Documentos de Académico
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SUBMITTED BY:
Under guidance of
MARCH 2013.
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A M K TECHNOLOGICAL POLYTECHNIC COLLEGE
CHEM BARAMBAKKAM, CHENNAI – 602 103
BONAFIDE CERTIFICATE
This is the bonafide record of work carried out by him under our supervision
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ACKNOWLEDGEMENT
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ACKNOWLEDGEMENT
valuable advice.
We also owe our sincere thanks to all staff members of the Mechanical
Ultimately, we extend our thanks to all who had rendered their co-operation
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CONTENTS
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CONTENTS
1 SYNOPSIS 4
2 INTRODUCTION 6
3 PROJECT PLANNING 11
4 FABRICATION DETAILS 19
6 LIST OF MATERIAL 24
7 COST ESTIMATION 26
8 PLUMMER BLOCK 28
9 DRAWING 41
10 CONCLUSION 43
11 BIBILIOGRAPHY 46
12 PARTS OF DIAGRAM 48
13 ASSEMBLY OF DIAGRAM 50
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SYNOPSIS
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SYNOPSIS
Hydraulic systems use liquid under pressure to transmit power; canals and
hydroelectric power generation facilities harness natural water power to lift ships
or generate electricity. Pneumatic systems use gasses under pressure to transmit
power; compressed air is commonly used to operate pneumatic tools in factories
and repair garages. A pneumatic wrench (for instance) is used to remove and
install automotive tires far more quickly than could be done with standard manual
hand tools.
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INTRODUCTION
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INTRODUCTION
This is a self – assessment test on the part of the students to assess his
competency in creativity.
process.
This is the project work. That is the testimony for the strenuous training,
which the student had in the institute. This assures that he is no more a student,
he is an engineer.
This report discuses the necessity of the project and various aspects of
testing.
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PRECAUTION BEFORE SELECTION OF
THE PROJECT
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PRECAUTION BEFORE SELECTION OF THE PROJECT
Before rushing out of buy the material for the component first determine
the Size of material required for gearless drive in order to transmit the load.
Obviously the first thing to look at is Whether the drive having an easier
provisions to attach the with the input and output devices or what extent we
modify this. If the drive having easier provision fit the devices to transmit the
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PROJECT PLANNING
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PROJECT PLANNING
PROJECT CAPACITY
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MATERIAL REQUIREMENTS
The list of material required for manufacture is prepared from the drawing.
The list is known as “Bill of materials”. Availability of these materials is surveyed
and purchased from the market.
OPERATION PLANNING
Next work of planning is to “select the best method” manufacture the product,
so that the wastage of materials, labour, machines and time can be eliminated by
considering various methods. The best method is to be selected for fabrication
and other works.
The proper method and proper person and the purposes of operation, necessity
operation, proper machine planning. The best method is the developed and is
applied to fabricate the project.
MACHINE LOADING
While planning proper care should be taken to find the machining time for the
operation as correct as possible. So that arrangement of full use of machines can
be made and the machine loading program can be decided.
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PURCHASE CONSIDERATION
EQUIPMENT PROCEDURE
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FABRICATION DETAILS
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FABRICATION OF PARTS DETAILS
1. BED
2. GRINDING STONE
The stone is fixed in the spindle and rotated by motor.
The power is transmitted from the motor , V belt drive to the grinding wheel
through the these four L shaped rods having 8mm diameter. These rods are
transmit the power in perpendicular directions and sliding in two cylinders.
A belt is a loop of flexible material used to link two or more rotating shafts
mechanically. Belts may be used as a source of motion, to transmit power
efficiently, or to track relative movement. Belts are looped over pulleys. In a two
pulley system, the belt can either drive the pulleys in the same direction, or the belt
may be crossed, so that the direction of the shafts is opposite. As a source of
motion, a conveyor belt is one application where the belt is adapted to
continuously carry a load between two points. The power is transmitted from the
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motor to the grinding wheel through four L shaped rods and V belt drive.The
belt is a V belt of B 45.The driving pulley is made in cast iron material of 25 mm
diameter and the driven is made in cast iron material having 100 mm diameter. The
purpose of this V belt drive is to reduce the speed from the motor.
Vee belts
Vee belts (also known as V-belt or wedge rope) solved the slippage and alignment
problem. It is now the basic belt for power transmission. They provide the best
combination of traction, speed of movement, load of the bearings, and long service
life. They are generally endless, and their general cross-section shape is trapezoidal
(hence the name "V"). The "V" shape of the belt tracks in a mating groove in the
pulley (or sheave), with the result that the belt cannot slip off. The belt also tends
to wedge into the groove as the load increases—the greater the load, the greater the
wedging action—improving torque transmission and making the V-belt an
effective solution, needing less width and tension than flat belts. V-belts trump flat
belts with their small center distances and high reduction ratios. The preferred
center distance is larger than the largest pulley diameter, but less than three times
the sum of both pulleys. Optimal speed range is 1000–7000 ft/min. V-belts need
larger pulleys for their larger thickness than flat belts.
