GM INSTITUTE OF TECHNOLOGY, DAVANGERE · 2017-08-01 · GM INSTITUTE OF TECHNOLOGY, DAVANGERE...

GM INSTITUTE OF TECHNOLOGY, DAVANGERE

DEPARTMENT OF MECHANICAL ENGINEERING

CERTIFICATE

Certified that the project work entitled "DESIGN AND

FABRICATION OF MULTIPURPOSE MATERIAL HANDLING MACHINE"

carried out by Mr. SAGAR V JADHAV (USN: 4GM12ME087), Mr. ABHISHEK K

V (USN: 4GM13ME001), Mr. ADARSH KUMAR S (USN: 4GM13ME006),

Mr. TEJASVI A (USN:4GM13ME104) bonafide students of GM Institute of

Technology, Davanagere in partial fulfillment for the award of Bachelor of Engineering /

Bachelor of Technology in Mechanical Engineering of the Visvesvaraya Technological

University, Belagavi during the year 2016-2017. It is certified that all

corrections/suggestions indicated for Internal Assessment have been incorporated in the

Report deposited in the departmental library. The project report has been approved as it

satisfies the academic requirements in respect of Project work prescribed for the said

Degree.

----------------------- -----------------------

Signature of Guide Signature of Co Guide

Dr. Basavarajappa D N Mr. Basavarajappa S

Assistant Professor. Assistant Professor.

----------------------- -----------------------

Signature of Head of the Dept. Signature of Principal

Dr. Ganesh D B Dr. P Prakash

Professor. Professor.

Name of the Examiners Signature with date

1. _________________ 1. ________________

2. _________________ 2. ________________



CERTIFICATE



carried out by Mr. SAGAR V JADHAV (USN: 4GM12ME087) a bonafide student of

GM Institute of Technology, Davanagere in partial fulfillment for the award of Bachelor

of Engineering / Bachelor of Technology in Mechanical Engineering of the Visvesvaraya

Technological University, Belagavi during the year 2016-2017. It is certified that all




Degree.

----------------------- -----------------------




----------------------- -----------------------





1. _________________ 1. ________________

2. _________________ 2. ________________



CERTIFICATE



carried out by Mr. ABHISHEK K V(USN: 4GM13ME001) a bonafide student of GM

Institute of Technology, Davanagere in partial fulfillment for the award of Bachelor of

Engineering / Bachelor of Technology in Mechanical Engineering of the Visvesvaraya





Degree.

----------------------- -----------------------




----------------------- -----------------------





1. _________________ 1. ________________

2. _________________ 2. ________________



CERTIFICATE



carried out by Mr. ADARSH KUMAR S (USN: 4GM13ME006) a bonafide student of

GM Institute of Technology, Davanagere in partial fulfillment for the award of Bachelor

of Engineering / Bachelor of Technology in Mechanical Engineering of the Visvesvaraya





Degree.

----------------------- -----------------------




----------------------- -----------------------





1. _________________ 1. ________________

2. _________________ 2. ________________



CERTIFICATE



carried out by Mr. TEJASVI A (USN:4GM13ME104) a bonafide student of GM

Institute of Technology, Davanagere in partial fulfillment for the award of Bachelor of

Engineering / Bachelor of Technology in Mechanical Engineering of the Visvesvaraya





Degree.

----------------------- -----------------------




----------------------- -----------------------





1. _________________ 1. ________________

2. _________________ 2. ________________

ABSTRACT

Comfort coupled with safety and simplicity is what man strives for. Our project has been

to bring about both .The culmination of our effort has resulted in development of a new

“DESIGN & FABRICATION OF MULTIPURPOSE MATERIAL HANDLING MACHINE”.

The project present a basic as well as very professional treatment of the subject in a very

comprehensive, based on learning effort and understanding capability of today as per their levels.

The device is simple and comfortable. Basic calculation, drawing, designing is included in the

project

The salient features of our machine can be listed as the mechanism used is very simple,

easy for operation; no skill is required to operate the machine. Hydraulic cylinders are used at

high pressures and produce large forces and precise movement. For this reason they are

constructed of strong materials such as steel and designed to withstand large forces. Because gas

is an expansive substance, it is dangerous to use pneumatic cylinders at high pressures so they are

limited to about 10 bar pressure. Consequently they are constructed from lighter materials

such as aluminum and brass. Because gas is a compressible substance, the motion of a pneumatic

cylinder is hard to control precisely.

TABLE OF CONTENTS

Page No.

ACKNOWLEDGEMENT

ABSTRACT

LIST OF TABLES

LIST OF FIGURES

CHAPTER 1: INTRODUCTION 1

1.1 Transport equipment 1

1.2 Type of Material handling equipment 2

1.3 Advantage 3

CHAPTER 2: OBJECTIVES AND METHODOLOGY 4

CHAPTER 3: LITTERATURE SURVEY 5

3.1 Equipment 5

3.2 Hydraulic Cylinders 7

3.3 Cylinder Sizing for thrust 10

3.4 Clamping Application 11

3.5 Speed Control 12

3.6 Seals 14

3.7 Hydraulic Oil-68 15

3.8 Hydraulic Pump 15

3.9 Cylinders 16

3.10 Hydraulic Fluid or Oil 18

3.11 Safety 19

3.12 Tubes, Pipes and Hoses 20

3.13 Seals, Fittings and Connections 20

CHAPTER 4: EXPERIMENTS AND DATA COLLECTION 22

4.1 Working Principle 22

4.2 Design of Device 25

4.3 Structural Design Methods 26

CHAPTER 5: EXPERIMENTAL PROCEDURE 28

5.1 Cost Estimation 28

5.2 Material Cost Estimation 28

5.3 Machining Cost Estimation 29

5.4 Procedure for Calculation of Material Cost 29

5.5 Procedure of Calculating Machining Cost 30

5.6 Concept in Machine Design Production 30

5.7 Design of Welded Joint 31

5.8 Design of Angles 31

5.9 Design of Ram (Piston) 33

5.10 Application 36

CHAPTER 6: FUTURE SCOPE 37

CHAPTER 7: CONCLUSION 38

REFERENCES

LIST OF FIGURES

Sl.no Title Page no

1.1 Jib crane 2

1.2 Pallet truck 2

3.1 Main components of a cylinder 7

3.2 Single acting cylinder with spring, push and pull 8

3.3 Single acting cylinder with no spring, push and pull 8

3.4 Double acting non cushioned cylinder 9

3.5 Fixed cushion cylinder 9

3.6 Adjustable cushion cylinder 9

3.7 Rod less cylinder 10

3.8 Piston and Rod diameters 10

3.9 Full & restricted port aperture 12

3.10 Types of seals 14

3.11 Schematic representation of a hydraulic pump 15

4.1 Hydraulic circuit 22

4.2 CAD Model 23

4.3 Side view 2D model 24

4.4 Top view 2D model 24

4.5 Front view 2D model 24

4.6 Front view of Vaccum cups 24

4.7 Top view of Vaccum cups 24

4.8 Top view single Vaccum cup 24

4.9 Side view of 3D Model 25

4.10 Top view of 3D Model 25

4.11 Front view of 3D Model 25

LIST OF TABLES

Sl.no Title Page no

3.1 Properties of Hydraulic Oil 15

3.2 Functions and properties of hydraulic fluid 18

VISVESVARAYA TECHNOLOGICAL UNIVERSITY

BELAGAVI, KARNATAKA - 590018

A Project Report on

“DESIGN AND FABRICATION OF MULTIPURPOSE

MATERIAL HANDLING MACHINE”

By

SAGAR V JADHAV (4GM12ME087)

ABHISHEK K V (4GM13ME001)

ADARSH KUMAR S (4GM13ME006)

TEJASVI A (4GM13ME104)

In the partial fulfillment for the award of Bachelor Degree in Mechanical

Engineering during the year 2016-2017.

Under the Guidance of Under the Co Guidance of

Dr. BASAVARAJAPPA D N Mr. BASAVARAJAPPA S

Professor Assistant Professor

DEPARTMENT OF MECHANICAL ENGINEERING GM INSTITUTE OF TECHNOLOGY, DAVANGERE

POST BOX NO-4 PB ROAD-577006

ACKNOWLEDGEMENT

We sincerely owe our gratitude to all the persons who helped and guided us in

completing this project work.

