a simple harmonic motion.
Advantage of SHM
The sinusoidal motion, cosinusoidal velocity, and sinusoidal acceleration (assuming constant
angular velocity) results in smoother operation of the mechanism.
8. ADVANTAGES AND DISADVANTAGES
The advantages compared to a standard crankshaft and connecting rod setup are:
High torque output with a small cylinder size.
Fewer moving parts.
Smoother operation.
Higher percentage of the time spent at top dead centre (dwell) improving engine
efficiency.
In an engine application, elimination of joint typically served by a wrist pin, and near
elimination of piston skirt and cylinder scuffing, as side loading of piston due to sine of
connecting rod angle is eliminated.
The disadvantages are:
Rapid wear of the slot in the yoke caused by sliding friction and high contact pressures.
Lesser percentage of the time spent at bottom dead centre reducing blow down time for
two stroke engines.
The shape of the motion of the piston is a pure sine wave over time given a constant rotational
speed.
9. CHAPTER 3
PROPOSED METHODOLOGY
3.1 PROBLEM STATEMENT
To design and development of MULTI PURPOSE MECHANICAL MACHINE, a structured
which is designed for the purpose of MULTI-OPERATIONs i.e. BLANKING, CUTTING,
SHAPING, HAMMERING & GRINDING
3.2 PROBLEM IDENTIFICATION
This machine perform multipurpose operation at same time with required speed & this machine is
automatic which is controlled or operated by motor which is run with the help of current. This
machine is based on the mechanism of whit worth return.
This model of the multi operational machine is may be used in industries and domestic operation
which can perform mechanical operation like BLANKING, CUTTING, SHAPING,
HAMMERING & GRINDING of a thin metallic as well as wooden model or body.
3.3 PROPOSED METHODOLOGY
In this project we will generally give the power supply to the shaft, At one end of the shaft is
connected to power supply , other end is being joined to a circular disc ,through this circular disc
scotch yoke mechanism is being performed horizontally (rotator y motion is converted to
reciprocating motion) for the cutting and shaping process . Same shaft’s other end is connected
with the grinding wheel in means of utilizing the rotation energy . at the same time the energy is
transferred to the another by means of belt drive. In this shaft two Whitworth’s mechanisms for
blanking and hammering function vertically.
13. 4.1 RESOURCES USED
Materials Dimensions
Mild steel plates 1. 50 mm x 5 mm
2. 50 mm x 2.5 mm
Mild Steel Rod 1. φ20 mm
2. φ25 mm
Mild steel hollow pipe φ30 mm (internal)
φ34 mm (external)
Mild steel square pipe 25 mm x 25 mm (external)
Thickness-2 mm
4.2 COMPONENTS
4.2.1 Crank and Handle
Obtained Cylindrical Rods Of Required Dimension Operations: Plain Turning
And Parting on Lathe machine
Welded Handle And Crank With Crank-shaft using electric arc welding.
14. Dimensions:As shown in the f
ollowing
figure
4.2.2 U-slot
Obtained square cross section pipe of required length by cutting the long pipe
with the power hacksaw
Used surface grinding machine to obtain smooth exterior surface on the pipe
Used power cutter to remove one face of the square pipe
Dimensions: as shown in the following figure-
15. 4.2.3 Yoke (Slider block)
Obtained a cylindrical block of required length by turning and parting on Lathe
machine.
Converted the cylindrical block into a cuboid of required dimensions on Shaping
Machine.
Hole is drilled in the middle of block to accommodate the crank using the drilling
machine.
Dimensions: As shown in the following figure
4.2.4 Foundation
Obtained metallic strips of required lengths by cutting the long bar using the
power hacksaw
Drilled holes to mount the crankshaft on the proper metallic strips using drilling
machine
Welded the metallic strips to get a rigid foundation
16. Dimensions: As shown
4.2.5 Guides
Obtained metallic strips of required lengths by cutting from long bar using the
power hacksaw
Obtained slots in the metallic strips using the power cutter
Dimensions:
17. 4.2.6 Piston and piston rod
Obtained cylindrical rods of required diameters and lengths using plain turning
and parting on the Lathe machine.