For high-power requirements, two or more vee belts can be joined side-by-side in
an arrangement called a multi-V, running on matching multi-groove sheaves. This
is known as a multiple-V-belt drive (or sometimes a "classical V-belt drive").
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fibers may be of textile materials such as cotton or polyester or, for greatest
strength, of steel or aramid (such as Twaron or Kevlar).
When an endless belt does not fit the need, jointed and link V-belts may be
employed. However they are weaker and only usable at speeds up to 4000 ft/min.
A link v-belt is a number of rubberized fabric links held together by metal
fasteners. They are length adjustable by disassembling and removing links when
needed.
V pulley
5. AC INDUCTION MOTOR
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An AC motor is an electric motor driven by an alternating current (AC).
It commonly consists of two basic parts, an outside stationary stator having coils
supplied with alternating current to produce a rotating magnetic field, and an inside
rotor attached to the output shaft that is given a torque by the rotating field.
There are two main types of AC motors, depending on the type of rotor used. The
first type is the induction motor, which runs slightly slower than the supply
frequency. The magnetic field on the rotor of this motor is created by an induced
current. The second type is the synchronous motor, which does not rely on
induction and as a result, can rotate exactly at the supply frequency or a sub-
multiple of the supply frequency. The magnetic field on the rotor is either
generated by current delivered through slip rings or by a permanent magnet. Other
types of motors include eddy current motors, and also AC/DC mechanically
commutated machines in which speed is dependent on voltage and winding
connection.
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Capacitor start motor
PLUMMER BLOCK
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STRUCTURE
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HANDLING THE PLUMMER BLOCK AND BEARING
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Prepare installation tools, measured instruments, oil stone,
lubricant and factory cloth. Before the installation work,
remove dust and impurities from these tools
Make sure that the shaft is free from bends or other damages
and that it has been dimensioned and formed as specified.
Remove dent marks even through very small from the mating
faces with an oil stone or fine emery paper. Check that the
contact face to the seal has specified surface roughness. Wipe
dust away from the shaft with clean factory cloth.
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Check the flatness of the mounting face of the plummer block.
When placed on a frame, the plummer block must be stably
seated.
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Preparation for Installing the Bearing
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INSTALLATION OF THE BEARING AND ASSOCIATED COMPONENTS
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To convey the force via the rolling elements to the other bearing ring
inner ring to install the latter. Otherwise, a dent mark or other
damage can occur on either or both rings.
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When installing a non-separable bearing to the shaft and
housing at a time, apply a press-fitting force to both the inner and
outer rings by using a pressure distribution pad.
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Once the bearing has been installed to the shaft and the
associated components have been inserted over the shaft, assemble
the plummer blocks according to the following procedure.
3. Vibration on shaft.
VI.BEARING DISASSEMBLY
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Straighten the bent tab on the washer, and loosen the nut by
two or three turns. Place a drift to a face of the nut. Sightly tap the
drift to turn the sleeve. Once be sleeve is shifted in the axial can be
direction, the bearing easily removed.
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VII.CYLINDRICAL BORE BEARING
One for rough cleaning and the other for finish cleaning.
Prepare a cleaning station that has a metal screen as illustrated. So
that the bearing does not directly contact the fouling on the bottom
of vessel. In rough cleaning, virtually all oil and foreign matters
should be removed from the bearing which should be immediately
transferred to the finish vessel. The finish vessel must be provide
with a filter unit to maintain the cleaning agent clean.
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3. Operating conditions such as loading and bearing speed.
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Introduction to Grinding wheel
Grinding wheels
The wheels are generally made from a matrix of coarse particles pressed and
bonded together to form a solid, circular shape, various profiles and cross sections
are available depending on the intended usage for the wheel. They may also be
made from a solid steel or aluminium disc with particles bonded to the surface.
The manufacture of these wheels is a precise and tightly controlled process, due
not only to the inherent safety risks of a spinning disc, but also the composition
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and uniformity required to prevent that disc from exploding due to the high stresses
produced on rotation.
Characteristics
There are five characteristics of a cutting wheel: material, grain size, wheel grade,
grain spacing, and bond type. They will be indicated by codes on the wheel's label.
Material, the actual abrasive, is selected according to the hardness of the material
being cut.
• Ceramic (C)
Grain size, from 8 (coarsest) 1200 (finest), determines the physical size of the
abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but
poor surface finish. Ultra-fine grain sizes are for precision finish work.
Wheel grade, from A (soft) to Z (hard), determines how tightly the bond holds the
abrasive. Grade affects almost all considerations of grinding, such as wheel speed,
coolant flow, maximum and minimum feed rates, and grinding depth.
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a large effect on surface finish. It is also able to take a deeper or wider cut with less
coolant, as the chip clearance on the wheel is greater.
Wheel bond, how the wheel holds the abrasives, affects finish, coolant, and
minimum/maximum wheel speed.
• Vitrified (V)
• Resinoid (B)
• Silicate (S)
• Shellac (E)
• Rubber (R)
• Metal (M)
• Oxychloride (O)
Types
Straight wheel
Straight wheel
To the right is an image of a straight wheel. These are by far the most common
style of wheel and can be found on bench or pedestal grinders. They are used on
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the periphery only and therefore produce a slightly concave surface (hollow
ground) on the part. This can be used to advantage on many tools such as chisels.