We are thankful to Dr. P PRAKASH, Principal, GM Institute of Technology,

Davanagere without his help this project would have been dream.

Our special thanks to Dr. GANESH D B, Head Of the Department of Mechanical

Engineering, for his suggestions for the effectiveness of the project.

We would like to thank Dr. BASAVARAJAPPA D N, Assistant Professor and Mr.

BASAVARAJAPPA S, Assistant Professor Dept. of Mechanical Engineering, for his

valuable guidance, constant assistance and constructive suggestions for the effectiveness

of this project, without which this project would have not been possible.

We would like to thank our Project Co-ordinator, Dr. BHARATH K N, Asst. Professor,

and Mr. MOWNESH G K, Assistant Professor Dept. of Mechanical Engineering, for

all the support.

We would also like to thank all our teaching and non-teaching staff who has always been

with us extending their precious suggestions, guidance and encouragement throughout

the project.

PROJECT ASSOCIATES

SAGAR V JADHAV

ABHISHEK K V

ADARSH KUMAR S

TEJASVI A

We dedicate this thesis to our loving parents

who encouraged us to excel in a scholarly

career. We wish to express our gratitude to

our parents for their love and support

during our studies.

DESIGN & FABRICATION OF MULTI PURPOSE HANDLING MACHINE

GM INSTITUTE OF TECHNOLOGY, DAVANAGERE. Page 1

CHAPTER 1

INTRODUCTION

The device affords plenty of scope for modifications, further improvements &

operational efficiency, which should make it commercially available & attractive. If taken

up for commercial production and marketed properly, we are sure it will be accepted in

the industry.

Cylinders are linear actuators which convert fluid power into mechanical power.

They are also known as JACKS or RAMS. Hydraulic cylinders are used at high pressures

and produce large forces and precise movement. For this reason they are constructed of

strong materials such as steel and designed to withstand large forces. Because gas is an

expansive substance, it is dangerous to use pneumatic cylinders at high pressures so they are

limited to about 10 bar pressure. Consequently they are constructed from lighter

materials such as aluminum and brass. Because gas is a compressible substance, the

motion of a pneumatic cylinder is hard to control precisely. The basic theory for

hydraulic and pneumatic cylinders is otherwise the same.

Material handling equipment is mechanical equipment used for the movement,

storage, control and protection of materials, goods and products throughout the process of

manufacturing, distribution, consumption and disposal.

The different types of handling equipment can be classified into four major categories [1].

Transport equipment, positioning equipment, unit load formation equipment, and storage

equipment [2].The major subcategories of transport equipment are conveyors, cranes, and

industrial trucks. Material can also be transported manually using no equipment [3].

1.1. Transport equipment

Transport equipment is used to move material from one location to another (e.g.,

between workplaces, between a loading dock and a storage area, etc.), while positioning

equipment is used to manipulate material at a single location.

1.2. Type of material handling equipment:

1.2.1. Conveyors

Conveyors are used when material is to be moved frequently between specific

points over a fixed path and when there is a sufficient flow volume to justify the fixed

conveyor investment [4] Different types of conveyors can be characterized by the type of



product being handled: unit load or bulk load; the conveyor‘s location: in-floor, on-floor,

or overhead, and whether or not loads can accumulate on the conveyor. Accumulation

allows intermittent movement of each unit of material transported along the conveyor,

while all units move simultaneously on conveyors without accumulation capability

1.2.2. Cranes

Fig.1.1: Jib crane.

Cranes are used to transport loads over variable (horizontal and vertical) paths

within a restricted area and when there is insufficient (or intermittent) flow volume such

that the use of a conveyor cannot be justified. Cranes provide more flexibility in

movement than conveyors because the loads handled can be more varied with respect to

their shape and weight. Cranes provide less flexibility in movement than industrial trucks

because they only can operate within a restricted area, though some can operate on a

portable base. Most cranes utilize trolley-and-tracks for horizontal movement and hoists

for vertical movement, although manipulators can be used if precise positioning of the

load is required. The most common cranes include the jib, bridge, gantry, and stacker

cranes.

Fig.1.2: Pallet truck.

https://en.wikipedia.org/wiki/File:Jib_crane.jpg

https://en.wikipedia.org/wiki/File:Hubwagen.jpg



1.2.3. Industrial trucks

Pallet jacks are Industrial trucks that are not licensed to travel on public roads

(commercial trucks are licensed to travel on public roads). Industrial trucks are used to

move materials over variable paths and when there is insufficient (or intermittent) flow

volume such that the use of a conveyor cannot be justified. They provide more flexibility

in movement than conveyors and cranes because there are no restrictions on the area

covered, and they provide vertical movement if the truck has lifting capabilities. Different

types of industrial trucks can be characterized by whether or not they have forks for

handling pallets, provide powered or require manual lifting and travel capabilities, allow

the operator to ride on the truck or require that the operator walk with the truck during

travel, provide load stacking capability, and whether or not they can operate in narrow

aisles.

1.3. Advantages

Advantages of Using Material Handling Equipment for Industrial Storage Storing

and managing bulk of manufactured products is not an easy task. It demands proper

planning, careful handling and arrangement of materials within the warehouse. Therefore,

product manufacturing industries prefer to have material handling equipment such as

pallet rack, shelving, conveyor etc. which meets their storage requirements. Such

equipment is not only used in big industries but is also used in small industries.

Before you make buying decision, take a look at some of the key advantages of

using material handling equipment:

• It is used for easy arrangement of products according to their classification numbers.

Warehouse operator can easily find out the products that are in demand and accordingly

manages the demand and supply of the product.

• The rows in the pallet racking system can be adjusted as per the convenience of its user

and hence maximizes the storage capacity.

• Conveyors, an effective material handling equipment, are useful in easy transportation

of heavy or bulky materials.

If you think the above mentioned benefits can help you to manage your products in a

warehouse, you can look for a reliable company dealing in such material handling

equipment.



CHAPTER 2

OBJECTIVES AND METHODOLOGY

2.1 Objectives of the project work

1. To make a complete mechanical device: The idea is to make a device which does not

use any electrical power so that it is fully independent of its electricity.

2. To make a device which is suitable economical for small Scale industries: taking in to

consideration the cost factor this device is suitable for small scale as well as large scale

industries.

3. Taking safety as a prime consideration: This device is safer in all aspects.

4. To build a device which can do various operations like glass handling and fork lift.

2.2 Methodology of the project work

1. Collected the information about the raw materials to be used in the project.

2. Design of the machine using Solid Works 9.0.

3. Collection of the spare parts.

4. Building of frame work and assembly of parts.

5. The result of machine verified and noted down.



CHAPTER 3

LITERATURE SURVEY

3.1. Equipment

FERRET Company has released a multipurpose materials handling machine

capable of moving soil, rubble, pavers and rolls of turf in confined spaces. It is 700mm

wide with a capacity of 170L or 250kg.

It is a highly maneuverable, self-propelled machine able to fit through standard doorways

and narrow access areas on small house blocks. It is suitable for the gardening,

landscaping and building industries. Its power drive four wheel drive system allows it to

climb steps.

3.1.1. Design of MH Systems

A common approach to the design of MH (Material Handling) systems is to

consider MH as a cost to be minimized. This approach may be the most appropriate in

many situations because, while MH can add real value to a product, it is usually difficult

to identify and quantify the benefits associated with MH; it is much easier to identify and

quantify the costs of MH (e.g., the cost of MH equipment, the cost of indirect MH labor,

etc.). Once the design of a production process (exclusive of MH considerations) is

completed, alternate MHS designs are generated, each of which satisfies the MH

requirements of the production process. The least cost MHS design is then selected. The

appropriateness of the use of MHS cost as the sole criterion to select a MHS design

depends on the degree to which the other aspects of the production process are able to be

changed. If a completely new facility and production process is being designed, then the

total cost of production is the most appropriate criterion to use in selecting a MHS—the

lowest cost MHS may not result in the lowest total cost of production. If it is too costly to

even consider changing the basic layout of a facility and the production process, then

MHS cost is the only criterion that need be considered. In practice, it is difficult to

consider all of the components of total production cost simultaneously, even if a new

facility and production process is being designed.

