Development of Motorized Hammer
Development of Motorized Hammer
Chapter-1
Introduction:-
1.1 Introduction
Forging is the one type of mechanical process in which metal is heated and
hammered by blacksmith, but in the present scenario the forging operation done by
means of hammer machine tool. Whole operation is replaced from manual to automatic.
Power hammer is one type of machine tool which is used in forging operation.
This machine use power source for up-down the hammer to being hammered any parts or
components. They have been used by blacksmiths since 1880s, by replacing trip
hammers. Generally power hammer consists of Ram, Frame, Anvil, Hammer head, Dies,
Connecting Rod, Leaf Spring and power source like electric motor.
Simply, power hammer is the machine tool which uses the electric power source
to run the motor and this rotary motion of the motor is utilize to reciprocate the ram by
In this invention we have been modeling the machine in the software and made a
simple and compact layout of the machine as per requirement of forging operations.
This project is basically worried about the upset outline process and assembling
the issue of off base hammering and strange effect of hammering in procedure of
such an idea was explored as far as delivering reasonable and compacted plan for
any hammering operation in mass production its principle function is to safely and
preciously hammering work like to perform the punching operation, filleting operation,
riveting operation and smithy operation i.e. upset forging etc for all designed operating
conditions. This paper describes cad modeling, design and analysis of automatic portable
pivots, car frame forming, molding of metal and so forth. The present development
identified with metal squeezing machine and forming machine included certain
outstanding challenges in regard of to drive nail, fit parts, forge metal and break separated
question. The innovation has for its question cure this downside and to empower, by
including helper implies, to drive nail, fit parts, manufacture metal and break separated
protest the like. Hammering is the most generally utilized in mechanical operation and
maintain simplicity and economy in the design the locally fabricated unit has been used.
Our project achieves higher safety, reduces human effort, increases the efficiency,
reduces the work load, reduces the fatigue of workers and reduces maintenance cost.
Chapter-2
Literature Review
[1]. John Byron Henry, et.al. Invention relates to power hammers, and particularly
cylinder provided with a piston and piston rod carrying a ram or hammer attached.
[2]. Richard W. Hall, et.al, invention is to double acting forging hammers and,
more particularly, to forging hammers actuated by pressurized gas and/or hydraulic fluid.
and/or hydraulic hammer driving systems, yet does not have the energy losses associated
forging hammers used for industrial purposes. As we aware that in forging operation the
temperature of the metal is so high that manual hammering operation is quite difficult for
this purpose. So in this project they provided control valves which directing the ram up or
tool and operating mechanism of the reciprocating, rotary cam actuated type, and
scaling chisel, piercing punch, rock drill, and other similar power tools.
[5]. John I. Kupta et.al, invention herein disclosed relates to steam and air
hammers of the pile driver type and in which, usually, the motive fluid is just admitted to
lift and then released to drop the ram. ‘Operating in this manner such hammers naturally
are inetiicient the use of steam or air and since gravity is the force relied on for the
striking blow, the ram and other parts have had to be heavy and bulky.
[6]. David A. Giardino, et.al, invention relates to the art of rotary impact wrenches
of a type in which a rotating member is periodically reciprocated into and out of rotary
From the detailed literature review it can be observed that there was not any
simple and compact machine designed. All the research was heavy and complex machine
related. So, we have been trying to modelling a simple power hammer machine to
Chapter-3
Construction & Working of Project
3.1 Parts used in the project
Shaft
DC Motor
Hammer
Mounts & Fixtures
Supporting Frame
Joints & Screws
Motor
Power supply
Hammer
Frame Structure
matting the objectives. these means we will have to implement and compare our different
design to insure the best product on our sat of objectives .this paths have changed as we
progressed through our project, and there were few fore seen methods that we expand
The basic design for automatic hammering machine is to have motor fixed on stand, and
then motor shaft is inserted in center hole of the disc. Disc is connected to the hammer
rod with the link rod when we supply the dc current to the dc motor by using adopter then
the motor shaft start rotating further transmit the spinning motion to the disc by using
shaft the first decision is to create an impact force for the respective operation this will
A more efficient yet expensive design would be to have battery instead of adopter. There
Chapter-4
4.1.1 Introduction:
Project design may be defined as the iterative decision making activity to create a
plan or plans by which the available resources are converted, preferably optimally, into
systems, processes or devices to perform the desired functions and to meet human needs.
