PROFILE CUTTING MACHINE - DSpace at Ganpat...

PROFILE CUTTING MACHINE

PROJECT REPORT

On

B.S. PATEL POLYTECHNIC, KHERVA

Project group: (1)Kaila UmangGunvantbhai (126440319085)

(2) ModipoojanBharatbhai (126440319116)

(3) ModiAkashyNileshbhai (126440319120)

(4) MistariUtsavKamlesbhai (126440319121)

(5) Patel ShubhamKanaiyalal (126440319126)

Internal /External guide: (1) Prof :K.P.Patel (H.O. D)

(2) Mr.Anil Sharma


B.S.P.P. 2014-15


Certificate

This is to certify that Mr.KailaUmangGunvantbhaihaving Enrolment No :126440319085 has completed Part-I IDP Project work having title PROFILE CUTTING MACHINE. He has undergone the process of Shodhyatra, literature survey and problem definition. He is supposed to carry out the residue IDP Part-II work on same problem during Semester-VI for the final Fulfillment of the IDP work which is prerequisite to complete Diploma Engineering.

Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel

B.S.P.P. 2014-15


Certificate

This is to certify that Mr.ModiPoojanBharatbhaihaving Enrolment No :126440319116 has

completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has

undergone the process of Shodhyatra, literature survey and problem definition. He is

supposed to carry out the residue IDP Part-II work on same problem during Semester-VI

for the final Fulfillment of the IDP work which is prerequisite to complete Diploma

Engineering.


B.S.P.P. 2014-15


Certificate

This is to certify that Mr..ModiAkshayNileshbhaihaving Enrolment No : 126440319120 has

completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has




Engineering.


B.S.P.P. 2014-15


Certificate

This is to certify that Mr.MistriUtsavKamleshbhaihaving Enrolment No : 126440319121

has completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has




Engineering.


B.S.P.P. 2014-15


Certificate

This is to certify that Mr. Patel ShubhamKanaiyalalhaving Enrolment No : 126440319126

has completed Part-I IDPProject work having title PROFILE CUTTING MACHINE. He has




Engineering.


B.S.P.P. 2014-15


INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM

STUDENT PARTICULARS-1

FIRST NAME Umang

LAST NAME Kaila

MOBILE NO. 1.

9974787809 2.

EMAIL [email protected]

ENROLLMENT NO. 126440319085

COLLEGE NAME B.S.Patel Polytechnic, Ganpat University.

ADDRESS

107 VrundavanSociety,Viramgam,Ahmedabad

BRANCH Mechanical Engineering

SEMESTER 5th Sem. Year 2013-2014

TEAM NAME G-1

SIGNATURE OF STUDENT

B.S.P.P. 2014-15

mailto:[email protected]



FIRST NAME Poojan

LAST NAME Modi

MOBILE NO. 1.

9662053129 2.

EMAIL

ENROLLMENT NO.126440319116


ADDRESS

D/26 ,AvadhapuriSociety,Behind Galaxy Cinema,Naroda,

Ahmedabad-382330

BRANCH Mechanical Engineering.


TEAM NAME G-1


B.S.P.P. 2014-15



FIRST NAME Akshay

LAST NAME Modi

MOBILE NO. 1 7802925942 2


ENROLLMENT NO. - 126440319120


ADDRESS

A/12/134,Krisnanager HouseingColony,Krisnanager,Naroda

Ahmedabad-382345



TEAM NAME G-1


B.S.P.P. 2014-15



FIRST NAME Utsav

LAST NAME Mistry

MOBILE NO. 1. 8735867636 2.




ADDRESS

9/ kirtikungsoc.Dhobigatroad,oppositeshahpurgate,Ahmedabad.



TEAM NAME G-1


B.S.P.P. 2014-15



FIRST NAME Shubham

LAST NAME Patel

MOBILE NO. 1.

7698280814 2.




ADDRESS

52 JayNagerSociety,Mhadevnager,Vastral Road, Ahmedabad- 382418.

BRANCH Mechanical Engineering.


TEAM NAME G-1


B.S.P.P. 2014-15


INDUSTRY PARTICULARS

---------------INDUSTRY COORDINATOR---------------

NAME Mr.Anilbhai P. Sharma.