Aspects of the design that have the largest impact on total cost are at some point

fixed and become constraints with respect to the remaining aspects of the design.



3.1.2. Principles of Material Handling

Although there are no definite ―rules‖ that can be followed when designing an

effective MHS, the following ―Ten Principles of Material Handling,‖3 as compiled by the

College-Industry Council on Material Handling Education (CIC-MHE) in cooperation

with the Material Handling Institute (MHI), represent the distillation of many years of

accumulated experience and knowledge of many practitioners and students of material

handling:

1. Planning Principle. All MH should be the result of a deliberate plan where the needs,

performance objectives, and functional specification of the proposed methods are

completely defined at the outset.

2. Standardization Principle. MH methods, equipment, controls and software should be

standardized within the limits of achieving overall performance objectives and without

sacrificing needed flexibility, modularity, and throughput.

3. Work Principle. MH work (defined as material flow multiplied by the distance

moved) should be minimized without sacrificing productivity or the level of service

required of the operation.

4. Ergonomic Principle. Human capabilities and limitations must be recognized and

respected in the design of MH tasks and equipment to ensure safe and effective

operations.

5. Unit Load Principle. Unit loads shall be appropriately sized and configured in a way

that achieves the material flow and inventory objectives at each stage in the supply chain.

6. Space Utilization Principle. Effective and efficient use must be made of all available

(cubic) space.

7. System Principle. Material movement and storage activities should be fully integrated

to form a coordinated, operational system which spans receiving, inspection, storage,

production, assembly, packaging, unitizing, order selection, shipping, and transportation,

and the handling of returns.

8. Automation Principle. MH operations should be mechanized and/or automated where

feasible to improve operational efficiency, increase responsiveness, improve consistency

and predictability, decrease operating costs, and to eliminate repetitive or potentially

unsafe manual labor.



9. Environmental Principle. Environmental impact and energy consumption should be

considered as criteria when designing or selecting alternative equipment and MHS.

10. Life Cycle Cost Principle. A thorough economic analysis should account for the

entire life cycle of all MHE and resulting systems.

3.2.1. Hydraulic Cylinders

Hydraulic actuators, of which cylinders are the most common, are the devices

providing power and movement to automated systems, machines and processes. A

hydraulic cylinder is a simple, low cost, easy to install device that is ideal for producing

powerful linear movement over a wide range of velocities, and can be stalled without

causing internal damage. The diameter or bore of a cylinder determines the maximum

force that it can exert and the stroke determines the maximum linear movement that it can

produce. Cylinders are designed to work at different maximum pressures. The pressure

actually supplied to a cylinder will normally be reduced through a pressure regulator to

control the thrust to a suitable level. As an example of cylinder power, a 40mm bore

cylinder working at 6 bars could easily lift an 80kg man. The basic construction of a

typical double acting single rod cylinder is shown in the cut away section (Fig.3.1), where

the component parts can be identified.

Fig.3.1: Main components of a cylinder.

1 Cushion seal 8 Front port

2 Magnet 9 Magnetically operated switch

3 Cushion sleeve 10 Piston rod

4 Barrel 11 Wear ring

5 Nose bearing 12 Piston seal

6 Rod seal and wiper 13 Rear end cover

7 Front end cover 14 Cushion adjustment screw.



3.2.2. Single Acting Cylinders

Single acting cylinders use hydraulic oil for a power stroke in one direction only.

The return stroke is affected by a mechanical spring located inside the cylinder. For single

acting cylinders with no spring, some external force acting on the piston rod causes its

return. Most applications require a single acting cylinder with the spring pushing the

piston and rod to the in stroked position. For other applications sprung out stroked

versions can be selected. Fig.3.2 shows both types of single acting cylinder.

Fig.3.2: Single acting cylinder with spring, push and pull.

The spring in a single acting cylinder is designed to provide sufficient force to

return the piston and rod only. This allows for the optimum efficiency from the available

pressure. Most single acting cylinders are in the small bore and light duty model ranges

and are available in a fixed range of stroke sizes. It is not practical to have long stroke or

large bore single acting cylinders because of the size and cost of the springs needed.

Single acting cylinders with no spring have the full thrust or pull available for performing

work. These are often double acting cylinders fitted with a breather filter in the port open

to atmosphere. The cylinder can be arranged to have a powered outstroke or a powered in

stroke shown in Fig.3.3

Fig.3.3. Single acting cylinder with no spring, push and pull.



3.2.3. Double Acting Cylinders

Double acting cylinders use compressed air to power both the outstroke and in

stroke. This makes them ideal for pushing and pulling within the same application.

Superior speed control is possible with a double acting cylinder, achieved by controlling

the exhausting back pressure. Non cushioned cylinders will make metal to metal contact

between the piston and end covers at the extreme ends of stroke. They are suitable for full

stroke working only at slow speeds which result in gentle contact at the ends of stroke

shown in Fig 3.4. For faster speed, external stops with shock absorption are required.

These should be positioned to prevent internal contact between the piston and end covers.

Fig.3.4: Double acting non cushioned cylinder.

Cushioned cylinders have a built in method of shock absorption. Small bore light

duty cylinders have fixed cushions which are simply shock absorbing discs fixed to the

piston or end cover shown in Fig.3.5.

Fig.3.5: Fixed cushion cylinder

Other cylinders have adjustable cushioning. This progressively slows the piston

rod down over the last part of the stroke by controlling the escape of a trapped cushion of

air shown in Fig.3.6.

Fig.3.6: Adjustable cushion cylinder



3.2.4. Rod less Cylinders

For some applications it is desirable to contain the movement produced by a

cylinder within the same overall length taken up by the cylinder body. For example,

action across a conveyor belt or for vertical lifting in spaces with confined headroom. The

novel design of a rod less cylinder is ideal in these circumstances. The object to be moved

is attached to a carriage running on the side of the cylinder barrel. A slot, the full length

of the barrel, allows the carriage to be connected to the piston. Long sealing strips on the

inside and outside of the cylinder tube prevent loss of air and ingress of dust. The slot is

unsealed only between the lip seals on the piston as it moves backwards and forwards

shown in Fig.3.7. Direction and speed control is by the same techniques as applied to

conventional cylinders.

Fig.3.7: Rod less cylinder

3.3.1. Cylinder Sizing For Thrust

CYLINDER The theoretical thrust (outstroke) or pull (in stroke) of a cylinder is

calculated by multiplying the effective area of the piston by the working pressure. The

effective area for thrust is the full area of the cylinder bore. The effective area for pull is

reduced by the cross section area of the piston rod shown in Fig.3.8.

Fig.3.8: Piston and rod diameters



Current practice specifies bore (D) and piston rod diameter (d) in millimeters and

working pressure (P) in bar gauge. In the formula, P is divided by 10 to express pressure

in Newton‘s per square millimeter (1 bar = 0.1 N/mm 2)

The theoretical force (F) is given by

F= (p / A)

Where

D = Cylinder bore in millimeters

d = Piston rod diameter in millimeters

P = Pressure in bar

F = Thrust or Pull in Newton‘s.

3.3.2. Usable Thrust

When selecting a cylinder size and suitable operating pressure, estimation must be

made of the actual thrust required. This is then taken as a percentage of the theoretical

thrust of a suitably sized cylinder. The percentage chosen will depend on whether the

thrust is required at the end of movement as in a clamping application or during

movement such as when lifting a load. 63 48\\254 46 55.6 (14) (2

3.4.1. Clamping Applications

In a clamping application the force is developed as the cylinder stops. This is

when the pressure differential across the piston reaches a maximum. The only losses from

the theoretical thrust will be those caused by friction. These can be assumed to be acting

even after the piston has stopped. As a general rule, make an allowance of 10% for

friction. This may be more for very small bore cylinders and less for very large ones. If

the cylinder is operating vertically up or down the mass of any clamping plates will

diminish or augment the clamping force.