In fact project design has been defined in many ways but the simplest ways to define
project design as
to formulate a plan to satisfy a particular need and to create something with a physical
reality.
Decision making comes in every stage of design. Consider two cars of different
makes. They may both be reasonable cars and serve the same purpose but the designs are
different. The designers consider different factors and come to certain conclusions
leading to an optimum design. Market survey gives an indication of what people want.
Existing norms play an important role. Once a critical decision is made, the rest of the
design features follow. For example, once we decide the engine capacity, the shape and
size, then the subsequent course of the design would follow. A bad decision leads to a
Design may be for different products and with the present specialization and
knowledge bank, we have a long list of design disciplines e.g. ship design, building
1. Adaptive design
adopted for a new application. Conveyor belts, control system of projects and
mechanisms or haulage systems are some of the examples where existing design systems
2. Developmental designs
Here we start with an existing design but finally a modified design is obtained. A
3. New design
This type of design is an entirely new one but based on existing scientific
problem. Examples of this type of design may include designing a small vehicle for
transportation of men and material on board a ship or in a desert. Some research activity
may be necessary.
4. Rational design:
This is based on determining the stresses and strains of components and thereby
5. Empirical design:
This is based on empirical formulae which in turn are based on experience and
experiments. For example, when we tighten a nut on a bolt the force exerted or the
stresses induced cannot be determined exactly but experience shows that the tightening
force may be given by P=284d where, d is the bolt diameter in mm and P is the applied
6. Industrial design:
These are based on industrial considerations and norms viz. market survey,
external look, production facilities, low cost, use of existing standard products.
There are many factors to be considered while attacking a design problem. In many
cases these are a common sense approach to solving a problem. Some of these factors are
as follows:
(a) What device or mechanism to be used? This would decide the relative
(b) Material
(d) Size, shape and space requirements. The final weight of the product is also a
major concern.
(h) Inspectibility
mechanisms and the designer has to decide which one is most effective under the
circumstances. A rough design or layout diagram may be made to crystallize the thoughts
1. Material:
This is a very important aspect of any design. A wrong choice of material may
lead to failure, over or undersized product or expensive items. The choice of materials is
thus dependent on suitable properties of the material for each component, their suitability
2. Load:
The external loads cause internal stresses in the elements and these stresses must be
determined accurately since these will be used in determining the component size.
v) Frictional forces.
which the energy is converted into useful mechanical forms and of mechanisms required
to convert the output of the project to the desired form. The design may lead to an
entirely new project or an improvement on an existing one. Thus project design is the
the complete description in the form of blue prints of the final product. The following
First Step:
In the very first step a complete list of specifications for the functional
requirement of the product is to be prepared. The requirement may include, for example:
(c) Cost;
control are important requirements. Depending upon the type of product, various
requirements are given Weight age and a priority list of specifications is prepared.
Second Step:
After a careful study of the requirements the designer prepares rough sketches of
different possible mechanisms of project and depending upon the cost competitiveness,
availability of raw material, and manufacturing facilities, the possible mechanisms are
compared with each other and the designer selects the best possible mechanism for the
product
Third Step:
In the third step of the design procedure a block diagram is to be prepared which
showing the general layout of the selected configuration. In this step designer specifies
the joining methods, such as riveting, bolting, and welding to connect the individual
Fourth Step:
Selecting the proper material for the component depending upon the functional
requirement, such as strength, wear, rigidity, hardness and bearing properties etc.
Determine the likely mode of failure & select the criterion of failure like, yield
safety and modify the dimensions from manufacturing considerations. This stage
Fifth Step:
The last stage in design process is to prepare the blue prints of assembly and
Project design is the chronological vertical structure of the various phases or steps
together from the project analysis to the retirement of the product. Thus Project of design
The aim is to produce a number of feasible and useful solutions. Here the
alternatives are assessed in stages. The first stage is made on the basis of common sense.
