DESIGN AND MANUFACTURING OF SPM FOR BRAKE WHEEL CYLINDER

DESIGN AND MANUFACTURING OF SPM FOR BRAKE WHEEL CYLINDER
PROJECT REPORT
ON
DESIGN AND MANUFACTURING OF SPECIAL PURPOSE
MACHINE FOR BRAKE WHEEL CYLINDER
Submitted to
IN PARTIAL FULFILLMENT OF THE REQUIREMENT FOR
THE AWARD OF BACHELOR DEGREE IN
MECHANICAL ENGINEERING
Submitted by,
Mr AKSHAY V. DESHPANDE. 14ETRXMECH127
Mr PRASAD M. MALI 13MECH59
Mr OMKAR A. ALMAN 12MECH03
B.E. (MECHANICAL)
Under guidance of
PROF. A. M. RATHOD.
DEPARTMENT OF MECHANICAL ENGINEERING
TEXTILE AND ENGINEERING INSTITUTE, ICHALKARANJI.
AN AUTONOMOUS INSTITUTE AFFILIATED TO SHIVAJI UNIVERSITY,
KOLHAPUR.
ACCREDIATED WITH ‘A+’ GRADE BY NAAC.
AN ISO 9001:2015 CERTIFIED INSTITUTE.
2016-17
TEXTILE AND ENGINEERING INSTITUTE ICHALKARANJI Page 1

DESIGN AND MANUFACTURING OF SPM FOR BRAKE WHEEL CYLINDER
CERTIFICATE
This is to certify that,
M AKSHAY V. DESHPANDE. 14ETRXMECH127
Has presented and submitted the Project work entitled “DESIGN AND
MANUFACTURE SPECIAL PURPOSE MACHINE FOR BRAKE WHEEL
CYLINDER”. In the partial fulfilment for the award of degree of Bachelor in
Mechanical Engineering at SHIVAJI UNIVERSITY, KOLHAPUR. This is the record
of their work carried out during the academic year 2016-2017.
DATE: / / 2017
PLACE: ICHALKARANJI
PROF. A. M. RATHOD PROF.DR.V.R.NAIK
(PROJECT GUIDE) (H.O.D)
PROF.DR.P.V.KADOLE
(PRINCIPAL)
TEXTILE AND ENGINEERING INSTITUTE ICHALKARANJI Page 2

ACKNOWLEDGEMENT
It is with immense pleasure that we present our project on ““DESIGN AND
MANUFACTURE SPECIAL PURPOSE MACHINE FOR BRAKE WHEEL CYLINDER”.
At the outset. We would like to pay our respect and profound gratitude to our professor
PROF. A. M. RATHOD, for his timely advice and without whose motivation and expertise,
this project would have been devoid of richness.
We would like to express our sincere Gratitude to our H.O.D. PROF.DR.V.R.NAIK for
his valuable role in making this project successful.
Lastly, we would like to express my sincere thanks to all my colleagues and friends who
have assuredly helped to us a lot and without their availability collecting this matter would
have been facile.
Mr AKSHAY V. DESHPANDE. 14ETRXMECH127

ABSTRACT
Manufacturing plays vital role in any industry for producing the product. With stiff
competition & challenges in the present day market, manufacturers are compelled to be more
responsive to the customer’s demand regarding not only quality, but scheduled delivery.
Enhancing productivity is a key concern for almost all of the mass manufacturing industries
In this project we are going to design and fabricate SPM for BAJAJ RE component
for drilling, surfacing, tapping grooving etc. operations.
In this the design of SPM tool post, fixture, rotary turret, clamping arrangement and
hydraulic power pack is required. The main objective of this project is to design and
manufacture a SPM for increase in production rate and minimisation of worker requirement
at optimum cost. This also eliminate bottleneck of machine line.
The production rate is very low due to time required for loading, clamping and
manual drilling operation and de-clamping operation. The man-power required is more and
skilled. If machine design and may workable it will boost the company’s production rate at
lesser labour requirement rate.

1. INTRODUCTION
1.1. WHAT IS SPM?
A SPM (Special Purpose Machine) is a machine tool designed and manufactured to
suit a specific requirement and perform a limited range of operations. SPM is built such that
unwanted movements and operations are eliminated so that machine is confined to perform
machining on single variety components.
As SPM is self-contained machine having inbuilt units like a gear box, a bed,
hydraulic drives pneumatic systems of combination of all at a time. SPM is a machine which
is component or work piece oriented.
For the design and manufacturing of the SPM the components and the related
machining processes are taken into considerations and the specific customer requirements are
considered, from all above considerations takes place in the design of an SPM. SPM is
considered as the development of the basic machine tools available.
As part of our academics, we were in search of project, which would help us to
strengthen our theoretical knowledge with practical base. Also in our course Mr SANDIP
VIBHUTE, Sandip engineering PVT. Ltd. They offered us a project related to special purpose
machine. The aim of this particular project is to design and develop a single multitasking
machine for various operation performed on BAJAJ-RE break wheel cylinder.
Special purpose machine is part of multi-tasking machine. This is new approach to
increase the productivity of an organization. If we compare between ordinary machine and
special purpose machine in terms of cycle time, number of steps involved, manpower, etc. the
special purpose machine is preferred choice. Designing of SPM is decided upon the
principles of minimization of cost, improved productivity and better safety etc., which posses
with high initial investment, higher maintenance cost etc. Special Purpose Machine is higher
degree mechanism in which human participation is replaced by an application of mechanical,
electrical, electronics, hydraulic system.
In this project the following studies are carried out Time saved by component
handling (loading and unloading), using hydraulic clamping, Increase in productivity both
qualitative and quantitative, Less human intervention, indirectly reduction in operator fatigue,
Increase the profit of company. Special purpose machine is part of multi-tasking machine.