CONTACT ADDRESS

A/ 938 Ambicanagar society,

Odhav Road,

Ahemadabad.

MOBILE NO. 9998425663

EMAIL

---------------INDUSTRY---------------

NAME ShriShivam Industries.

CONTACT

ADDRESS

B/4, Ambica Industries, Estate,

Near, Ambica Nagar,

G.I.D.C. Road, Odhav,

Ahemadabad- 382415.

CONTACT NO. MOBILE 9998425663

NAME OF INDUSTRIAL ESTATE Ambica Industrial Estate

COMPANY LOGO

B.S.P.P. 2014-15


SR. NO.

TOPICS NAME

PAGE NO.

1. Introduction. 2. Company Profile. 3. Project Description. 4. Design Calculation. 5. 2D Drawing & 3D Modelling. 6. Cost Estimation Calculation. 7. Conclusions. 8. Future Scope. 9. References.

INDEX

B.S.P.P. 2014-15


INTRODUCTION

ABTRACT

Project is predefined process which is Applicable on any Application.In that we include all details about our planning of application. There are two types of project one is IDP and other is UDP. IDP is industry defined project and UDP is user defined project.

We are making profile cutting machine. It is used for cutting the material in circular shape upto 7 inches. It is used in utensils industry. With this machine unskilled worker can also produce perfect shape and lots of time and material can be saved. In lathe machine process which material removes it is in powder form and it is useless. In our machine material is removed in chip form which can be sold and profit is earned.

PROBLEM DEFINITION

We can use the lathe machine also for cutting, but in lathe machine there is need skill workers for single lathe work and may be very long process and time consuming. And it also need more man power. In that spinning process with different types of dies are required. Profile cutting machine overcomes the lathe machine problem. It needs less man power and gives mass production. It takes less time for processing. It gives more profit than lathe machine. And not needed skilled worker only, there can be unskilled worker also.

SCOPE

During execution of this project, we will implement following areas:

• Design / Selection of main components. • Material selection. • Detailed 2D drawings of all components. • 3D models using parametric modelling software. • Select machines and manufacturing processes. • Prepare operation process chart, flow process chart, flow diagram. • Prepare operation and route sheets for various components. • Manufacturing and assembly of different parts. • Testing and problem solving.

B.S.P.P. 2014-15


COMPANY PROFILE:

Shivam Industries is middle scale industry established in year 2000 and is owned by Mr. Anil Sharma. They are pioneer in manufacturing of various machines like power press, deep drawing machines, preshearingprepartation machines and other job works.

Machines:

1. Lathe Machine (3 Nose) - 12 Feet

2. Lathe Machine (1 Nose) - 04 Feet

3. Horizontal Shaper Machine (1Nose) - 7 Feet

4. Verticle Shaper machine- (1Nose)- 5.5 Feet

5. Power press Machine (1 Nose) - 10 Feet

6. Drilling Machine (1 Nose) - 4 Feet

7. Drilling Machine (1 Nose) - 6 Feet

8. Arc Welding Machine (1 Nose) - 2 Feet.

B.S.P.P. 2014-15


Lathe machine specification:

Lathe machine size 12 feet: (3 Nose.)

Max. swing over bed- 280 mm. dia.

Max. swing over cross slide- 150 mm. dia.

Distance between centers- 610 mm.

Width of bed- 180 mm.

Spindle bore- 26 mm.

Inch thread can be cut- 8-35 TPI.

Max. travel of cross slide- 110 mm.

Max. travel of slide- 70 mm.

Motor power- 750 W.

Lathe machine 4 feet: (1 Nose.)

Max. swing over bed- 210 mm.

Max. length of work piece- 450 mm.

SpIndLe Bore- 20 mm.

Inch thread can be cut- 8-24 TPI.

B.S.P.P. 2014-15


Output power- 1000 W.

Diameter of chuck- 100 mm.

Voltage- 100-120V AC.

Spindle speed- 100-2000 rpm.