Straight Wheels are generally used for cylindrical, centreless, and surface grinding
operations. Wheels of this form vary greatly in size, the diameter and width of face
naturally depending upon the class of work for which is used and the size and
power of the grinding machine.
Cylinder wheels provide a long, wide surface with no center mounting support
(hollow). They can be very large, up to 12" in width. They are used only in vertical
or horizontal spindle grinders. Cylinder or wheel ring is used for producing flat
surfaces, the grinding being done with the end face of the wheel.
Tapered wheel
A straight wheel that tapers outward towards the center of the wheel. This
arrangement is stronger than straight wheels and can accept higher lateral loads.
Tapered face straight wheel is primarily used for grinding thread, gear teeth etc.
Straight cup
Straight cup wheels are an alternative to cup wheels in tool and cutter grinders,
where having an additional radial grinding surface is beneficial.
Dish cup
A very shallow cup-style grinding wheel. The thinness allows grinding in slots and
crevices. It is used primarily in cutter grinding and jig grinding.
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Saucer wheel
A special grinding profile that is used to grind milling cutters and twist drills. It is
most common in non-machining areas, as sawfilers use saucer wheels in the
maintenance of saw blades.
Diamond wheel
Diamond wheel
Diamond wheels are grinding wheels with industrial diamonds bonded to the
periphery.
They are used for grinding extremely hard materials such as carbide cutting tips,
gemstones or concrete. The saw pictured to the right is a slitting saw and is
designed for slicing hard materials, typically gemstones.
Diamond mandrels
Diamond mandrels are very similar to their counterpart, a diamond wheel. They
are tiny diamond rasps for use in a jig grinder doing profiling work in hard
material.
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Cut off wheels, also known as parting wheels, are self-sharpening wheels that are
thin in width and often have radial fibres reinforcing them. They are often used in
the construction industry for cutting reinforcement bars (rebar), protruding bolts or
anything that needs quick removal or trimming. Most handymen would recognise
an angle grinder and the discs they use.
Use
To use the grinding wheel it must first be clamped to the grinding machine. The
wheel type (e.g. cup or plain wheel below) fit freely on their supporting arbors, the
necessary clamping force to transfer the rotary motion being applied to the wheels
side by identically sized flanges (metal discs). The paper blotter shown in the
images is intended to distribute this clamping force evenly across the wheels
surface.
Dressing
Grinding wheels are self sharpening to a small degree; for optimal use they may be
dressed and trued by the use of wheel or grinding dressers. Dressing the wheel
refers to removing the current layer of abrasive, so that a fresh and sharp surface is
exposed to the work surface. Trueing the wheel makes the grinding surface parallel
to the grinding table or other reference plane, so that the entire grinding wheel is
even and produces an accurate surface.
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WORKING PRINCIPLE
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WORKING PRINCIPLE
This drive consists of
4. Plummer block support bearings with shaft drive for grinding wheel.
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The power is transmitted from the motor , V belt drive to the grinding wheel
through the these four L shaped rods having 8mm diameter. These rods are
transmit the power in perpendicular directions and sliding in two cylinders.
The power is transmitted from the motor to the grinding wheel through four L
shaped rods and V belt drive.The belt is a V belt . The purpose of this V belt drive
is to reduce the speed from the motor.
These four rods are slide inside the cylindrical barrel and simultaneously transmit
the power from the motor to grinding wheel.
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Gearless drive specification;
LIST OF MATERIALS
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LIST OF MATERIALS
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3 PULLEY CAST IRON 2
ADVANTAGES
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ADVANTAGES
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Cost of the unit is less when compared to other Machines
No fire hazard problem due to over loading
Comparatively the operation cost is less
The speed of forward and reverse stroke is varied
Continuous operation is possible without stopping
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APPLICATIONS
APPLICATIONS
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• Industrial Application
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LIMITATIONS
LIMITATIONS
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High torque cannot be obtained
Load carrying capacity of this unit is not very low
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FINISHING AND
PAINTING
JOB PREPARATION;
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Before welding, remove any bend in the L angle with the sludge hammer on
the anvil block. Then it is cut to the required length with the hacksaw blade and
fabricated to required dimensional shape with arc welding.
After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed
with the emery sheet.
Metal primer is applied on the surfaces with the brush .After drying the metal
primer, the second coating is applied with the paint.
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COST ESTIMATION
COST ESTIMATION
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4 V-BELT ABSERIVE 1 600
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DRAWINGS
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CONCLUSION
CONCLUSION
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We are assembling the gearless drive to enable the machine to perform one
additional operation. At present this attachment is purely operated and
controller by means of mechanical.
The present made can eliminate the rescue work of the geared drive and at
the same time reduce the maintenance cost of the same machine.
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BIBLOGRAPHY
BIBLOGRAPHY
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WORKSHOP : W.J. CHAPMAN
RAJAGOPAL &
G. BALAJI SINGH
P.N. VENKATESAN
TECHNOLOGY
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PHOTO VIEW
PHOTO VIEW
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