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    Design and Fabrication of Multi Operational Material Removal Machine

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    DHAMOTHARAKUMAR
    This document describes the design and fabrication of a multi-operational material removal machine. The machine is designed to perform multiple machining operations like grinding, cutting, filing, and superfinishing simultaneously using a single motor. This reduces the need for separate machines for each operation and lowers production costs. The machine transmits power from the motor to two shafts using a V-belt and pulley system. Tools for different operations are attached to the ends of each shaft. The speed of each shaft can be controlled independently using pulleys of different diameters. This allows operations to be run individually or together. The design calculations for torque, shaft strength, bearing selection, and weld strength are also presented.

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    Design and Fabrication of Multi Operational Material Removal Machine

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    DHAMOTHARAKUMAR
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    This document describes the design and fabrication of a multi-operational material removal machine. The machine is designed to perform multiple machining operations like grinding, cutting, filing, and superfinishing simultaneously using a single motor. This reduces the need for separate machines for each operation and lowers production costs. The machine transmits power from the motor to two shafts using a V-belt and pulley system. Tools for different operations are attached to the ends of each shaft. The speed of each shaft can be controlled independently using pulleys of different diameters. This allows operations to be run individually or together. The design calculations for torque, shaft strength, bearing selection, and weld strength are also presented.

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    1. 01-03

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    This document describes the design and fabrication of a multi-operational material removal machine. The machine is designed to perform multiple machining operations like grinding, cutting, filing, and superfinishing simultaneously using a single motor. This reduces the need for separate machines for each operation and lowers production costs. The machine transmits power from the motor to two shafts using a V-belt and pulley system. Tools for different operations are attached to the ends of each shaft. The speed of each shaft can be controlled independently using pulleys of different diameters. This allows operations to be run individually or together. The design calculations for torque, shaft strength, bearing selection, and weld strength are also presented.

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    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    33 views3 pages

    Design and Fabrication of Multi Operational Material Removal Machine

    Uploaded by

    DHAMOTHARAKUMAR
    This document describes the design and fabrication of a multi-operational material removal machine. The machine is designed to perform multiple machining operations like grinding, cutting, filing, and superfinishing simultaneously using a single motor. This reduces the need for separate machines for each operation and lowers production costs. The machine transmits power from the motor to two shafts using a V-belt and pulley system. Tools for different operations are attached to the ends of each shaft. The speed of each shaft can be controlled independently using pulleys of different diameters. This allows operations to be run individually or together. The design calculations for torque, shaft strength, bearing selection, and weld strength are also presented.

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    of 3

    IOSR Journal of Engineering (IOSRJEN) www.iosrjen.

    org
    ISSN (e): 2250-3021, ISSN (p): 2278-8719
    PP 01-03

    Design and Fabrication of Multi Operational Material Removal


    Machine
    Kuldeepak Mugutrao1, Deepak pawar2 ,Rakesh jadhav3, Yuvraj Sawant4 ,Dhiraj
    Narayanee5
    (Department of Mechanical Engineering, VPS College of Engineering Lonavala, SPPU, Pune, India)

    Abstract:In an industry a considerable portion of investment is being made for machinery installation.
    Industries are basically meant for Production of useful goods and services at low production cost, machinery
    cost and low inventory cost. So in this paper we have a proposed a machine which can perform operations like
    grinding, cutting, filing and super finishing at different working centres simultaneously which implies that
    industrialist need not to pay for machine performing above tasks individually. This paper presents the concept
    of multi-functional material removal machine mainly carried out for production based industries. We have
    developed a conceptual model of a machine which would be capable of performing different operations
    simultaneously and is also economically efficient. In this machine we are actually transmitting power by using V
    belt which is attached to the main shaft on which pulleys are mounted. Mainly this belt provides the power at
    two ends i.e. two shafts and at the end of each shaft we are fixing the tools for operation to be carried. This
    machine can carry the number of operations at a time but in some cases if we required to operate the machine
    with single or two operations we are providing the simple flange and gasket mechanism to main shaft on which
    the four tools are fixed. This arrangement reduces the power consumption by keeping the required operations
    running and rest of the operations idle.
    Keywords :Grinding, Superfinishing, Cutting, Filing.

    I. Introduction
    Research into machines is expanding rapidly. There are several reasons why this is happening at this
    particular time. In production system the cycle time is very important term. The tendency of manufacturing
    industry is continuously done design & development in reducing cycle time. For performing multiple operations
    on single components required number of machines which carries single operation.
    So, concentrating on the above points, it seemed to be necessary to design a machine, which can overcome the
    above difficulty. So we designing a machine which is answer to above problem & which will prove to be
    effective & greatly useful to industries.
    Grinding, Cutting, Super Finishing, Filing are the operations which are required numbers of times in
    each and every industry for producing small as well as large components, also for installation of all small or
    large machine this basic operations or tools are required to settle the machines correctly. This operation is
    required in number of manufacturing operation to remove burr & sized the job. Grinding is an art and science of
    metal removing and makes the surface smooth. Basically it is the process or removing material by abrasive
    action of grinding wheel on the surface finish to the desired dimension.
    The operations are performed at different machining centers. The simple arrangements are used to
    provide the drive from the single motor to the different working tools. The tools material and geometry of tools
    are selected as per the material of the work piece, load on the machine tools, cycle time, and rate of material to
    be remove etc. For selecting the tool material for different operations are mainly depends upon the tool life and
    the number of work pieces are to be handle in certain time.