Frequency- 50/60 Hz

Horizontal shaper machine specification:

Horizontal shaper machine size 7 feet: (1 Nose.)

specification SP-475 SP-910 Table size 39”1/2*271/2” 98”*271/2” Front Extension support

98”

Height of work table

331/2” 331/2”

Spindle Dimension

Diameter 11/4” 11/4” stroke 8” 8” Speed(RPM) 3500/7000/1000 2900/4400/6000/7800/10000 Motor 71/2 HP,3 PH 10 HP,3 PH

B.S.P.P. 2014-15


Verticle Shaper Machine:

Verticle Shaper Machine Size 5.5 Feet: (1 Nose.)

Length of Ram Stroke- 660 mm.

Length of Ram- 1225 mm.

Width of Ram- 300 mm.

Max.DistanceFrom Table to Ram- 450 mm.

Min. Distance From Table to Ram- 50 mm.

Verticle Travel to Tool Slide- 140 mm.

Table Size- 610*380 mm.

Horizontal Travel to Table- 600 mm.

Verticle Travel to Table- 350 mm.

B.S.P.P. 2014-15


Power Press Machine Specification:

Power Press Machine Size 10 Feet: (1 Nose.)

Table length

1500

Table width 150

Clear pass

1060

Open height 250

Throat Depth 100

Weight 1500

Power 2 HP

B.S.P.P. 2014-15


Drilling Machine Specification:

Drilling Machine Size 4 Feet: (1 Nose.)

Max. drilling capacity- 32 mm.

Spindle stroke- 115 mm.

Spindle bore taper- MT3

Spindle speed (L) 55-350 r.p.m

Spindle speed (350-2300)

Coiumn Diameter 120 mm.

Net / gross weight- 310/360 kg.

B.S.P.P. 2014-15


Drilling Machine Size 6 Feet: (1 Nose.)

Drilling hole diameter- 400- 800 mm.

Drilling depth- 20 mm.

Machine Weight- 40 kg.

Max. drilling rod speed- 24.2 mm.

Max. MotorTorque- 29.2 mm.

B.S.P.P. 2014-15


Arc Welding machine specification:

Arc Welding machine size 2 Feet:

Input power- 50/60 Hz.

Rated input capacity- 53

Rated input current- 80

Efficiency- 0.88 %

Welding Speed- 43-250.

Insulation Grade- IP21S.

Weight- 60 kg.

Wire Feed Speed- 8-170.

Voltage Adj.Range- 24-44.

B.S.P.P. 2014-15


PROJECT DESCRIPTION

Profile cutting machine can be work by 1 hpmotor.In this machine motor connected with driving pully and Driving Pully connected with Driven Pully with help of V- Belt. Driven pully connected with pinion and pinion connected with main big gear. Main big gear connected with shaft 4 Adjustable gear.This gear box used in machine to reduce the rpm (1400 rpm covert in to the 350 rpm) Gear is connected to 2 shaft and 2 shaft connected with cutter. 2 cutter in between moved on work plate. Cutters are rotate in opposite direction. Work plate connected with table and chuck is fitted on work plate. We can increase and decrease the depth of cut by adjusting screw under the work plate. Work piece is moved due to the rotating of the cutters then after circular cutting can be cut. In this machine maximum circular profile cutting up to 7 inches.

In this project Following parts are Required to Manufacturing.

1.Table.

2. Work Plate.

3. Verticle Plate.

4. Shafts.

5. Gear.

6. Cutter.

During 5th Semester We have Concentrated on Designing and Drafting Aspects and Cost Estimation.

B.S.P.P. 2014-15


DESIGN CALCULATION

GEAR:

1. MAIN BIG GEAR:

Tooth= 75

Tooth Thickness= 30

Module= 2.5

Outer diameter= 192.5

Root diameter= 181.25

Pitch diamerter = 2 m

= 2 *2.5

= 5

Addendum= m

= 2.5

Dedendum= 1.25*m

=1.25*2.5

= 3.125

P.C.D.= No of teeth* Module

= 75 * 2.5

= 80

Pitch circle= 8.063

B.S.P.P. 2014-15


Shaft Adustiable Gear (2 Nose)