3.4.2. Dynamic Applications

The actual thrust and speed from a moving cylinder are determined by friction and

the rate at which oil can flow in and out of the cylinder‘s ports. The thrust or pull

developed is divided into two components. One for moving the load, the other for

creating a back pressure to help expel the oil on the exhausting side of the piston. For a

lightly loaded cylinder, most of the thrust is used to expel the back pressure and will

result in a moderately fast speed. This is self limiting however as the faster the speed, the

less will be the pressure differential across the piston. This is due to the increasing

resistance through the ports, tubing, fittings and valve as the rate of flow increases. For a

heavily loaded cylinder most of the thrust is used to move the load. The exhausting



pressure will fall considerably to give a higher pressure differential before movement

starts. The acceleration and speed will be determined by the inertia of the load and rate at

which the lower back pressure is expelled. A heavy load simply diverts a greater

proportion of the power of the cylinder away from creating a back pressure to moving the

load. Although the speed for a heavily loaded cylinder is going to be slower it is not

unreasonably so, providing the cylinder has been correctly chosen. As a general rule, the

estimated thrust requirement should be between 50% and 75% of the theoretical thrust.

This should give sufficient back pressure for a wide range of adjustable speed control

when fitting flow regulators.

3.5. Speed Control

For many applications, cylinders can be allowed to run at their own maximum

natural speed. This results is rapid mechanism movement and quick overall machine

cycle times. However, there will be applications where uncontrolled cylinder speed can

give rise to shock fatigue, noise and extra wear and tear to the machine components. The

factors governing natural piston speed and the techniques for controlling it are covered in

this section.

The maximum natural speed of a cylinder is determined by:

• Cylinder size

• Port size

• Inlet and exhaust valve flow

• Oil pressure

• Bore and length of the hoses

• Load against which the cylinder is working.

From this natural speed it is possible to either increase speed or as is more often

the requirement, reduce it. First we will look at how the natural speed for any given load

Can be changed by valve selection. Generally the smaller the selected valve, the slower

the cylinder movement. When selecting for a higher speed however, the limiting factor

will be the aperture in the cylinder ports (Fig.3.9)

Fig.3.9: Full & restricted port aperture.



Valves with flow in excess of this limitation will give little or no improvement in

cylinder speed. The aperture in the cylinder ports is determined by the design. Robustly

constructed cylinders will often be designed full bore ports. This means that the most

restrictive part of the flow path will be the pipe fitting. These cylinders are the type to

specify for fast speed applications and would be used with a valve having at least the

same size ports as the cylinder. Lighter duty designs, particularly small bore sizes, will

have the port aperture much smaller than the port‘s nominal thread size. This has the

desired effect of limiting the speed of the cylinder to prevent it from self destructing

through repeated high velocity stroking. The maximum natural speed of these cylinders

can often be achieved with a valve that is one or two sizes down from the cylinder port

size. Larger bore cylinders are designed with port sizes large enough to allow fast

maximum speeds.

In many applications however they are required to operate at relatively low

speeds. For an application like this, a cylinder can be driven from a valve with smaller

sized ports than those of the cylinder. Once a cylinder/valve combination has been

chosen, and the load is known, the natural maximum speed will be dependent on pressure.

For an installed cylinder and load, an experiment can be carried out. Connect a control

valve that will cause the cylinder to self reciprocate. Then start the system running at low

pressure and gradually increase it. The cylinder will cycle faster and faster until a limiting

speed is reached. This is the optimum pressure for that application. Increase the pressure

further and the cylinder starts to slow down. This is caused by too much air entering the

cylinder on each stroke. More time is therefore taken to exhaust it and results in a slower

cylinder speed with any fixed combination of valve, cylinder, pressure and load, it is

usually necessary to have adjustable control over the cylinder speed. This is affected with

flow regulators, and allows speed to be tuned to the application. For the majority of

applications, best controllability results from uni-directional flow regulators fitted to

restrict the flow out of the cylinder and allow free flow in. The regulator fitted to the front

port controls the outstroke speed and the one fitted to the rear port controls the in stroke

speed. Speed is regulated by controlling the flow of air to exhaust which maintains a

higher back pressure. The higher the back pressure the more constant the velocity against

variations in load, friction and driving force. On the other side of the piston full power

driving pressure is quickly reached. Many flow regulators are designed specifically for

this convention.



3.6. Seals

There are a variety of seals required within a hydraulic cylinders Single acting non

cushioned cylinders use the least, double acting adjustable cushioned cylinders use the

most.

Fig.3.10: Types of seals.

1) Cushion screw seal 4) Piston seal

2) Cushion seal 5) Barrel seal

3) Wear ring 6) Piston rod/wiper seal.

A sliding seal such as fitted to a piston, has to push outwards against the sliding

surface with enough force to prevent compressed air from escaping, but keep that force as

low as possible to minimize the frictional resistance. This is a difficult trick to perform,

since the seal is expected to be pressure tight from zero pressure to 10bars or more. There

is a large difference between static and dynamic friction. Static friction or break-out

friction as it is sometimes called builds up when the piston stops moving. Seals inherently

need to exert a force radically outward to maintain a seal. This force gradually squeezes

out any lubricants between the seal and the barrel wall and allows the seal to settle in to

the fine surface texture. After the piston has been standing for a while, the pressure

required to start movement is therefore higher than it would be if it is moved again

immediately after stopping. To minimize this effect, seals should have a low radial force

and high compliance. High compliance allows the seal to accommodate differences in

tolerance of the seal molding and machined parts without affecting the radial force by a

great degree.



3.7. Hydraulic Oil-68

Table.3.1: Properties of Hydraulic Oil

Hydraulic oil AOE-68

Mineral based hydraulic oil

Property Value in metric

unit

Value in US

unit

Density at 60°F (15.6°C) 0.880 *10³ kg/m³ 54.9 lb/ft³

Kinematic viscosity at 104°F (40°C) 68.0 cSt 68.0 cSt

Kinematic viscosity at 212°F

(100°C) 10.2 cSt 10.2 cSt

Viscosity index 135 135

Flash point 204 ºC 400 ºF

Pour Point -40 ºC -40 ºF

Aniline Point 88 ºC 190 ºF

Color max.7.0 max.7.0

3.8. Hydraulic Pump

Basically a hydraulic system consists of a pipe of liquid ending in a piston at each

end. One piston is small and the other one is large, effort is applied to the smaller piston

pursuing it into the liquid and creating pressure throughout the liquid. The pressure then

causes the larger piston to move, thus transmitting the effort. The force produced is equal

to the liquid pressure multiplied by the area of the piston, so the large piston produces a

greater force than that exerted on the small piston depending upon the difference in their

areas. It will also move a shorter distance than the smaller piston.

Fig.3.11: Schematic representation of a hydraulic pump.

RAM

D

F W

OD



F = force applied on the plunger

W = weight lifted by the ram

D = diameter of the ram

OD = outer diameter of the piston

Hydraulic machinery offers a very large amount of power and force with relatively

small components. A typical hydraulic cylinder with a 75mm (3inch) bore, for example,

can supply 89000 N.

Hydraulic pump supplies fluid to the components in the system. Pressure in the

system develops in reaction to the load. Hence a pump rated for 1000psi is capable of

maintaining flow against a load of 1000psi.

Pumps have a power density about ten times greater than an electric motor. They are

powered by an electric motor or an engine, connected through gears, belts, or a flexible

elastomeric coupling to reduce vibrations.

Hydraulic Pump is a mechanical device that converts mechanical power into

hydraulic energy. It generates flow with enough power to overcome pressure induced by

the load.

Pumps are hydrostatic for positive displacement and hydrodynamic pumps for non-

positive displacement. Hydrostatic means that the pump converts mechanical energy to

hydraulic energy.

3.9. Cylinders As per their functions, cylinders are classified as

3.9.1. Single acting cylinders

In these, the oil pressure is fed only on one side of the cylinder either during extension or

retraction. When the oil pressure is cut-off, these cylinders return to the normal position

either by a spring or by an external load.

3.9.2. Double acting cylinders

These are operated by applying oil pressure to the cylinder in both directions. Due

to inherent mechanical problems associated with the spring, single acting cylinders with

spring return are not used in applications using larger stroke lengths. They may be either

single rod ended or double rod ended type

3.9.3. Plunger or ram cylinders

These are used as a single acting cylinder in a vertical position so that the load on

the cylinder can retract when the oil supply is stopped. E.g. Cylinders used as lifts in

automobile service stations.

http://en.wikipedia.org/wiki/Newton



3.9.4. Telescoping cylinders

These cylinders provide long working strokes in a short retracted envelope and are

used in mobile applications such as tilting of truck dump bodies and fork lift trucks,

hydraulic cranes etc.