This is new approach to increase the productivity of organization. If we compare between
ordinary machine and special purpose machine in terms of time, costs, number of steps
involved, etc. The multi-tasking machine is preferred choice. The most noteworthy aspect
when using multi-spindle machines is the cycle time, due to parallel machining the total
operating time is dramatically decreased.
Special purpose machine (SPM) is combining the two machines which used for
drilling and riveting operation separately. This machine concept provided most compact,
economical and simple in operation by a single person. The machine consist of single phase
induction motor transmit power to drive mechanism by pulleys through V-belt and a
hydraulic cylinder which drive the process unit.
1.2. APPLICATIONS
The modern manufacturing industry is concerned to automobile, food processing
metal cutting sectors. All these sectors refer to high productivity and mass production.
Productivity has now become everyday watchword. It is crucial to the well fair of the
industrial firm as well as for the country. High productivity refer to doing the work in shortest
possible time with least expenditure on inputs without sacrificing quality and with minimum
rejection.
Following are the SPM’s used in modern manufacturing,
Modern SPM’s,
1. Piston turning lathe.
2. Camshaft grinder.
3. Gear generating machine.
4. CNC vertical mould milling machine.
5. Super finishing machine.
6. Punching and marking machine for piston.
7. Carburettors cap machine SPM.
1.3. ADVANTAGES
1. Cycle time is less for SPM as compared to GPM.
2. High or mass production rates thus increasing profit level.
3. High accuracy and performance.

4. Very less human intervention required, thus unskilled and low operator skill is
required.
5. Efficient and very less use of shop floor area.
6. Reduction in operator’s fatigue, hence more efficient work output.
7. Efficient payback period.
1.4. LIMITATIONS OF SPM
1. As every other machine SPM also has some practical limitations.
2. SPM is less flexible and versatile as other machines working range is limited.
3. Risk of out dating or obsolescing of the SPM is more as it is designed for specific
requirement.
4. Initial cost is high as compared to GPM, due to high tooling, sensors, online gauging
etc.
5. Maintenance cost is high as trained personnel are required to debug the fault.
6. Precision and high quality tooling required hence costly.
7. Breakdown of SPM will cause tremendous fall in production rate hence boost in the
company profit.

2. REQUIREMENT OF COMPANY
A total of 11 operations are to be performed on the job in a particular sequence and
on a single machine under the supervision of single operator. The operations are currently
done on Quick Change Drilling machine where the cycle time is very high and since the rate
of production is low. In order to deal with the increased demand of the jobs the company
needs a machine which will do all of the 11 operations simultaneously on a job or
simultaneously on 11 different jobs. This will reduce the fatigue of the worker caused due to
frequent clamping and unclamping of jobs as well as tools. Also since the operations are done
simultaneously the cycle time is reduced and the productivity will boost. The time study
considering the conventional method is given on further pages.
The operations required to be done are listed below.
SR.
NO.
OPERATION
DIAMETER
(mm)
OPERATION
DEPTH (mm)
1 DRILLING 9 9.5
2 SPOT FACING 19 2
3 THROUGH DRILL 2.5 2.5
4 FLAT DRILL 9 10.5
5 INTERNAL TURNING
MIN – 3.5
MAX. - 9
12.5
6 TAPPING 10 9.5
7 CENTER DRILL 6 8.5
8 DRILL 6 1
9 DRILL 6 11
10 THROUGH DRILL 2.5 15.5
11 TAPPING 7 8.5
TABLE NO. 1:- OPERATION DETAILS
3. PROBLEM DEFINITION AND SOLUTION

3.1. PROBLEM DEFINATION
In the conventional manner only one job can be worked at a time for either of the above
operations, but with increase in productivity demands a special purpose device or attachments
is need which will increase productivity by,
1. Performing operations on more than one job at a time,
2. Performing multiple operations in one cycle
3. Indexing capability to sequence operations one after another.
3.2. SOLUTION OF PROBLEM
The special purpose Multitasking machine is an ideal solution to the above problem
which is used to perform eleven operations at a time. In the multitasking machine eleven
operations are carried out simultaneously.
We also had different alternatives which we could have opted such as fully automatic
machine, semi-automatic machine or CNC machine. But we choose to produce an in house
special purpose machine for manual operation which would be far more economical for small
scale industries for increasing production output.

4. LITERATURE REVIEW
4.1. Mr S. R. Gawande, Mr S. P. Trikal: - This paper discusses the study of design of
multi spindle drilling machine. In case of mass production where variety of jobs is less
and quantity to be produced is large, it is very essential to produce the job at a faster rate.
The best way to improve the productivity along with quality is by designing special
purpose machine.
4.2. Prof. Ms A. A. Shingavi, Dr A. D. Dongare, and Prof. S. N. Nimbalkar: - This paper
discuss the case study and comparison of productivity of component using conventional
radial drilling machine and special purpose machine. Productivity can be improved by
reducing the total machining time, combining the operations etc. In case of mass
production where variety of jobs is less and quantity to be produced is huge, it is very
essential to produce the job at a faster rate. This paper deals with design and
development of multi-spindle drilling head for cycle time optimization of the
component.
4.3. Mr A. S. Udgav, Prof. V. J. Khot: - This paper deals with growth of Indian
manufacturing sector depends largely on its productivity & quality. Usefulness and
performance of the existing radial drilling machine will be increased by designing and
development of multi-spindle drilling head attachment. This paper deals with such
development undertaken for similar job under consideration along with industrial case
study.
4.4. Prof. P.R. Sawant, Mr R. A. Barawade: - This paper discuss the case study and
comparison of productivity of component using conventional radial drilling machine and
special purpose machine(SPM) for drilling and tapping operation. In this case study, the
SPM used for 8 multi drilling operation, linear tapping operation of Ø12 and angular
tapping operation of Ø5.1 of TATA cylinder block.
SUMMARY
By referring all above research paper we got general guideline about design and
manufacturing of special purpose machine. We also got information about increasing the
productivity of production line.

5. JOB DESCRIPTION
A wheel cylinder is a component in a drum brake system. It is located in each wheel and
is usually positioned at the top of the wheel, above the shoes. Its function is to exert force
onto the shoes so as to bring them into contact with the drum and stop the vehicle with
friction. The wheel cylinders are usually connected to the shoes with small bird-beak shaped
rods.
It is very similar to slave cylinder and functions in much the same way, internally
consisting of only a simple plunger. On older vehicles these may begin to leak and hinder the
performance of the brakes, but are normally inexpensive and relatively easy to replace.
FIGURE NO. 1:- BRAKE WHEEL CYLINDER
5.1. MECHANICAL PROPERTIES
1. Hardness of material: - 180 HB to 230 HB (This values based on Brinell hardness test
which tested in accordance with IS: 1500).
2. Tensile properties of material: - 260 N/mm2.
(Which tested in accordance with IS:
1608).