Many of the broad solutions may not be worth consideration. Considering technical
feasibility some of the solutions can be eliminated. The last stage is the economic
Feasibility study yields a set of useful solutions. The aim in this phase is to choose
The chosen alternative is then tested and predictions are made concerning its
performance.
a tested and producible design for manufacture. A detailed design includes manufacturing
component. It specifies clearly the tooling, fixtures and production projects. This phase
may include planning, and inventory control, quality control system, the fixing of
The success ofa design depends on the skill exercised in marketing the product. Also
the user-oriented concern such as reliability, ease of maintenance, product safety, and
convenience in use, aesthetic appeal, economy and durability must meet. The product life
planned.
cells that convert stored chemical energy into electrical energy. Each cell contains a
positive terminal, or cathode, and a negative terminal, or anode. Electrolytes allow ions to
move between the electrodes and terminals, which allows current to flow out of the
energy. Its action is based on the principle that when a current carrying conductor is
We know,
We know,
= (2×3.14×30×5)/60
= 15.7 watt
Chapter-5
5.1Introduction
technical staff in industry must know the various manufacturing processes, materials
products with optimal process plan using proper precautions and specified safety rules to
avoid accidents. Beside above, all kinds of the future engineers must know the basic
and other infrastructure facilities needed to be positioned properly for optimal shop
layouts or plant layout and other support services effectively adjusted or located in the
technology is highly difficult for anyone to claim expertise over it. The study deals with
several aspects of workshops practices also for imparting the basic working knowledge of
shops in an industrial environment. It also describes and demonstrates the use of different
hand tools (measuring, marking, holding and supporting tools, cutting etc.), equipment’s,
machinery and various methods of manufacturing that facilitate shaping or forming the
different existing raw materials into suitable usable forms. It deals with the study of
industrial environment which involves the practical knowledge in the area of ferrous and
nonferrous materials, their properties and uses. It should provide the knowledge of basic
workshop processes namely bench work and fitting, sheet metal, carpentry, pattern
making, moulds making, foundry, smithy, forging, metal working and heat treatment,
welding, fastening, machine shop, surface finishing and coatings, assembling inspection
improvement over a large number of old processes, new and compact designs, better
alternatives to the existing materials and tooling systems, automatic and numerical
Manufacturing is derived from the Latin word manufactus, means made by hand.
In modern context it involves making products from raw material by using various
study of the processes required to make parts and to assemble them in machines. Process
physical, chemical and other laws governing the manufacturing process. The study of
manufacturing reveals those parameters which can be most efficiently being influenced to
5.2.Manufacturing Process
concerned with the change of form or dimensions of the part being produced. It does not
include the transportation, handling or storage of parts, as they are not directly concerned
with the changes into the form or dimensions of the part produced.
ingots into usable products may be classified into six major groups as primary shaping
surface finishing processes and processes effecting change in properties. These are
discussed as under.
material. Some processes produces finish products or articles into its usual form whereas
others do not, and require further working to finish component to the desired shape and
size. Castings need re-melting of scrap and defective ingots in cupola or in some other
melting furnace and then pouring of the molten metal into sand or metallic moulds to
obtain the castings. The parts produced through these processes may or may not require
(1) Casting, (2) Powder metallurgy, (3) Plastic technology, (4) Gas cutting, (5) Bending
operations in machine shops, to obtain the desired shape and dimensional accuracy on flat
and cylindrical jobs. Thus, the jobs undergoing these operations are the roughly finished
products received through primary shaping processes. The process of removing the
required shape using a cutting tool is known as machining. This can be done by a manual
process or by using a machine called machine tool (traditional machines namely lathe,
milling machine, drilling, shaper, planner, slotter). In many cases these operations are
accuracy and a very high degree of surface finish. The secondary processes require the
use of one or more machine tools, various single or multi-point cutting tools (cutters), job
holding devices, marking and measuring instruments, testing devices and gauges etc. for
getting desired dimensional control and required degree of surface finish on the
workpieces. The example of parts produced by machining processes includes hand tools
machine tools instruments, automobile parts, nuts, bolts and gears etc. Lot of material is
wasted as scrap in the secondary or machining process. Some of the common secondary
(1) Turning, (2) Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring, (7)
Planning, (8) Shaping, (9) Slotting, (10) Sawing, (11) Broaching, (12) Hobbing, (13)
Grinding, (14) Gear cutting, (15) Thread cutting and (16) Unconventional machining
processes namely machining with Numerical Control (NC) machines tools or Computer
Numerical Control (CNC) machines tools using ECM, LBM, AJM, USM setups etc.
3. Joining Processes
Many products observed in day-to-day life, are commonly made by putting many
parts together may be in subassembly. For example, the ball pen consists of a body, refill,
barrel, cap, and refill operating mechanism. All these parts are put together to form the
product as a pen.