3.9.5. Cable cylinders

These are double acting cylinders that can be powered either pneumatically or

hydraulically and find usage in applications requiring relatively long strokes and

moderate forces and can be operated in limited spaces.

3.9.6. Diaphragm cylinders

These are often used in pneumatic applications and are either of the rolling

diaphragm or flat diaphragm type. They have very low break-out friction.

3.9.7. Bellows cylinders

These are used for very low force applications in sensitive pneumatic control

systems. The pressure and the spring rate of the bellows determine the amount of tension

and contraction and may be used for basic servo-control systems since metal bellows

have a linear spring rate.

3.9.8. Tandem cylinders

These are commonly used in hydraulic and pneumatic systems; two cylinders are

mounted in line with the pistons connected to a common piston rod in order to multiply

the force in a limited lateral space [1]

.

3.10. Hydraulic Fluid or Oil

Hydraulic fluids or liquids are the medium by which power is transferred in

hydraulic machinery. Common hydraulic fluids are based on mineral oil or water. The

primary function of a hydraulic fluid is to convey power. In use, however, there are other

important functions of hydraulic fluid such as protection of the hydraulic machine

components from corrosion, wear and tear etc

3.10.1 Composition

Base stock: Base stock may be any of: castor oil, glycol, esters, ethers, mineral

oil, organophosphate ester, polyalphaolefin, propylene glycol, or silicone.

Nak-77, an eutectic alloy of Sodium-Potassium, can be used as a hydraulic fluid in

high temperature and high radiation environments, for temperature ranges 10oF to 1400

oF

http://en.wikipedia.org/wiki/Castor_oil

http://en.wikipedia.org/wiki/Glycol

http://en.wikipedia.org/wiki/Ester

http://en.wikipedia.org/wiki/Ether

http://en.wikipedia.org/wiki/Mineral_oil

http://en.wikipedia.org/wiki/Mineral_oil

http://en.wikipedia.org/w/index.php?title=Organophosphate_ester&action=edit&redlink=1

http://en.wikipedia.org/wiki/Polyalphaolefin

http://en.wikipedia.org/wiki/Propylene_glycol

http://en.wikipedia.org/wiki/Silicone



3.10.2 Other components

Hydraulic fluids can contain a wide range of chemical compounds, including: oils,

butanol, esters (e.g. adipates, like bis(2-ethylhexyl) adipate), polyalkylene glycols (PAG),

phosphate esters (e.g. tributylphosphate), silicones, alkylated aromatic hydrocarbons,

polyalphaolefins (PAO) (e.g. polyisobutenes), corrosion inhibitors, etc.

3.10.3. Bio-degradable hydraulic fluids

Environmentally sensitive applications (e.g. farm tractors and marine dredging)

may benefit from using biodegradable hydraulic fluids based upon rapeseed (Canola)

vegetable oil when there is the risk of an oil spill from a ruptured oil line. Typically these

oils are available as ISO 32, ISO 46, and ISO 68 specification oils. ASTM standards

ASTM-D-6006, Guide for Assessing Biodegradability of Hydraulic Fluids and ASTM-D-

6046, Standard Classification of Hydraulic Fluids for Environmental Impact are relevant.

Table.3.2: Functions and properties of hydraulic fluid

Function Property

Medium for power transfer and control

Low compressibility (high bulk

modulus)

Fast air release

Medium for heat transfer Good thermal capacity and

conductivity

Sealing Medium

Adequate viscosity and viscosity

index

Shear stability

Lubricant

Viscosity for film maintenance

Low temperature fluidity

Pump efficiency

Proper viscosity to minimize

internal leakage

High viscosity index

http://en.wikipedia.org/wiki/Oil

http://en.wikipedia.org/wiki/Butanol

http://en.wikipedia.org/wiki/Adipate

http://en.wikipedia.org/wiki/Bis(2-ethylhexyl)_adipate

http://en.wikipedia.org/w/index.php?title=Polyalkylene_glycol&action=edit&redlink=1

http://en.wikipedia.org/wiki/Organophosphate

http://en.wikipedia.org/wiki/Tributylphosphate

http://en.wikipedia.org/wiki/Polyisobutene

http://en.wikipedia.org/wiki/Corrosion_inhibitor

http://en.wikipedia.org/wiki/Tractor#power_and_transmission

http://en.wikipedia.org/wiki/Dredging

http://en.wikipedia.org/wiki/Rapeseed

http://en.wikipedia.org/wiki/Canola

http://en.wikipedia.org/wiki/Vegetable_oil#industrial_uses

http://en.wikipedia.org/wiki/Oil_spill

http://en.wikipedia.org/wiki/International_Organization_for_Standardization

http://en.wikipedia.org/wiki/ASTM



3.10.4. Brake fluid

Brake fluid is a subtype of hydraulic fluid with high boiling point and low

freezing point. It is intentionally hygroscopic, so that it will absorb water which could

otherwise cause corrosion of brake system components.

3.11. Safety

Because industrial hydraulic systems operate at hundreds to thousands of psi and

temperatures reaching hundreds of degrees Celsius, severe injuries and death can result

from component failures and care must always be taken when performing maintenance on

hydraulic systems. Fire resistance is a property available with specialized fluids.

Trade names: Some of the trade names for hydraulic fluids include Durad, Fyrquel,

Houghton-Safe, Hydraunycoil, Lubritherm Enviro-Safe, Pydraul, Quintolubric, Reofos,

Reolube, and Skydrol .

3.12. Tubes, Pipes and Hoses

Hydraulic tubes are seamless steel precision pipes, specially manufactured for

hydraulics. The tubes have standard sizes for different pressure ranges, with standard

diameters up to 100mm. The tubes are supplied by manufacturers in lengths of 6m,

cleaned, oiled and plugged. The tubes are interconnected by different types of flanges

(especially for the larger sizes and pressures), welding cones (with o-ring seal), and

several types of flare connection and by cut-rings. In larger sizes, hydraulic pipes are

used. Direct joining of tubes by welding is not acceptable since the interior cannot be

inspected.

Hydraulic pipe is used in case standard hydraulic tubes are not available.

Generally these are used for low pressure. They can be connected by threaded

connections, but usually by welds. Because of the larger diameters the pipe can usually be

inspected internally after welding. Black pipe is non-galvanized and suitable for welding.

Hydraulic hose is graded by pressure, temperature, and fluid compatibility. Hoses are

used when pipes or tubes cannot be used, usually to provide flexibility for machine

operation or maintenance. The hose is built up with rubber and steel layers. A rubber

interior is surrounded by multiple layers of woven wire and rubber. The exterior is

designed for abrasion resistance. The bend radius of hydraulic hose is carefully designed

into the machine, since hose failures can be deadly, and violating the hose‘s minimum

bend radius will cause failure. Hydraulic hoses generally have steel fittings swaged on the

ends. The weakest part of the high pressure hose is the connection of the hose to the

http://en.wikipedia.org/wiki/Brake_fluid

http://en.wikipedia.org/wiki/Boiling_point

http://en.wikipedia.org/wiki/Freezing_point

http://en.wikipedia.org/wiki/Hygroscopic

http://en.wikipedia.org/wiki/Skydrol

http://en.wikipedia.org/wiki/Tubing_(material)

http://en.wikipedia.org/wiki/Pipe_(material)

http://en.wikipedia.org/w/index.php?title=Black_pipe&action=edit

http://en.wikipedia.org/wiki/Galvanization

http://en.wikipedia.org/wiki/Welding

http://en.wikipedia.org/wiki/Hose_(tubing)

http://en.wikipedia.org/wiki/Swaging



fitting. Another disadvantage of hoses is the shorter life of rubber which requires periodic

replacement, usually at five to seven year intervals.

Tubes and pipes for hydraulic applications are internally oiled before the system is

commissioned. Usually steel piping is painted outside. Where flare and other couplings

are used, the paint is removed under the nut, and is a location where corrosion can begin.

For this reason, in marine applications most piping is stainless steel.