    II. Design Calculations


    (1) Calculation of Torque:
    Power of Motor Shaft = Pm = 1 hp x 746 = 746 watt.
    Rpm of motor =1420 rpm
    Motor shaft Torque: Tm

    2π Nm Tm
    Pm = -----------------
    60
    2π x 1420 x Tm
    746 = ----------------------

    7th National conference on Recent Developments In Mechanical Engineering RDME-2018 1 |Page


    Design and Fabrication of Multi Operational Material Removal Machine

    60
    Tm = 5.016 x 103 N-mm

    (2) Shaft Design


    Material selection –C 45
    Syt = 360 N/mm2
    F.O.S = 3
    Allowable tensile stress st = Syt / F.O.S
    st = 360 / 3
    st = 120 N/mm2

    Allowable shear stress = 0.5 st


    0.5 X 120 = 60 N/mm2

    Select pulley of diameter 65 mm for motor shaft and grinding shaft pulley is 75 mm, So grinding shaft is near to
    motor speed.
    Nm/Ns = Ds/Dm
    1420/Ns = 75/65
    Ns = 1230 rpm
    Now torque on grinding shaft
    T = (π /16)X d3 X 
    5.016 X 10 = (π /16) X 203 X 
    3

     = 3.19 N/mm2


    So induced shear stress is less than allowable shear stress.
    So design of grinding shaft is safe

    (3) Selection of bearing


    For 20mm dia shaft select the bearing from PSG P204
    P = Pedestal
    2 = deep groove ball bearing
    04 = 4 x 5 = 20mm inside bore diameter

    (4) Checking the strength of the welded joints for safety


    The transverse fillet weld welds the side plate and the edge stiffness plates.
    The maximum load which the plate can carry for transverse fillet weld is
    P = 0.707 X S XL X ft
    Where, S = Size of weld, L = Contact length = 45 mm
    The load of shear along with the friction is 50 kg = 500 N
    Hence let us find the safe value of ’ft’
    500
    Therefore, Ft = ---------------------
    0.707 X 5 X 45

    Ft = 3.14 N/mm2

    Since the calculated value of the tensile load is very smaller than
    The permissible value as Ft = 56 N/mm2 . Hence welded joint is safe.

    III. model description and working


    The Fig.1 shows the simplest model of machine. A prototype model of multi-purpose machine which
    operates on single motor with the help of V-Belt which is used for power transmission with the help of pulleys
    to the shafts. The shaft rotated with the pulley and at both the end of shaft we are making an arrangement of
    tools for the machining purpose. The shaft rotated with the help of pulley therefore the speed of the shaft and
    pulleys are same. As to operate the various operations at various speeds, the speed of rotation of the tools should
    be different. So we are selecting the various sizes pulleys which are maintaining the speed of rotation of the
    shaft or the tools as per the requirement of operations. To operate required operation at one time rest are to keep
    ideal we are introduce the lawjaw coupling on shaft at each side of pulley.

    7th National conference on Recent Developments In Mechanical Engineering RDME-2018 2 |Page


    Design and Fabrication of Multi Operational Material Removal Machine

    Fig 1 – Plan view of model

    Power Supply

    Motor

    V-belt rotating on pulley

    Operation Tool 1 Operation Tool 3

    Shaft 1 rotating with pulley 1 Shaft 2 rotating with pulley 2

    Operation Tool 2 Operation Tool 4


    Process Flow Chart

    IV. Conclusion
    We conclude that this machine is perform the multiple operations i.e. Grinding, Cutting, Super
    finishing, and Filing operation on single motor operated machine to reduce power consumption, minimize the
    cost of producing the product and also reducing the floor space area.

    This machine fulfill the requirement of small workshop of multi-operations.

    References
    Journal Papers:
    [1] T. Moriwaki “Multi-functional machine tool”, Department of Industrial and Systems Engineering, Setsunan University,
    [2] Neyagawa, Japan CIRP Annals - Manufacturing Technology DOI: 10.1016/j.cirp.2008.09.004 .
    [3] Heinrich Arnold1” The recent history of the machine tool industry and the effects of technological change “University of
    [4] Munich, Institute for Innovation Research and Technology Management, November 2001.
    [5] Linxu, WeinanBai, JingyuRu, Qiang Li, “Design and Implementaion of the Reciprocating Pedal Powered Electricity Generating
    [6] Device”, Advanced Materials Research (Vol.282-283 (2011) pp 735-738.
    [7] DharwaChaithanyaKirthikumar, “A Research on Multi Purpose Machine”, International Journal for Technological Research in
    [8] Engineering (Vol.1, Issue.1, ISSN: 2347-4718) (2013).
    [9] .G.Bahaley, Dr.A.U.Awate, S.V.Saharkar, “Performance Analysis of Pedal Powered Multipurpose Machine”, International
    [10] Journal of Engineering Research and Development (IJERD) (Vol.1, Issue.5, eISSN: 2278-0181) (2012).
    [11] Takalwe and V.R. Naik, “Design & manufacturing of Multi spindle drilling head forits cycle time optimizationforits cycle time
    [12] optimization (Vol03, Issue01; Januarypril2012) International Journal
    [13] Z.W. Zhong, V.C. Venkatesh, Recent Developments in grinding of advance
    [14] material, International Journal of Engineering Research and Development (IJERD)
    [15] M Ozaki, Y. Adachi, Y. Iwahori, and N. Ishii, Application of fuzzy theory to writer recognition of Chinese characters,
    [16] International Journal of Modelling and Simulation, 18(2), 1998, 112-11

    7th National conference on Recent Developments In Mechanical Engineering RDME-2018 3 |Page

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