Welded piston to piston rod using electric arc welding
Welded the above piston assembly with the U-slot
4.2.7. Hollow Cylinder
Cut the pipe of required length using power hacksaw
Dimensions:
4.2.8 CAM ARRANGEMENT
A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming
rotary motion into linear motion or vice-versa. It is often a part of a rotating wheel (e.g. an
eccentric wheel) or shaft (e.g. a cylinder with an irregular shape) that strikes a lever at one or
more points on its circular path. The cam can be a simple tooth, as is used to deliver pulses of
power to a steam hammer, for example, or an eccentric disc or other shape that produces a
smooth reciprocating (back and forth) motion in the follower, which is a lever making contact
with the cam. The cam can be seen as a device that rotates from circular to reciprocating (or
sometimes oscillating) motion. A common example is the camshaft of an automobile, which
18. takes the rotary motion of the engine and translates it into the reciprocating motion necessary to
operate the intake and exhaust valves of the cylinders. Cams can also be viewed as information-
storing and transmitting devices. Examples are the cam-drums that direct the notes of a musical
box or the movements of a screw machine's various tools and chucks. The information stored
and transmitted by the cam.
4.2.9 Vice
It is a device consisting of two parallel jaws for holding a work piece; one of the jaws is fixed
and the other movable by a screw, a lever, or a cam. When used for holding a work piece during
hand operations, such as filing, hammering, or sawing, the vise may be permanently bolted to a
bench. In vises designed to hold metallic work pieces, the active faces of the jaws are hardened
steel plates, often removable, with serrations that grip the work piece; to prevent damage to soft
parts, the permanent jaws can be covered with temporary jaws made from sheet copper or
leather. Pipe vises have double V-shaped jaws that grip in four places instead of only two.
Woodworking vises have smooth jaws, often of wood, and rely on friction alone rather than on
serrations.
For holding work pieces on the tables of machine tools, vises with smooth hardened-steel jaws
and flat bases are used. These machine vises are portable but may be clamped to the machine
table when in use; means may also be provided for swiveling the active part of the vise so that
the work piece can be held in a variety of positions relative to the base. For holding parts that
cannot be clamped with flat jaws, special jaws can be provided.
19. CHAPTER 5
OPERATION OF THE MACHINE
1. CUTTING
2. SHAPING
3. BLANKING
4. HAMMERING
5. GRINDING
5.1 CUTTING
A hacksaw is a fine tooth saw with a blade held under tension in a frame, used for cutting
materials such as metal or plastics, hand held hacksaws consist of a metal arch with a handle,
usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other
mechanism is used to put the thin blade under tension. The blade can be mounted with a teeth
facing toward or away from the handle, resulting in cutting action on either the push or pull
stroke. On the push stroke, the arch will flex slightly, decreasing the tension on the blade.
Cutting machine
Blades are available in standardized lengths, usually 10 or 12 inches for a standard hand
hacksaw. “junior” hacksaws are half the size. Powered hacksaw may use large blade in a range
of sizes, or small machines may use the same hand blades.
20. Specification of hacksaw
Size of hacksaw blade:-
Thickness = 1.27-2.54mm
Width = 25.40-50.80mm
Length = 304.80-609.60mm
Work piece material Cutting speed in m/s
Mild steel 0.75
Cast iron 0.50
Brass/ aluminum 1.5
Bronze 1.25
Thin section(pipes & tubes) 1.5
5.2 SHAPING
The shaping machine is used to machine flat metal surfaces especially where a large amount of
metal has to be removed. Other machines such as milling machines are much more expensive
and more suited to removing smaller amounts of metal, very accurately.