3.13. Seals, Fittings and Connections

In general, valves, cylinders and pumps have female threaded bosses for the fluid

connection, and hoses have female ends with captive nuts. A male-male fitting is chosen

to connect the two. Many standardized systems are in use. The seals play an important

role in the hydraulic systems, since the hydraulic system does not work if there is any

leakage in the joints.

Fittings serve several purposes

1. To bridge different standards; O-ring boss , or pipe threads to face seal, for

example.

2. To allow proper orientation of components, a 90°, 45°, straight, or swivel fitting is

chosen as needed. They are designed to be positioned in the correct orientation

and then tightened.

3. To incorporate bulkhead hardware.

4. A quick disconnect fitting may be added to a machine without modification of

hoses or valves

A typical piece of heavy equipment may have thousands of sealed connection points and

they are of different types

Pipe fittings, the fitting is screwed in until tight, difficult to orient an angled

fitting correctly without over or under tightening.

O-ring boss, the fitting is screwed into a boss and orientated as needed, an

additional nut tightens the fitting, washer and o-ring in place.

Flare seal, a metal to metal compression seal with a cone and flare mating.

Face seal, metal flanges with a groove and o-ring are fastened together.

Beam seal, a costly metal to metal seal used primarily in aircraft.

Swaged seals, tubes are connected with fittings that are swaged permanently in

place. Primarily used in aircraft.

http://en.wikipedia.org/wiki/Seal_(mechanical)

http://en.wikipedia.org/wiki/Compression_fitting

http://en.wikipedia.org/wiki/Valve

http://en.wikipedia.org/wiki/Cylinder_(engine)

http://en.wikipedia.org/wiki/Pump

http://en.wikipedia.org/wiki/Gender_of_connectors_and_fasteners

http://en.wikipedia.org/wiki/O-ring_boss_seal

http://en.wikipedia.org/wiki/Threaded_pipe

http://en.wikipedia.org/w/index.php?title=Face_seal_%28o-ring%29&action=edit

http://en.wikipedia.org/wiki/Angle

http://en.wikipedia.org/w/index.php?title=Pipe_threads&action=edit

http://en.wikipedia.org/wiki/O-ring_boss_seal

http://en.wikipedia.org/wiki/O-ring

http://en.wikipedia.org/w/index.php?title=Flare_seal&action=edit

http://en.wikipedia.org/w/index.php?title=Face_seal_%28o-ring%29&action=edit

http://en.wikipedia.org/w/index.php?title=Beam_seal&action=edit

http://en.wikipedia.org/wiki/Swage



Elastomeric seals (O-ring boss and face seal) are the most common types of seals in

heavy equipment and are capable of reliably sealing 6000+ psi (41368+ kPa) of fluid

pressure .

3.13.1. Mild steel

Mild steel differs from stainless steel in its chromium content. Stainless steel

contains a lot more chromium than ordinary carbon or mild steel. Mild steel is a type of

steel alloy that contains a high amount of carbon as a major constituent.

3.13.2 Mild steel properties and uses

Let us see, what makes the mild steel composition. Other than maximum limit of 2

% carbon in the manufacture of carbon steel, the proportions of manganese

(1.65%), copper (0.6%) and silicon (0.6%) are fixed, while the proportions of

cobalt, chromium, niobium, molybdenum, titanium, nickel, tungsten, vanadium

and zirconium are not.

A high amount of carbon makes mild steel different from other types of steel.

Carbon makes mild steel stronger and stiffer than other type of steel. However, the

hardness comes at the price of a decrease in the ductility of this alloy. Carbon

atoms get affixed in the interstitial sites of the iron lattice and make it stronger.

What is called as mildest grade of carbon steel or ‗mild steel‘ is typically carbon

steel, with a comparatively mild amount of carbon (0.16% to 0.19%). It has

ferromagnetic properties, which make it ideal for manufacture of electrical

devices and motors.

The calculated average industry grade mild steel density is 7.85 gm/cm3. Its

Young‘s modulus, which is a measure of its stiffness, is around 210,000 Mpa.

http://en.wikipedia.org/wiki/Pound-force_per_square_inch

http://en.wikipedia.org/wiki/Pascal_(unit)#Definition

http://www.buzzle.com/articles/chromiumthe-element.html

http://www.buzzle.com/articles/carbon-the-element.html

http://www.buzzle.com/articles/copper/



CHAPTER 4

EXPERIMENTS AND DATA COLLECTION

4.1 Working Principle

Oil Circulation is there through all components as per hydraulic circuit, here we

are Appling the pressure with the help of a handle and it works according to the Pascal

law this machine does the work of lifting the glass well as fork lift this machine is used to

lift glass, and any plane object

4.1.1. Hydraulic Circuit

Fig.4.1: Hydraulic circuit.



Fig.4.2: CAD Model.

Solid supportive bar

Small Pulley

Piston arrangement

J-Hook

Vaccum Cups

Castle Wheels



Fig.4.3: Side view 2D model. Fig.4.4: Top view 2D model.

.

Fig.4.5: Front view 2D model. Fig.4.6: Front view of Vaccum cups.

Fig.4.7: Top view of Vaccum cups. Fig.4.8: Top view of Single Vaccum cup.



Fig.4.9: Side view of 3D Model. Fig.4.10: Top view of 3D Model.

Fig.4.11: Front View of 3D Model.

4.2 Design of Device

4.2.1. General Requirements of Machine Design

1. High productivity.

2. Ability to produce and provide required accuracy of shape and size and also

necessary surface finish.

3. Simplicity of design.

4. Safety and convenience of control

5. Low Cost.

6. Good Appearance.



4.2.2. Design Procedure

Before we proceed to the process of manufacturing, it‘s necessary to have some

knowledge about the project design essential to design the project before starting the

manufacturing. Maximum cost of producing a part of product is established originally by

the designer. The product consists of:

1. Functional Design.

2. Product Design

3. Engineering Design

4.2.3. Design Procedure for a Product

When a new product or their elements are to be designed, a designer may proceed

as follows:

1. Make a detailed statement of the problems completely; it should be as clear as possible

& also of the purpose for which the machine is to be designed

2. Make selection of the possible mechanism which will give the desire motion.

3. Determine the forces acting on it and energy transmitted by each element of the

Machine.

4. Select the material best suited for each element of the machine.

5. Determine the allowable or design stress considering all the factors that affect the

Strength of the machine part.

6. Identify the importance and necessary and application of the machine.

7 Problems with existing requirement of the machine productivity and demand

8. Determine the size of each element with a view to prevent undue distortion or breakage

under the applied load.

9. Modify the machine element or parts to agree with the past experience and judgment

and to facilitate manufacture.

10. Make assembly and detail drawings of machine with complete specification for the

materials and manufacturing methods i.e. accuracy, Surface finish etc.

4.3 Structural Design Methods

Introduction: This chapter describes some of the mathematical technique used by

designers of complex structures. Mathematical models and analysis are briefly describe

and detail description is given of the finite – element method of structural analysis.

Solution techniques are presented for static, dynamic & model analysis problems. As part

of the design procedure the designer must be analyses the entire structure and some of its

components. To perform this analysis the designer will develop mathematical models of



structure that are approximation of the real structure, these models are used to determine

the important parameters in the design. The type of structural model the designer uses

depends on the information that is needed and the type of analysis the designer can

perform.

Three types of structural models are

1. Rigid Members: The entire structure or parts of the structure are considered to be

rigid; hence no deformation can occur in these members.

2. Flexible members: The entire structure or parts of the structure are modeled by

members that can deform, but in limited ways. Examples of this members trusses,

beams and plates.

3. Continuum: A continuum model of structure is the most general, since few if any

mathematical assumptions about the behavior of the structure need to be made prior to

making a continuum model. A continuum member is based on the full three –

dimensional equations of continuum models.

In selecting a model of the structure, the designer also must consider type of analysis to

be performed. Four typical analysis that designers perform are:

1. Static equilibrium: In this analysis the designer is trying to determine the overall

forces and moments that the design will undergo. The analysis is usually done with a rigid

member of model of structure and is the simplest analysis to perform.

2. Deformation: This analysis is concerned with how much the structure will move when

operating under the design loads. This analysis is usually done with flexible members.

3. Stress: In this analysis the designers wants a very detailed picture of where and at what

level the stresses are in the design. This analysis usually done with continuum members.