More than 800 parts are put together to make various subassemblies and final
assembly of car or aero-plane. A complete machine tool may also require to assemble
more than 100 parts in various sub assemble or final assembly. The process of putting the
parts together to form the product, which performs the desired function, is called
assembly. An assemblage of parts may require some parts to be joined together using
various joining processes. But assembly should not be confused with the joining process.
Most of the products cannot be manufactured as single unit they are manufactured as
different components using one or more of the above manufacturing processes, and these
Joining processes are widely used in fabrication and assembly work. In these
process two or more pieces of metal parts are joined together to produce desired shape
and size of the product. The joining processes are carried out by fusing, pressing,
rubbing, riveting, screwing or any other means of assembling. These processes are used
for assembling metal parts and in general fabrication work. Such requirements usually
occur when several pieces are to be joined together to fabricate a desired structure of
products. These processes are used developing steam or water-tight joints. Temporary,
screws and bolts. Adhesives are also used to make temporary joints. Some of the
(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering, (4) Riveting, (5)
Screwing, (6) Press fitting, (7) Sintering, (8) Adhesive bonding, (9) Shrink fitting, (10)
Explosive welding, (11) Diffusion welding, (12) Keys and cotters joints, (13) Coupling
Surface finishing processes are utilized for imparting intended surface finish on
the surface of a job. By imparting a surface finishing process, dimension of part is not
changed functionally; a very negligible amount of material is removed from the certain
material is added to the surface of the job. These processes should not be misunderstood
as metal removing processes in any case as they are primarily intended to provide a good
cleaning process also called as a surface finishing process. Some of the commonly used
surface finishing processes are: (1) Honing, (2) Lapping, (3) Super finishing, (4) Belt
grinding, (5) Polishing, (6) Tumbling, (7) Organic finishes, (8) Sanding, (9) Debarring,
(10) Electroplating, (11) Buffing, (12) Metal spraying, (13) Painting, (14) Inorganic
coating, (15) Anodizing, (16) Sheradising, (17) Parkerizing, (18) Galvanizing, (19)
Plastic coating, (20) Metallic coating, (21) Anodizing and (22) Sand blasting.
Product functions
Product specifications
Conceptual design
Standards
Detailed design
Prototype development
Testing
Simulation
Drafting
hypotheses, we must observe our theoretical concepts at the operational level. In simple
words, we must measure what we have defined. But there are different levels of
construct. There are also some basic issues about the adequacy of measurement which we
must address.
Usually, the portion that is fractured away is in small sized pieces, called chips. Common
cutting processes include sawing, shaping (or planning), broaching, drilling, grinding,
turning and milling. Although the actual machines, tools and processes for cutting look
very different from each other, the basic mechanism for causing the fracture can be
In all machining processes, the workpiece is a shape that can entirely cover the
final part shape. The objective is to cut away the excess material and obtain the final part.
This cutting usually requires to be completed in several steps – in each step, the part is
held in a fixture, and the exposed portion can be accessed by the tool to machine in that
portion. Common fixtures include vise, clamps, 3-jaw or 4-jaw chucks, etc. Each position
of holding the part is called a setup. One or more cutting operations may be performed,
using one or more cutting tools, in each setup. To switch from one setup to the next, we
must release the part from the previous fixture, change the fixture on the machine, clamp
the part in the new position on the new fixture, set the coordinates of the machine tool
with respect to the new location of the part, and finally start the machining operations for
this setup. Therefore, setup changes are time-consuming and expensive, and so we should
try to do the entire cutting process in a minimum number of setups; the task of
determining the sequence of the individual operations, grouping them into (a minimum
number of) setups, and determination of the fixture used for each setup, is called process
planning.
Turning is a cutting operation in which the part is rotated as the tool is held
against it on a machine called a lathe. The raw stock that is used on a lathe is usually
cylindrical, and the parts that are machined on it are rotational parts – mathematically,
process of finishing by which work pieces are produced to the desired dimensions and
surface finish by gradually removing the excess material from the preformed blank in the
form of chips with the help of cutting tool(s) moved past the work surface(s).Most of the
engineering components such as gears, bearings, clutches, tools, screws and nuts etc.need
dimensional and form accuracy and good surface finish for serving their purposes.