6. COMPONENT DRAFT COPY
FIGURE NO. 2: - COMPONENT DRAFT COPY

7. PURPOSE OF THE PROJECT
The purpose of this project is development of a Special Purpose Machine for mass
production of Drum Brake Wheel Cylinder. The SPM designed and manufactured will be
able to perform total of 11 operations simultaneously which in turn reduce the cycle time and
will increase the rate of production.
We have done the Time Study for current manufacturing method. According to our study
it takes on an average of 15 seconds for clamping the job and about 5 seconds for changing
the tools after each operation. The main purpose is to reduce the time required for production
of one job by a factor of four. Also this will reduce the fatigue of the worker.
7.1. BENEFITS:-
1. Increased rate of production.
2. Minimized worker requirement.
3. Eliminated bottlenecking of machining line.
7.2. PRODUCTIVITY OF CONVENTIONAL MACHINE
We have recorded the total time required for production of one job. The time analysis
with considering different allowances is listed below.
1 Clamping of the job 5 sec
2 Changing the tool 3 sec
3 Operation time
3 sec ( average of all
operations)
4 Removing the job 3 sec
TABLE NO 2:- TIME CONSIDERATIONS [CONVENTIONAL METHOD]
Since there are total of 11 operations are to be performed after clamping of the job.
Total time required for one job = (Time for changing tool x 11) +

(Time for operation x 11) +
(Time for clamping the job) +
(Time for removing the job).
= (3 x 11) + (3 x11) + 5 + 3
= 74 sec
= 1 min (approximately).
7.3. ORDER CALCULATION (CONVENTIONAL METHOD)
1 Per day production 250 jobs
2 Per hour production 32 jobs
3 Time period for one job 1 min
4 Profit per job Rs.1
TABLE NO 3:- ORDER CALCULATION (CONVENTIONAL METHOD)
7.4. LIMITATIONS OF CONVENTIONAL METHOD
Conventionally, the job is done on a quick change drilling machine. Working over this
machine is very cumbersome since it involves manually changing the tools after every
operation.
This results in a large cycle time and consequently a smaller rate of production. Also
changing tools of drilling machine is very risky due to the uncertainties present in the
switching of motors. The conventional method being very slow is not able to fulfil the
demands of the production. A worker with conventional method can produce 250 jobs per
shift (8 hours) i.e. 32 jobs per hour.
So as to increase the production rate the company is in need of a special machine that
will increase the production rate from 32 jobs per hour to 250 jobs per hour (that will increase

the production rate by seven time). To achieve such a drastic increase in the production rate
either the special purpose machine must be able to perform different operations
simultaneously on a single job or it must be able to perform different operations on different
jobs successively but simultaneously. Since the product being too small in size it will be
inconvenient to perform different operations simultaneously on the single job hence choosing
the later method is right.
FIGURE NO. 3:- QUICK CHANGE DRILLING MACHINE

8. DESIGN CONSIDERATION IN SPM
The concept of the special purpose machine for this particular job, consist of a
rotating turret at the centre and the fixed tools at various stations around. The turret at the
centre will hold the fixtures for fixing the job. The tools fixed around the central turret will be
in sequence such that the jobs fixed on the central turret will undergo subsequent operations
as the reach the next tool after the rotation of the central turret. The jobs will be fixed in a
way that the surface on which the operation is to be performed will always face towards the
tool, this is possible because the operation that currently performed on QUICK CHANGE
MACHINE are to be performed on the same surface and hence the critical task of rotating the
job will be eliminated.
Also the tools fixed will be arranged at the precise locations such that the surface on
which the operation is to be performed comes next to the tool and will make the required
angle at which the operation is to be performed. The locations of the tools will be decided on
the basis of the sequence of the operations and according to the angular rotation of the turret.
8.1. DESIGN CONSIDERATIONS IN FIXTURE PLATE
Since the total 11 operations are to be done on the same face (some of them at
different angles to the face) the fixture is designed accordingly. The CATIA model of
the fixture is shown in the figure. The various design related consideration about
every component of the fixture plate are listed below.
1. Base plate – This is the rectangular plate on which the central turret as well as all the
11 tool posts will be mounted. This plate should have enough strength to bear the load of the
turret as well as the tool posts. As we consider the ergonomics the plate should be at enough
height that the fixture plate mounted on the turret will reach to height of stomach of the
human operator who is going to mount and unmounts the job in the fixture. The dimensions
of the base plate are given below. This base plate will rest on a foundation of 35cm in
height. A tray will be attached on the upper edges of the foundation to collect the burr
formed during the operation.
2. Fixture plate - This is the circular plate which will hold all the 12 fixtures on its
circumference. The diameter if the fixture plate is 550mm and it is made of cast iron. The
fixture plate will mount on the indexing plate of the turret. We have imported the 12 station
turret BTP-125-12-R-415 from PRAGATI AUTOMATION PVT. LIMITED BANGLORE.
The dimensions of the turret indexing plate are given below in the drawing. Our fixture plate

with 12 fixtures on its circumference will mount on this indexing plate of the turret and the
plate is fixed with 6 bolts of diameter 20mm. Fixture plate should be light in weight so as to
reduce the torque required to rotate it. The diameter of the fixture plate is 550mm.
3. Fixture – The fixture designed for holding the job is shown in the drawing below. This
fixture is mounted on the circumference of the fixture plate. This is fixed to the fixture plate
with 3 vertical bolts at the base. The diameter of the bolts is 10mm. Use of three bolts in a
single plane ensures that the fixture won’t move in any direction as the thrust force applies
during the operation. The drafting of the fixture designed is shown below.
FIGURE NO. 4:- CATIA DESIGN OF FIXTURE
8.2. DESIGN CONSIDERATIONS IN SPM
As we know the SPM is totally a job oriented and custom built machine. The design
of SPM is totally dealing with the processes and the details of the work pieces. The
SPM is “Machine made based on job”. Hence the has some design considerations as
1. Cycle time.
2. Ergonomics.
3. Slides and guide ways.
4. Control panels.
5. Lubrication.