4. Frequency: This analysis is concerned with determining the natural frequencies and

made shape of a structure. This analysis can be done with either flexible members of a

structure. This analysis can be done with either flexible members or continuum members

but now the mass of the members is included in the analysis.

The subject of machine design deals with the art of designing machine of

structure. A machine is a combination of resistance bodies with successfully constrained

relative motions which is used for transforming other forms of energy into mechanical

energy or transmitting and modifying available design is to create new and better

machines or structures and improving the existing ones such that it will convert and

control motions either with or without transmitting power. It is the practical application of

machinery to the design and construction of machine and structure. In order to design

simple component satisfactorily, a sound knowledge of applied science is essential.



CHAPTER 5

EXPERIMENTAL PROCEDURE

5.1. Cost Estimation

Cost estimation may be defined as the process of forecasting the expenses that

must being occurred to manufacture a product. These expenses take into a consideration

all expenditure involved in a design & manufacturing with all related service facilities

such as pattern making, tool, making as well as a portion of the General Administrative &

selling costs.

5.1.1. Purpose of Cost Estimating

1) To determine the selling price of a product for a quotation or contract so as to

ensure a reasonable profit to the company.

2) Check the quotations supplied by vendors.

3) Determine the most economical process or material to manufacture the product.

4) To determine standards of production performance that may be used to control the

cost.

Basically the cost estimation is of two types

1) Material cost

2) Machining cost.

5.2. Material Cost Estimation

Material cost estimation gives the total amount required to collect the raw material

which has to be processed or fabricated to desired size and functioning of the

components. These materials are divided into two categories.

5.2.1. Material for Fabrication:

In this the material in obtained in raw condition and is manufactured or processed

to finished size for proper functioning of the component.

5.2.2. Standard Purchased Parts :

This includes the parts which was readily available in the market like Allen

screws etc .A list in for-chard by the estimation stating the quality, size & standard parts,

the weight of raw material and cost per kg. For the fabricated parts.



5.3 . Machining Cost Estimation

This cost estimation is an attempt to forecast the total expenses that may include to

manufacture apart from material cost. Cost estimation of manufactured parts can be

considered is judgment on and after careful consideration which includes Labor, Material

and Factory services required to produce the required part.

5.4. Procedure for Calculation of Material Cost

The general procedure for calculation of material cost estimation is:

1) After designing a project a bill of material is prepared which is divided into two

categories.

A) Fabricated components.

B) Standard purchased components.

2) The rates of all standard items are taken and added up.

3) Cost of raw material purchased taken and added up.

This is done as follows:

1) Dimension for each part is noted and the volume of the material is calculated by

multiplying it with specific gravity of that material to give the weight of the

component. The density of mild steel in taken as 785 kg/m3.

2) The weight of material for each part is multiplied by the rate per kg. Of the

material to give the material cost for each component.

3) The summarization of all the cost of the standard products thus the cost of

material to be fabricated gives the material cost estimation of that project.

There are three categories of costs:

A) material cost

B) Machining cost

C) Labor cost

A) Material cost:

It is again sub-divided as

a) Raw material cost and

b) b) finished product cost

B) Labor Cost

It is the cost of remuneration (wages, salaries, commission, bonus etc.) of the

employees of a concern or enterprise.



Labor cost is classified as:

1) Direct Labor Cost

2) Indirect Labor Cost

Direct Labor Cost

The Direct Labor Cost is the cost of labor that can be identified directly with the

manufacture of the product and allocated to cost centers or cost units. The Direct Labor is

one who counters the Direct Material into saleable product, wages etc. of such employees

constitute direct labor cost. Direct Labor Cost may be apportioned to the unit cost of job

or either on the basis of time spend by a worker on the job or as a price for some physical

measurement of product.

Indirect Labor Cost

It is that labor cost which cannot be allocated but which can be apportioned to or

absorbed by cost centers or cost units. This is the cost of labor that doesn‘t alters the

construction, confirmation, composition or condition of direct material but is necessary

for the progressive movement and handling of product to the point of dispatch e.g.

maintenance, men, helpers, machine setters, supervisors and foremen etc.The total labor

cost is calculated on the basis of wages paid to the labor for 8 hours

5.5. Procedure of Calculating Machining Cost

1) Time taken by a particular machine for machining each and every component is

calculated including allowances for tiny set up inspection time, centering time

etc. because a component cannot have more than one operations. The machining

cost is calculated using standard working rates of machine per hours. The time

taken by a particular machine for machining every component is multiplied by the

machining rate to give the machining cost.

Therefore total cost includes:

TOTAL COST = MATERIAL COST + MACHINING COST + LABOR COST.

SELLING COST = MANUFACTURING COST + 10% PROFIT

5.6. Concept in Machine Design Production

Consideration in Machine Design

When a machine is to be designed the following points to be considered: -

i) Types of load and stresses caused by the load.

ii) Motion of the parts and kinematics of machine. This deals with the type of motion

i.e. reciprocating. Rotary and oscillatory.



iii) Selection of material & factors like strength, durability, weight, corrosion

resistant, weld ability, machine ability are considered.

iv) Form and size of the components.

v) Frictional resistances and ease of lubrication.

vi) Convince and economical in operation.

vii) Use of standard parts.

viii) Facilities available for manufacturing.

ix) Cost of making the machine.

x) Numbers of machine or product are manufactured.

5.7. Design of Welded Joint

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 x L x ft

Where, S = size of weld = 3, L = contact length = 35mm

The load of shear along with the friction is 50 kg = 500N

Hence, 500 = 0.707 x 3 x 35 x ft

Hence let us find the safe value of ‗ft‘

ft = 6.73536 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.

5.8. Design of Angles

Here, The maximum load due to all factors = 450 kg (including friction)

F= 450kg = 450 x 9.81 = 4414.5 N.

We know that he load on each link,

F1 = 4414.5/4 = 1103.63N.

Assuming a factor of safety as 3, the links must be designed for a buckling load of

Wcr = 1103.63 x 3 = 3310.9 N

Let t1= Thickness of the link

b1= width of the link

So, cross sectional area of the link = A = t1x b1



Assuming the width of the link is three times the thickness of the link, i.e.b1= 3 x t1

Therefore

A= t1x 3 t1 = 3 t12

And moment of inertia of the cross section of the link,

I = 1/12 t1b13

= 2.25 t14

We know that I = AK2, where k = radius of gyration.

K2 = I/A = 2.25 t1

4 / 3 t1

2 = 0.75 t1

2

Since for the buckling of the link in the vertical plane, the ends are considered as hinged,

Therefore, the equivalent length of the link

L = l = 600 mm.

And Rankin‘s constant, a = 1/ 7500

Now using the relation,

with usual notation,

Here f = 100 N / mm2

300 t14 – 3310.9 t1

2 –64 x 3310.9 = 0

t12

= 41.2

t1 = 6.418 mm

b1 = 3 x t1 = 3 x 6.418 = 19.25 mm.

But the standard angle available of 35x 35 x 3

Hence, for safer side we have

Selected it, which can bear the impact loading. Hence our design is safe.

5.8.1. Hydraulic cylinder

The hydraulic cylinder is designed for a load of 2 ton

Load = 2 ton

= 2000kg



= 2000 x 9.81

= 19620 N

Stroke length = 70mm

Material: structural steel st - 42 hollow tubes.

For bore diameter (inner dia) = 60mm

Working pressure =31.5 N/mm2

Stroke = 70mm.

For factor of safety fos = 4.

ft = 412.02 N/mm2

Therefore ft = (412.02)/4 = 103.00 N/mm2

To find the thickness (closed end cylinders)

to = d/2 x {√ [st + (1-2µ) P ] / [st – (1+µ) P] -1}

t = 60/2 x{ √[103 + (1-2 x 0.3) 31.5] / [103 – (1 + 0.3) 31.5] -1}

= 30 x 0.36

= 10.8 mm

t = 10.8mm

The outer diameter of the tube

D = d + 2t

= 60+ 2(3)

= 66mm. = 70 mm

To calculate hoop stress for t = 5 mm.

Ft = (p x d) / 2t

= (31.5 x 60) / (2 x 5)

= 189 N/mm2

Where as the stress given is 412 N/mm2 hence it is safe.