The reciprocating motion of the mechanism inside the shaping machine can be seen in the
diagram. As the disc rotates the top of the machine moves forwards and backwards, pushing a
cutting tool. The cutting tool removes the metal from work which is carefully bolted down.
21. Shaping machine
The shaping machine is a simple and yet extremely effective machine. It is used to remove
material, usually metals such as steel or aluminum, to produce a flat surface. However, it can
also be used to manufacture gears such as rack and pinion systems and other complex shapes.
Inside its shell/casing is a crank and slider mechanism that pushes the cutting tool forward and
returns it to its original position. This motion is continuous.
5.3 BLANKING
Blanking and piercing are shearing processes in which a punch and die are used to
modify webs. The tooling and processes are the same between the two, only the terminology is
different: in blanking the punched out piece is used and called a blank; in piercing the punched
out piece is scrap. The process for parts manufactured simultaneously with both techniques is
often termed "pierce and blank." An alternative name of piercing is punching.
22. Blanking Machine
Fine blanking is a specialized form of blanking where there is no fracture zone when
shearing. This is achieved by compressing the whole part and then an upper and lower punch
extract the blank. This allows the process to hold very tight tolerances, and perhaps eliminate
secondary operations.
Materials that can be fine blanked include aluminium, brass, copper, and carbon, alloy,
and stainless steels.
5.4 HAMMERING
A hammer is a tool or device that delivers a blow (a sudden impact) to an object. Most
hammers are hand tools used to drive nails, fit parts, forge metal, and break apart objects.
Hammers vary in shape, size, and structure, depending on their purposes.
23. Hammering Machine
Hammers are basic tools in many trades. The usual features are a head (most often made
of steel) and a handle (also called a helveor haft). Most hammers are hand tools, but there are
also many powered versions, called power hammer (such as steam hammersand trip hammers)
for heavier uses, such as forging.
5.5 GRINDING
A grinding machine, often shortened to grinder, is any of various power tools or machine
tools used for grinding, which is a type of machining using an abrasive wheel as the cutting tool.
Each grain of abrasive on the wheel's surface cuts a small chip from the wor kpiece via shear
deformation.
Grinding is used to finish work pieces that must show high surface quality (e.g., low surface
roughness) and high accuracy of shape and dimension. As the accuracy in dimensions in
grinding is on the order of 0.000025 mm, in most applications it tends to be a finishing operation
and removes comparatively little metal, about 0.25 to 0.50 mm depth. However, there are some
roughing applications in which grinding removes high volumes of metal quite rapidly. Thus,
grinding is a diverse field.
25. CHAPTER 6
6.1 MERITS
Easy to operate.
Reduces time and increases production rate.
Low maintenance.
Easy to implement
Multi machine are performed at one time.
Our machine is used Return stroke (whit worth) mechanism.
The return stroke of shaper machine is utilized as cutting operation.
All operation is performed by only one motor.
Size is compact therefore it requires less space.
Time saving.
Less man power is required.
Low manufacturing & maintenance cost.
6.2 APPLICATIONS
Used in small scale industries to reduce machine cost.
In such places where frequent change in operation are required.
26. CHAPTER 7
FUTURE IMPLIMENTATION
We can perform various operations like BLANKING, CUTTING, SHAPING,
HAMMERING & GRINDING individually by introducing coupling (engagement &
disengagement) between them.
We can perform grinding operation by introducing a drilling tool at the main shaft by
bevel gear arrangement.
We can perform boring operation by introducing a boring tool.
We can change the speed of motor by regulator.
27. CHAPTER 8
CONCLUSION
After completing the major project on “MULTI PURPOSE MECHANICAL MACHINE” we are
much happy and would like to thank our teacher guides and the lectures of the concerned
department who have guided us.
While making this project we have been also to learn a lot and understand the various aspects of
“MULTI PURPOSE MECHANICAL MACHINE” we can use our knowledge, which we get
during our study.