Performing like casting, forging etc. generally cannot provide the desired accuracy and
finish. For that such preformed parts, called blanks, need semi-finishing and finishing and
These four methods all produce holes of different types. Drilling produces round
holes of different types; reaming is used to improve the dimensional tolerance on a drilled
hole; boring uses a special machine operating like a lathe, to cut high precision holes; and
tapping creates screw-threads in drilled holes. Drilling: The geometry of the common
twist drill tool (called drill bit) is complex; it has straight cutting teeth at the bottom –
these teeth do most of the metal cutting, and it has curved cutting teeth along its
cylindrical surface. The grooves created by the helical teeth are called flutes, and are
useful in pushing the chips out from the hole as it is being machined. Clearly, the velocity
of the tip of the drill is zero, and so this region of the tool cannot do much cutting.
before utilizing the drill. Center-holes are made by special drills called center-drills; they
also provide a good way for the drill bit to get aligned with the location of the center of
the hole. There are hundreds of different types of drill shapes and sizes; here, we will
Common drill bit materials include hardened steel (High Speed Steel, Titanium
Nitride coated steel); for cutting harder materials, drills with hard inserts, e.g.
In general, drills for cutting softer materials have smaller point angle, while those
for cutting hard and brittle materials have larger point angle;
special guiding support for the drill, which itself has to be very long; such
operations are called gun-drilling. This process is used for holes with diameter of
few mm or more, and L/D ratio up to 300. These are used for making barrels of
guns;
Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since the tool
Usually, the size of the hole made by a drill is slightly larger than the measured
diameter of the drill – this is mainly because of vibration of the tool spindle as it
rotates, possible misalignment of the drill with the spindle axis, and some other
factors;
For tight dimension control on hole diameter, we first drill a hole that is slightly
smaller than required size (e.g. 0.25 mm smaller), and then use a special type of
drill called a reamer. Reaming has very low material removal rate, low depth of
Internal threads can be cut into holes that mate with screws/bolts. These are cut by
joins different metals/alloys, with or without the application of pressure and with or
without the use of filler metal. The fusion of metal takes place by means of heat. The heat
may be generated either from combustion of gases, electric arc, electric resistance or by
chemical reaction. During some type of welding processes, pressure may also be
employed, but this is not an essential requirement for all welding processes. Welding
provides a permanent joint but it normally affects the metallurgy of the components. It is
therefore usually accompanied by post weld heat treatment for most of the critical
industries. Some of the typical applications of welding include the fabrication of ships,
pressure vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of
nuclear fuel and explosives, etc. Most of the metals and alloys can be welded by one type
However, some are easier to weld than others. To compare this ease in welding term
‘Weld ability’ is often used. The weld ability may be defined as property of a
metal which indicates the ease with which it can be welded with other similar or
dissimilar metals.
Weld ability of a material depends upon various factors like the metallurgical
changes that occur due to welding, changes in hardness in and around the weld,
gas evolution and absorption, extent of oxidation, and the effect on cracking
tendency of the joint. Plain low carbon steel has the best weld ability amongst
metals. Generally it is seen that the materials with high cast ability usually have
There are several types of grinding machines. The main ones are surface grinders,
grinding wheels, cylindrical grinders and center less grinders. The figure below shows
examples of a few of these. Surface grinders produce flat surfaces. The part is held on the
flat table (steel parts can be held by a magnetic force – this is called magnetic chucking).
The table moves in a reciprocating motion, and the rotating wheel is lowered so that it
To improve dimension control on cylindrical parts, center less grinders, which use
long cylindrical wheels, are employed. The axis of the regulating wheel and grinding
wheel are slightly misaligned, causing the part to travel slowly in the axial direction, and
after some time, the part automatically moves beyond the length of the wheel.
Controlling the angle of misalignment can control the time that the part is subjected to
grinding. If a turned part of complex shape (e.g. stepped shafts) are to be ground, then
cylindrical grinding is used, which employs specially made grinding wheels, whose
Chapter-6
Advantages, Disadvantages and Application of the project
6.1. Advantages of the project
Advantages of the projectas per following like as:
No conventional grid electricity required
Long operating life
Highly reliable and durable
Easy to operate and maintain
Eco-friendly
Chapter-7
Conclusion
Our project is successfully implemented for we have successfully calculated the
torque force of the motor. For the design the impact velocity and torque force for riveting
of 2 mm rivet is calculated accurately. The entire modelling of the project is done with
fabrication. In this addition to this. The project work has provided us an excellent
opportunity and experience, to use our limited knowledge. We gained a lot of practical
knowledge regarding. Planning, Perching, assembling and machining while doing this
feel that the project work is good solution to bridge the gates project work. We between
institutions and industries. We are proud that we have completed the work with limited
Reference