5.9. Design of Ram (Piston)

Material Used - Mild Steel.

Grade EN-8bar (carbon ℅ 0.45)

In order to overcome frictional resistance more force must be exerted on top of the

ram by fluid

Load =F= A x P

= {(π / 4) d2

x 16}

= {(π / 4) x 402 x 16}

F = 20 KN



The tensile stress of the material is 135.5 N/mm2

Also F = A x σt

20 x 103

= {(π / 4) x dp2 x 135.5}

dp2 = (20.106 x 10

3 x 4) / (π x 135.5)

dp = 13.74mm

But for safe and standard rods, therefore the diameter of piston is

dp = 25mm

To check for shear stress

τs = F / (π x dc x t x n)

F = 20.106KN

The threads of M20 with 1.5mm pitch is chosen

Core diameter of M20 is dc = 16.933mm

t = p / 2

= 1.5 / 2

= 0.75mm

n = number of threads.

For EN - 8 bar τs = 90.25MPa (from mechanical industrial data hand book)

τs = 20106.19 / (π x 16.933 x 0.75 x n)

n = 20106.19 / (π x 16.933 x 0.75 x 90.25)

n = 5.58

≈ 6

Length of threads = n p

= 6 x 1.5

= 9mm

But the length chosen is 20mm

5.9.1. Piston Head

The design of piston head is designed where diameter of piston head = 39.970 /

39.94

Clearance of 0.004 for dimensions and clearance between bore and piston head is 0.026

which is kept for sliding

The other two factors are

1) Stroke length of 150mm has to be maintained.

2) Seals are to be fixed for no leakage.

To check buckling of piston rod

The piston has two parts



1. Piston head

2. Ram

The length of ram is 165mm

Using the Rankine‘s formula.

Pcr = (σc A) / ( 1 + a (Le / K)2 )

K = radius of gyration = √ (I / A)

σc = compressive stress.

Le = effective length.

a = Rankine‘s constant

= σc /π2

E

For one end fixed & other end free

Le = 2 L

= 2 x 165

= 330mm

σc = 280 N / mm2

d = 25mm

A = π / 4 (d) 2.

= π / 4 (25)2.

= 490.873mm2

I = π / 64 d4

= π / 64 x (25)4

= 19174.759mm4

K = √ (I /A)

= √ (19174.759 / 490.873)

= 6.25

a = σc / π2E

Where E =Young‘s Modulus = 207x103 N/mm

2

A = 280 / (π2

x 207x103)

= 1.3705x10-4

Therefore Pcr = (280 x 490.873) / [1 + 1.3705x10-4

(330 / 6.25)2]

= 99.458x103

N

Since the critical load for buckling is 99.458KN & load applied is 20.16KN which is less

and hence the design is safe.



5.9.2. Seals

Piston PU Piston seal 40 X 33 X 7.

Ram PU-seal 25 X 33 X 7.

Wiper seal Rubber 25 X 33 X 5/7

O-Ring Rubber seal 34 X 3

5.9.3. Merits

1) Easy in operation.

2) Low cost

3) Simple construction.

4) Adaptable.

5) High capacity.

6) Performance.

7) Manually operated.

8) Environmental friendly.

9) Easy to setup

5.10. Application

1. Use to handle glass, from one place to another.

2. Use to position tiles on the floor.

3. Used as a fork lift in industry to carry goods in the plant

4. Used to lift tiles, glass or we can say any flat object with good surface finish



CHAPTER 6

FUTURE SCOPE

We feel the project that we have done has a good future scope in any engineering

industry. The main constraint of this device is the high initial cost but has low operating

costs.

Savings resulting from the use of this device will make it pay for itself with in

short period of time & it can be a great companion in any engineering industry dealing

with rusted and unused metals.

The device affords plenty of scope for modifications, further improvements &

operational efficiency, which should make it commercially available & attractive. If taken

up for commercial production and marketed properly, we are sure it will be accepted in

the industry. It has plenty of scope if the device is made larger in size so that the capacity

of shearing the metals is more and it can be used in the factory premises.



CHAPTER 7

CONCLUSION

1) The Purpose is to make a machine which does not use any electrical power so that

it is fully independent of electricity.

2) Mainly the design was made to lift 100 kg but in practical it lifted 80 kg.

3) Biggest challenge is vaccum cup alignment with high suction force.

4) Maneuverability of device is good and handling of device is simple.

5) Future application like traverse movement of the sleeve where it cannot be

reached manually



REFERENCES

[1] Pantazopoulos G, Vazdirvanidis A. ―Fractographic and metallographic study of

spalling failure of steel straightener rolls‖. Journal of Failure Analysis and

Prevention 2008;8(6):509–14.

[2] Pantazopoulos G, Vazdirvanidis A, Toulfatzis A, Rikos A. ―Fatigue failure of steel

links operating as chain links in a heavy duty draw bench‖. Engineering

Failure Analysis 2009;16(7):2440–9.

[3] Figueiredo MV,et al. ―Analysis of a heavy duty lift truck. Engineering Failure

Analysis‖ 2001;8:411–21

[4] Sachs NW. ―Understanding the surface features of fatigue fractures: how they describe

the failure cause and the failure history‖. Journal of Failure Analysis and Prevention

2005;5(2):11–5.

[5] Wulpi DJ. ―Understanding how components fail‖. 2nd ed. Materials Park (OH): ASM

International; 2000.

[6] ASM handbook, vol. 7: ‗‗Atlas of Microstructures of Industrial Alloys‘‘. 8th ed. OH:

ASM International; 1973.

[7] Crowther, W et al. ―Fault Diagnosis of a Hydraulic Actuator Circuit Using Neural

Networks – A State Space Classification Approach‖. Proc IMechE, Part I, Journal of

Systems and Control Engineering, Vol. 212.

[8] Hiirsalmi, M. ―Design of a Feature Extraction and a Fault Classifier System Using

Data Mining Techniques. T4Liikkudia‖. Version 1.0-1, VTT Information Technology. 16

p. Research Report TTE1-2005-29.

[9] R.S. Khurmi And J. K. Gupta, a text book of ―Machine design‖, Eurasia Publishing

House Pvt. Ltd., Fourteenth Edition, 2005.

[10] R.S. Khurmi, ―Theory of machines‖. S. Chand publication Pvt. Ltd. Sixth Revised

Edition, 2005.

[11] Andrew Parr, ―Hydraulics and Pneumatics‖, Jaico publishing house, Tenth Edition,

2005.

Project Guide and Co Guide Bio-Data

PROJECT ASSOCIATES BIO-DATA

Name of the college/ place G M Institute Of Technology,

Davangere, Karnataka- 577006

Department of Mechanical Engineering

SAGAR V JADHAV

S/o Virupakshappa G

#4855/132 Aishwarya,

S S Layout B Block

Davangere-577004

Mobile-8892830113.

E-Mail: [email protected]

ABHISHEK K V

S/O G K Venkateshkumar

#1970/30 Sri ramanjaneya nilaya

S S Layout B Block

Davangere-577004

Mobile-9538701306

Email: [email protected]

ADARSH KUMAR S

S/O late Rudraswami

3rd cross A Block

Vidyanagar

Haveri-581110

Mobile- 8123640383


TEJASVI A

S/O late Adivappa T

#362/2 1st main 1st cross

K B Extension

Davangere-577001

Mobile- 9741816707.


mailto:[email protected]




PROJECT GUIDES BIO-DATA

Name of the College/

Place

G M Institute Of Technology,

Davanagere, Karnataka- 577006

Department

Mechanical Engineering

DR. BASAVARAJAPPA D N Assistant Professor

GMIT Davangere , Pin Code-577006

Mobile :9448873484

E-Mail:[email protected]

MR. BASAVARAJAPPA S Assistant Professor

GMIT Davanagere , Pin Code-577006

Mobile :9449052219

E-Mail:[email protected]



GM INSTITUTE OF TECHNOLOGY, DAVANGERE · 2017-08-01 · GM INSTITUTE OF TECHNOLOGY, DAVANGERE...

Documents

Transcript of GM INSTITUTE OF TECHNOLOGY, DAVANGERE · 2017-08-01 · GM INSTITUTE OF TECHNOLOGY, DAVANGERE...