6. Bearing
7. Economical consideration.
8.3. CYCLE TIME
Cycle time is the time required to complete the total machining operation from
loading to the finished component. As the requirement of SPM is high production
rate, the design of SPM is such that the cycle time is minimum. Thus in SPM the
approach and of tool are minimized by using
1. Dual speed motors for drivers.
2. Efficient tooling.
3. Accurate machining and high quality guide ways using less friction.
4. Alarm signals to inform cycle condition.
5. Efficient use of sensors.
6. Proper interlocking of operations.
7. Increase use of modern electronics and CNC processes.
8.4. ERGONOMICS
This factor as compared to GMP has prime importance in designed SPM.
The word Ergonomics has its origin in two Greek words Ergo means Work and
Nomos meaning laws. It can be defined as – “The applications of human biological
sciences along with engineering sciences to achieve optimum mutual adjustment of
men and his work, the benefits being measured in terms of human efficiency and
well-being.”
1. The various disciplines that are going to have influence of human factor are
a) Engineering: Design of work system suitable for worker.
b) Physiology: Study of man and is working environment.
c) Anatomy: Study of body dimensions and relations for work design.
d) Psychology: Study of adaptive behaviour and skill of people.
e) Industrial hygiene: Occupational hazards and workers health.
2. Man is better or unique at
a) At discriminating relent from irrelevant signals.
b) At innovative and creative in problem solving.
c) In reasoning.

d) Ability to select his own inputs.
e) Improving, adopting new procedures, judgements based on previous experience.
3. Machine is better or unique at
a) Routine processing and storage of previous memory.
b) For repetitive and monotonous work.
c) For monitoring man and machine.
d) Rapid response to the signals.
e) For hazardous environments.
4. Environmental factors
a) The role that ergonomics play in the environmental man machine reaction is essential
two fold.
b) First identifying the effects that environment plays on human physiological and
psychological processes.
c) Second, ensuring that work patterns equipment machine are designed to minimize the
personal variations.
d) Third, ensuring that all the necessary protective systems are designed to take an
account of physiological and psychological variations in man.
5. The environmental factor that affects the performance are:
a) Illumination: - When human activities are carried out indoor or at right, it is necessary
to provide some sort of artificial illumination the type of illumination depends upon the
type of work being performed, the size of objects, accuracy, speed and duration of the
work, etc. In the SPM, the lighting arrangement should have sufficient brightness, uniform
illumination, contrast between brightness of job and the background, no direct or reflected
glare and minimization of eye movement required to resolve the visual information by
arrangements of displays rather than reducing their size.
b) Noise: - Noise has been defined as unwanted sound and it has shown to have both
short and long term effects on human performance. These effects may be internal and
physiological in nature, resulting in the auditory system being unable to perceive sound.
The amount having loss is related to the level of the noise to which the operator is exposed
and it depends upon the exposure time for high frequency intensities.
c) Vibration: - Usually vibrations of the air are detected as sound but air vibration below
20Hz are not heard but it can felt. Thus efficient damping of vibrations should be done to
the SPM. Normally protection from residual vibration is achieved by reducing force
transmitted, by converting vibration energy into thermal energy by using damper.

d) Thermal considerations: - Poor heat and humid conditions also produce stress on the
operator which effects the efficiency. Working at a temperature of 20-25 C is considered as
normal and 70% humidity is tolerable. If the humidity is high evaporation of sweet is
reduced, which result in dryness of mouth, throat and nose. The effect of heat can be
minimize by Shielding, isolating heat sources to reduce direct transitions of heat by
radiation and Permit rest pauses in cool, extreme hot condition.
8.5. SLIDE AND GUIDEWAYS
Slides and guide ways are the basic elements of any machines tool which support and
control the motion elements of any machine tool.
Generally available guide ways are of various sizes as flat dovetail, these guide ways are
used for machining requiring low accuracy, low sliding speed, and less reliable, considering
the modern concept the antifriction, aerostatic, hydrostatic guide ways are popular.
These guide ways are more reliable, good load carrying capacity the motion of these
guide ways is more precise and smooth. Also the recent development of linear guide ways is
a boon to SPM and CNC machines as they are extremely smooth with least friction.
Thus, from the design and the desirable accuracy of job to be done on a SPM, the most
feasible type of guide ways and slides can be selected. Also the economy of the customer
plays an important part in the guide ways selection.
8.6. CONTROL PANEL
The electrical control panels are most important part of SPM as the total SPM is operated
just by the various control buttons seen on the panels. Design and installation of electric
equipment of SPM ensure uniform design and installation procedure ease of maintenance and
safety of power supply by an ON OFF switch other voltage if required are obtained by
transformers. The control panel of SPM should have following features:
1. Emergency stopping device.
2. Opposing motions by limit switch.
3. Covers and door interlocks.
4. Spindle drive interlocked with feed.
5. Non reputation of the cycle.
6. Reverse current breaking.
Also control ensure and compartments are to be so enclosed as to give adequate
protection against ingress of dust, oil coolant chips and against mechanical damage.

The control devices in the enclosures are so installed that they are readily assessable.
When the doors are opened care is taken in the colour schemes are given in the table.
8.7. LUBRICATION
SPM generally work to a high degree of accuracy and expected to sustain this
accuracy over a long period. This requires proper control of friction and wear of parts which
are in relative motion and calls for effective lubrication of the vital elements like bearing,
slide ways etc.
8.8. BEARINGS
Viscosity is one of the important design parameter which influences the value of film
thickness, load capacity, friction torque etc. For a given oil thicker oil forms a larger film
thickness and improves load capacities but increase the heat generation.
The oil which is used should have a high Viscosity Index (VI) of 90 min. i.e. mineral
oil with minimum VI of 90-95 is used.
8.9. ECONOMIC CONSIDERATION
This is main factor governing the all above factors it is mainly related to
1. Reduction of idle time by
a) Reducing the number of idle operations.
b) Simultaneously the idle operations with other idle operation.
c) Highly productive and dynamically stable use of machine
d) Implementing techniques such as group technology
e) Sufficiently strong and rigid work and tool holding
f) Reduction of the tool change time.
g) Controlling the frequency of the tool failure by using tool of longer life.
As there will be complete automation of travel, retract, feed rate, so depth control is to be
considered.
The electrical control panel is located at appropriate location, height also enhance the
operators working ability.
Proper coolant provision during operation.
The above SPM will accommodate all design consideration. Hence above SPM will
beneficial to greater extend.

9. CALCULATION
9.1. CALCULATIONS FOR MOTOR SELECTION
1. FOR FIRST AND FORTH OPERATION:
Machining Data Required:
Cutting Speed Cs= 23 m/min
Feed per revolution S= 0.2 mm/rev.
Material Factor K=1.5, Drill diameter= D mm.
Spindle Speed ns =
Cs ×320
(D)
=
23×320
(9)
= 817.77 rpm.
Power at Spindle Ps =
1.25×D
2
×K ×ns ×(0.056+1.5S)
10
5
=
1.25×9
2
×1.5×817.77×(0.056+1.5×0.2)
10
5
= 0.44214 KW
= 442.14 W
Efficiency of transmission E ¿90 %.
Power at Motor Pm =
Ps
E
=
442.14
0.9
= 493.26 W.
Thus we have selected 0.75 HP Motor
Torque T =
975× Pm(KW )
ns
=
975×0.49326
817.77

= 0.58571 Kgf.m
= 5.746 Nm.
2. FOR SECOND OPERATION:
Cutting Speed Cs= 23 m/min.
Material Factor K=1.5
Drill diameter= D mm.
Speed n =
Cs ×320
(D)
=
23×320
(19)
= 387.368 rpm.
Spindle Speed for Spot facing ns =
n
3
=
387.368
3
= 129.123 rpm
Power at Spindle Ps ¿
1.25×D
2
×K ×ns ×(0.056+1.5S)
10
5
¿
1.25×16
2
×1.5×129.123×(0.056+1.5×0.2)
10
5
= 0.31114 KW
= 311.14W
Efficiency of transmission E = 90%.
Power at Motor Pm ¿
Ps
E
¿
311.14
0.9
= 345.71 W.
Thus we have selected 0.75 HP Motor.

Torque T ¿
975× Pm(KW )
ns
¿
975×0.34571
129.123
= 2.605 Kgf.m.
= 25.6 Nm.
3. FOR THIRD AND TENTH OPERATION:
Material Factor K=1.5, Drill diameter= D mm.
Spindle Speed ns ¿
Cs ×320
(D)
¿
23×320
(2.5)
= 2944 rpm.
1.25×D
2
×K ×ns ×(0.056+1.5 S)
10
5
¿
1.25×2.5
2
×1.5×2944×(0.056+1.5×0.06)
10
5
= 0.05037 KW
= 50.37 W
Ps
E
¿
50.37
0.9
= 55.96 W.
Thus we have selected Half HP Motor
Torque T =
975× Pm(KW )
ns

=
975×0.05596
2944
= 0.01853 Kgf.m.
= 0.18183 Nm.
4. FOR SEVENTH AND NINETH OPERATION:
Spindle Speed ns=
Cs ×320
(D)
=
Cs ×320
(D)
= 1226.67 rpm.
1.25×D
2
×K ×ns ×(0.056+1.5S)
10
5
=
1.25×6
2
×1.5×1226.67×(0.056+1.5×0.2)
10
5
= 0.29476 KW
= 294.76 W
Power at Motor Pm =
Ps
E
=
294.76
0.9
= 327.52W.
Torque T ¿
975× Pm(KW )
ns

¿
975×0.32752
1226.67
= 260.324 Kgf.m.
= 2.553 KNm.
5. FOR EIGHTH OPERATION:
Spindle Speed ns ¿
Cs ×320
(D)
¿
23×320
(7)
= 1051.428 rpm
1.25×D
2
×K ×ns ×(0.056+1.5S)
10
5
=
1.25×7
2
×1.5×1051.428×(0.056+1.5×0.18)
10
5
= 0.31491 KW
= 314.91 W
Power at Motor Pm =
Ps
E
=
314.91
0.9
= 314.91/0.9
= 349.90 W.

Torque T =
975× Pm(KW )
ns
=
975×349.90
1051.428
= 0.324 Kgf.m
= 0.3.13 Nm.
6. FOR SIXTH OPERATION:
Cutting Speed Cs = 80 SFM.
Pitch of thread p = 1 mm.
Tap diameter= D mm.
Spindle Speed ns=
SFM ×97.028
D
=
80×97.028
10
= 776.224 rpm.
0.433× D× p
2
×ns ×K
10
4
=
0.433×10×1
2
×776.224 ×1.5
10
4
= 504.15 W
Transmission Efficiency E = 90%.
Power at Motor Pm=
Ps
E
=
504.15
0.9
= 560.17 W
Thus we have selected 1 HP Motor
Torque T =
975× Pm(KW )
ns

=
975× Pm(KW )
ns
= 0.7036 Kgf.m
= 6.9024 Nm
7. FOR ELEVENTH OPERATION:
Cutting Speed Cs = 80 SFM.
Pitch of thread p = 1 mm.
Tap diameter= D mm.
Spindle Speed ns =
SFM ×97.028
D
=
80×97.028
7
= 1108.891 rpm.
0.433× D× p
2
×ns ×K
10
4
¿
0.433×7×1
2
×1108.891×1.5
10
4
= 504.15 W
Ps
E
¿
504.15
0.9
= 560.17 W
Torque T=
975× Pm(KW )
ns

=
975×0.56017
1108.891
= 0.4925 Kgf.m
= 4.831 Nm
8. FOR FIFTH OPERATION:
Material Factor K=1.5.
Spindle Speed, ns =
Cs ×320
(D)
=
23×320
(6.25)
= 1177.6 rpm.
Sm = S ×RPM
= 0.2×1177.6
= 235.52 mm/min.
Depth of cut, t = 2 mm.
Metal removal rate = Q = S ×t ×v
= 0.2×2×23
= 9.2 cm3
/min.
Approach angle, x = 90 deg.
Average chip thickness, as= S ×sin (x)
= 0.2×sin (90)
Unit power, U = 24 KW/cm3
/min.
Kh = 1.73
Side rake angle, r = 0 deg.

Coefficient angle for rake angle, Kr = 1.13
Power at spindle, Ps = U ×Kh ×Kr ×Q
= 24×1.73×1.13×9.2
= 431.61W
Ps
E
¿
431.64
0.9
= 479.60 W
Torque at Spindle, T =
975× Pm(KW )
ns
=
975×0.47960
1177.6
= 0.3971 Kgf.m
= 3.8954 Nm
9.2. CALCULATIONS FOR THRUST FORCES
1. First operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×9(100×0.2)
0.85
Th = 199.83 kg.f
2. Second operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×10(100×0.2)
0.85
Th = 222.04 kg.f
3. Third operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×2.5(100×0.06)
0.85

Th = 19.94kg.f
4. Forth operation
T h=1.16kD(100 S)
0.85
T h=¿ 1.16×1.5×9(100×0.2)
0.85
Th = 199.83 kg.f
5. Fifth operation
Pz ¿
6120×N
v
=
6120×431.64×10
−3
23
¿ 114.683 kg.f
6. Seventh operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×6(100×0.18)
0.85
Th = 121.80 kg.f
7. Eight operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×6(100×0.18)
0.85
Th = 121.80 kg.f
8. Ninth operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×6(100×0.18)
0.85
Th = 121.80 kg.f
9. Tenth operation
T h=1.16kD(100 S)
0.85
T h=1.16×1.5×2.5(100×0.06)
0.85
Th = 19.94kg.f
9.3. CALCULATIONS FOR PULLEY
Pulley at the motor side is kept constant i.e. of 60mm. and respectively diameters of other
pulley is calculated.

1. Pulley diameter for first and forth operation: -
Diameter of Spindle pulley =
Standard RPM of motor× Diaof motor pulley
RPM of spindle
=
1430×60
817.77
= 104.92 mm.
Standard Pulley Diameter= 100 mm.
RPM for standard pulley =
Motor RPM ×Motor pulley dia
Standard pulley dia
=
1430×60
100
= 858 rpm
2. Pulley diameter for second operation: -
RPM of spindle
=
1430×60
387.36
= 221.50 mm.
Standard Pulley Diameter = 200 mm.
Standard pulley dia
=
1430×60
200
= 429 rpm
3. Pulley diameter for third and tenth operation
Standard RPM of motor ×Diaof motor pulley
RPM of spindle
=
2870×60
2944
= 58.49 mm.

Standard pulley dia
=
2870×60
56
= 3075 rpm
4. Pulley diameter for sixth operation:
RPM of spindle
=
940×60
776.224
= 72.65 mm.
Standard pulley dia
=
940×60
71
= 794.36 rpm
5. Pulley diameter for seventh and ninth operation
RPM of spindle
=
1430×60
1226.67
= 69.94 mm.
Motor RPM× Motor pulley dia
Standard pulley dia
=
1430×60
71
= 1208.45 rpm
6. Pulley diameter for eighth operation:

RPM of spindle
=
1430×60
1051.42
= 81 mm.
Standard pulley dia
=
1430×60
80
= 1072 rpm
7. Pulley diameter for eleventh operation:
RPM of spindle
=
940×60
1108.91
= 50.86 mm.
Standard pulley dia
=
940×60
50
= 1125 rpm
9.4. SELECTION OF V- BELT
Since all the three type of motors we used are normal Torque, Synchronous motors the
correction factor according service for all the three types of motors is 1.2 ( operational hours
10to 12 per day)
Hence Design Power,
1. ½ HP Motor = 447.6 watts
2. ¾ HP Motor = 672 watts
3. 1 HP Motor = 895.2 watts.

9.5. SELECTION OF BELT SECTION
Since Design Power for all the three types of motor is below 1000 watts (1 KW).
FIGURE NO. 5: - CROSS-SECTION OF V-BELT
Hence all the dimensions of standard Z cross section V belt are as follows-
1. Pitch Width (Wp)– 8.5mm
2. Normal Top Width (W) – 10mm
3. Normal Height (T) – 6mm
4. Permissible Minimum Pitch Diameter of Pulley – 50mm
9.6. DETERMINATION OF PITCH LENGTH OF V BELT
The pitch length of V-belt can be calculated from the following Equation= L
L = 2C+
π (D+d)
2
+
(D−d)2
4c
Where,
L = Pitch Length in mm
C = Centre distance between two pulleys

D = Bigger pulley diameter
D = Smaller pulley diameter.
Let’s apply the above equation to all the operations
1. Drilling 9mm twist drill as well as flat drill
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (100+60)
2
+
(100−60)2
4 x250
L = 752.9 mm
Standard Length available is = 780 mm
2. Spot Facing
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (200+60)
2
+
(200−60)2
4 x 250
L = 928mm
Standard Length available is = 920mm.
3. Through Drill of 2.5mm
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (60+56)
2
+
(60−56)2
4 x 250
L = 682.22mm
Standard Length available is = 700mm.
4. Drilling 6mm

L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (71+60)
2
+
(71−60)2
4 x250
L = 705.89 mm
Standard Length available is = 700 mm.
5. Drilling 7 mm
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (80+60)
2
+
(80−60)2
4 x 250
L = 720.31mm
6. Internal turning operation
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (71+60)
2
+
(71−60)2
4 x250
L = 705.89 mm

7. Tap M10x1- 6H
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (140+60)
2
+
(140−60)2
4 x250
L = 820.55 mm
8. Tap M7x1 – 6H
L = 2C+
π (D+d)
2
+
(D−d)2
4c
L = 2x 250+
π (140+60)
2
+
(140−60)2
4 x250
L = 820.55 mm
9.7. ‘V’ GROOVED PULLEY
The standard dimensions of V- grooved pulley are shown below

FIGURE NO. 6: - V GROOVED PULLEY
lp = 8.5mm, (Pitch width of pulley groove)
b = 2mm, (Minimum height of pulley groove above the pitch line)
h = 9mm, (Minimum depth of groove below the pitch line)
f = 7-9 mm, (Distance of the edge of the pulley to first groove centre)
ά = 34 degree, (Groove angle)
dp = Up to 80mm, (Pitch diameter of the pulley).

10.HYDRAULIC ACTUATOR
The hydraulic cylinder that we have used in our project is designed to give the required thrust
force for the operation and conforming to the standards.
10.1. Specification of hydraulic actuator-
1. Bore diameter – 40 mm
2. Piston rod diameter - 20 mm
3. Stroke length – 150 mm
4. Bore side area – 1256.64 mm2
5. Rod side area – 942.48 mm2
6. Bore side volume – 0.000188 m3
7. Rod side volume – 0.000141 m3
10.2. OIL FLOW IN ACTUATORS:
ACTUATOR
NO.
THRUST
FORCE (KN)
PRESSURE
(bar)
TIME (sec) OIL FLOW
(lpm)
1 1.96 15.59 3.48 3.4
2 1.16 9.23 5.24 2.30
3 0.19 1.51 5.09 2.22
4 1.96 15.56 3.84 2.94
5 1.12 8.91 3.18 3.56
7 1.19 9.46 2.31 4.89
8 1.39 11.06 0.20 0.37
9 1.19 9.47 2.98 3.79
10 0.19 1.51 5.26 2.15
TABLE NO. 4: - OIL FLOW IN ACTUATORS
10.3. VALVES AND HYDRAULIC CIRCUIT USED IN HYDRAULLIC PACK
The circuit used in the hydraulic pack is called rapid feed and rapid return circuit. This circuit
consists of the following elements-

1. 4/3 direction control valve – (double solenoid)
2. 4/2 direction control valve - (single solenoid)
3. Flow control valve- (knob operated)
4. Pressure relief valve.
10.4. SPECIFICATIONS OF HYDRAULIC POWER PACK
The hydraulic power pack that we have manufactured at Steel Tech Yadrav, has the
capacity to simultaneously supply to three hydraulic actuators having 40mm bore size
diameter and 150mm of stroke length. According to standards the volume of the power pack
should be at least 5 times greater than the pump discharge per minute. Here in this hydraulic
power pack 3 gear pump providing a discharge of 7lt/min are used in a set since one power
pack supplies oil to 3 hydraulic actuators.
FIGURE NO.7:- HYDRAULIC POWER PACK

Following are some specifications-
1. Power of motor = 1.5 HP (continuous duty)
2. Discharge of gear type pump = 7 lt/min.
3. Volume of the reservoir = 105 lts.
4. Hose inner diameter = ¼ inch.
5. No of hoses used = 18
6. Type of hydraulic oil = 68
10.5. WORKING OF HYDRAULIC CIRCUIT
A programmable logic controller (PLC) is a digital electronic device that uses a
programmable memory to store instructions and to implement functions such as logic,
sequencing, timing, counting and arithmetic in order to control machines and processes and
has been specially designed to make programing easy. The term logic is used because the
programming is primarily concerned with implementing logic and switching operations.
Input devices, e.g. switches and output devices, e.g. motors, being controlled are connected to
the PLC and then the controller monitors the inputs and outputs according to the program
stored in the PLC by the operator and so controls the machine or process. Originally PLCs
are designed as a replacement for hard-wired relay and timer logic control systems. PLCs
have grate advantage that it is possible to modify a control system without having to rewire
the connections to the input and output devices, the only requirement being that an operator
has to key in a different set of instructions. Also they are much faster than relay-operated
systems. The result is a flexible system which can be used to control systems which are
widely used for the implementation of logic control functions because they are easy to use
and program.
PLCs are similar to computers but have certain features which are specific to their use
as controllers. As the machine starts PLC sends the signal to operate the valves and rapid feed
mechanism is brought in the operation in this case solenoid 1 and 3 are operated in orders to
give the tool maximum possible speed till it reaches the job. Once the tool reaches the job the
limit switch mounted at the back of slider is operated which in turn sends signal to the PLC to
operate slow feed mechanism. The tool is then fed at the required feed rate which is set
practically for each actuator. For slow feeding only solenoid 1 is operated. Once the operation
is done again another limit switch mounted at the rear is operated which again sends signal to

the PLC to activate rapid return mechanism. As the PLC receives the signal from second limit
switch it operates solenoid 2 and 3 to carry out the quick return of the tool. Another limit
switch is mounted at the back of the slider which is operated when the slider is returned back
to its initial position. As this switch is operated the PLC sends signal to operate pressure relief
valve which in turn stops the actuator.

11.WORKING OF SPM
The stepwise working of SPM is given below.
11.1. Clamping of job at 1st
tool station.
11.2. Drilling at 2nd
tool station.
Diameter: 9 mm,
Depth: 9.5 mm.
11.3. Spot facing at 3rd
tool station.
Diameter: 19mm,
Depth: 2mm.
11.4. Through Drill at 4th
tool station.
Diameter: 2.5 mm,
Depth: 15mm
11.5. Flat Drill at 5th
tool station.
Diameter: 9 mm,
Depth – 10.5 mm
11.6. Internal Grooving at 6th
tool station.
Diameter: min- 3.5mm, max- 9mm,
Depth – 12.5 mm
11.7. Tapping at 7th
tool station.
M10 x 1- 6H, Tap Diameter – 10mm,
Depth – 9.5mm.
11.8. Drill at 8th
tool station.
Diameter: 6mm,
Depth: 8.5mm.
11.9. Chamfer Drill at 9th
tool station.
Diameter: 6mm,
Depth: 1mm.
11.10.Drill at 10th
tool station.
Diameter: 6mm,
Depth: 11mm.
11.11.Through Drill at 11th
tool station.
Diameter: 2.5mm,
Depth: 15.5mm
11.12.Tapping at 12th
tool station.
M7 x 1- 6H, Diameter: 7,
Depth: 8.5mm.
At first the operator on the machine will press the button which unclamps the
machined job at tool station one and will mount the job to be machined. Once the job is

mounted again the same button is pressed. This will fix the job with hydraulic clamp and
reduce its degree of freedom to zero. As the job is clamped the fixture plate rotates and the
job at 1st
tool station will move to the next (2nd
) tool station and second to the 3rd
and so on.
Then at the 2nd
tool station the drilling operation is carried out where the continuous
duty ¾ HP motor provides the torque required through a V-belt drive transmission. The
diameter of the tool used is 9mm and hole formed is the inlet port hole to the cylinder. The
tool is fed at a feed rate of 0.2mm/rev. The feeding is powered by the hydraulic cylinder
whose pressure and flow is regulated by pressure and flow regulators respectively. The speed
of approach of tool, feed rate of machining and speed of retract are controlled by limit
switches which are automatically operated at different positions of the tool spindle as shown
in the CATIA design. As a particular limit switch operates it sends the signal to the PLC and
then the corresponding programme runs.
Every time the last tool retracts to its original position, the operator presses the start
button to initiate next cycle which begins with rotation of fixture plate and ends with
retraction of the last tool. At the third tool station spot facing operation is carried out on the
face of the port hole. This operation is generally carried out to provide seating for washer.
The depth of cut for spot facing is 2mm and the operation is powered by a continuous duty ¾
HP motor through a V-belt transmission system. At the next tool station (4th
) a through drill of
diameter 2.5mm is operated at the centre of the port hole. Since the power required for this
operation is less (as observed in the calculations) it is run by ½ HP motor. On the next tool
station a flat drill is operated in the port hole in order to increase the depth of the port whole
to 10.5mm and to remove the cone left due to the tip of the twist drill. The next tool station
(5th
) carries out the operation of internal grooving at the inner end of the port hole. It
penetrates the job up to a depth of 12.5mm. The geometry of tool forms a cone inside the port
hole. The maximum diameter of the cone (at the depth of 12.5mm) is 9mm and the minimum
diameter (at a depth of 10.5mm) is 3.5mm. The slant length of the cone makes an angle of 45
degree with the axis of tool.
On the next tool station M10 x 1 - 6H tap is operated. In order to get the precise feed
rate the lead screw mechanism is used for feeding the tap. The pitch of the lead screw is same
as that of the threading required ie.1mm. From the next tool station (7th
) the operations for
bleeder hole are carried out. First of all on the 7th
tool station centre drill of diameter 6mm is
operated up to a depth of 8.5mm. Then on the next tool station 7mm drill is used to chamfer

the outer edge of the hole it is fed up to 2mm depth from the edge of the hole. Next tool
increases the depth of the bleeder hole to 11mm. As the fixture plate rotates to move the job
to 11th
tool station a 2.5mm trough hole is drilled in the bleeder hole. At the last tool station
M7 x 1- 6H tap is operated in the bleeder hole. This tap is also fed through the lead screw
mechanism up to a depth of 8.5mm.

12.MACHINE ASSEMBLY
FIGURE NO. 8: - SPECIAL PURPOSE MACHINE

FIGURE NO. 9: - TOP VIEW OF SPECIAL PURPOSE MACHINE DESIGN.

FIGURE NO. 10:- SPECIAL PURPOSE MACHINE DESIGN.
13. PRODUCTIVITY OF SPM

ORDER CALCULATION (SPECIAL PURPOSE MACHINE)
1 Per day production (approx...) 2000 jobs
2 Per hour production (approx...) 250 jobs
3 Time period for one job 15 sec.
4 Profit per job Rs.3.
TABLE NO. 5:- ORDER CALCULATION (SPM)
EXPECTED ECONOMIC CONSIDERATIONS -
1 Project cost
Rs.20 Lakh
(approximately)
2 Worker salary Rs.4000 per month
3 Current order 30000 jobs per month
4 Per job cost Rs.5
5 Per job profit Rs.3
TABLE NO. 6:- ECONOMIC CONSIDERATIONS
TOTAL COST OF THE PROJECT – Rs.20, 40,000 LAKH.
PERIOD OF RECOVERY OF INVESTMENT- 2 YEARS.

14.ESTIMATION OF MACHINE
TABLE NO. 7: - MACHINE ESTIMATION
Sr. No. COMPONENT Quantity PRICE (RUPEES)
1 Rotary turret 01 2,50,000
2 Hydraulic cylinder 11 10,000
3 Power-pack 03 1,20,000
4 Structure - 14,00,000
5 PLC - 50,000
6 Control panel 01 1,00,000
7 Electric motor 11 1,10,000
Total - 20,40,000

15.ADVANTAGES OF THE SPM
15.1. Since 11 operations are done simultaneously the fatigue of the worker is reduced and
hence the enthusiasm of the worker is maintained throughout the shift.
15.2. Due to the significant reduction in cycle time for one job the production rate is
drastically increased and hence the profit is increased.
15.3. Due to atomisation of the operations the accuracy is maintained and hence the rate of
rejection of jobs is reduced.
15.4. Compact is size and hence less space is occupied than earlier machine.
15.5. Low cost of manufacturing.

16.FUTURE SCOPE
 Now a days, the multispindle drilling machine used are operated by single lever
which control all spindles at a time.
 Other operations such as reaming, tapping, boring can be done on the same head.
 The new idea is that we can operate various tool as per our need by switching to
manual mode on the SPM.
 Use of manual mode in the SPM opens doors to various permutations of operations
with different sequences.

17. CONCLUSION
In Global economic era the importance of mass production and the rate of production
of machine is increasing tremendously. Thus it was decided to design and manufacture of
special purpose machine (SPM).
The design and manufacturing of machine give us massive practical information in
which we reviewed our theoretical concepts we have learned. The machine is used for
drilling, internal-turning, tapping and spot-facing on component at production rate of 2000
jobs per shift approximately.
While designing the SPM the special design consideration like ergonomics lubrication
and control panel design are to be made, along with this the environment factors also taken
into account.

REFERENCES
1. Olga Guschinskaya, Alexandre Dolgui, Nikolai Guschinsky, and Genrikh Levin –
Scheduling for multi-spindle head machines with a mobile table. January 2007
(Research report 2007 – 500 – 002)
2. Ali Riza Motorcu, Abdulkadir Gullu - Statistical process control in machining, a case
study for machine tool capability and process capability. Materials and Design 27
(2006) 364–372
3. R. S. Khurmi and J. K. Gupta, A Textbook of Machine Design, Eurasia Publishing
House, New Delhi, India, 2002.
4. Joseph E. Shigley and Charles R. Mischke, Mechanical Engineering Design, McGraw
Hill,sss
5. V. B. Bhandari- “Design of Machine Elements”
6. Mr P. P. Harane, Prof. P. N. Gore- “Design And Manufacturing of Special Purpose
Subsystems For Drilling And Tapping Operations”
7. CMTI- “Machine Tool Design Handbook”

DESIGN AND MANUFACTURING OF SPM FOR BRAKE WHEEL CYLINDER

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