Tooth= 32

Tooth Thickness= 30

Module= 2.5

Outer diameter= 85



= 2 *2.5

= 5

Addendum= m

= 2.5

Dedendum= 1.25*m

=1.25*2.5

= 3.125


= 32 * 2.5

= 80

Pitch circle= 8.344

B.S.P.P. 2014-15


Adustiable Gear (2 Nose)

Tooth= 32

Tooth Thickness= 30

Module= 2.5

Outer diameter= 85



= 2 *2.5

= 5

Addendum= m

= 2.5

Dedendum= 1.25*m

=1.25*2.5

= 3.125


= 32 * 2.5

= 80

Pitch circle= 8.344

B.S.P.P. 2014-15


PINION

Tooth= 20

Tooth Thickness= 30

Module= 2.5

Outer diameter= 55

Root diameter=46.38


= 2 *2.5

= 5

Addendum= m

= 2.5

Dedendum= 1.25*m

=1.25*2.5

= 3.125


= 20 * 2.5

= 50

Pitch circle= 8.639

B.S.P.P. 2014-15


InvoluteGears Introduction

Thislessoncoversthedevelopmentof‘involute’gears.Aninvolutegearisbasedonaninvolute curve,whichisamathematicalshape.Tounderstandwhataninvoluteis,considerasimplecylinderandastringasshownbelow.Wrapthestringaroundthecylinder.Whilemaintainingtensiononthestring,tracethepaththattheendofthestringmakeswhileun-wrappingitaroundthecylinder.Thispathisaninvolutecurve.

Asimplecylinderandastring. Wrapthestringaroundthecylinder.

Pull Involute curve

Pullthestringtightandkeepittangenttothecylinder. Tracetheendofthestringwhileun-wrappingit around thecylinder.Theresultingtrajectoryisaninvolute

curve. Therearetwokeyparametersthatcontroltheinvolutecurve:thediameterofthecylinderandtheanglethatthestringisun-wrapped aroundthecylinder.Intheexampleabove,thestringisun- wrapped90º aroundthecylinder.

B.S.P.P. 2014-15


TheInvoluteCurve

Developmentofthemathematicalequationsfortheinvolutecurveusessimpletrigonometry.We willdeveloptheequationsfor90ºofonefullinvolute.Inotherwords,weareun-wrapping the string90º aroundthecylinderinacounterclockwisedirection.

Thecircumferenceofacircleisdefinedby: c=2 * π* r One quarter(90º) of thecircumferenceofacircleisthen: c= π* r/2

Inthefigurebelow,theline‘s’isthesamelengthasthepartofthecircumferencethestringhasbeenun-wrapped(s’).

xc, yc

θ

s

r x, y

s’

θ

0, 0 Wearetryingtodefinethiscurvebyfindingequationsforxandyasθ changes

Usingtrigonometry,wefindthat:

xc=r * cosθ x =xc+( s * sinθ ) yc=r * sinθ y=yc– ( s * cos θ )

B.S.P.P. 2014-15


DatumCurvesFromEquation

InPro/ENGINEER, datumcurvescanbedefinedusingmathematicalequations.Whenusingthisfeature, asystemvariable‘t’isused,thatvaries from0to1overthelengthofthecurve.Forthe involutecurve,lettheangle(ang)be equalto‘t’times90. Thismeansthatthevariable‘ang’will varyfromzeroto90º.

Todefine‘s’, we combinethecircumferenceequationand‘t’toform:

s =( π* r /2 ) * t Inthisexample,thediameterofthecylinderis1.500.Thisisthebasediameteringeardesignterminology.Theradius(r) of thecylinderis 0.75 inches.

Theequationsfor Pro/ENGINEERare:

r =0.75 ang=t* 90 s =(PI* r * t) /2 xc=0.75 * cos(ang) yc=0.75 * sin(ang) x=xc+( s * sin(ang)) y=yc– ( s * cos(ang)) z=0

Theresultingdatumcurveisshowninboldbelow.

B.S.P.P. 2014-15


CreatingtheGear

InPro/ENGINEER,thegearisstartedbymodelingacylinderattheoutsidediameterofthegear, seeFigure1.Severalsketchesarecreatedtodefinetherootdiameter, basediameter, andpitch diameterofthegear,seeFigure2.Next,theinvolute shapeddatumcurveiscreatedandmovedintothecorrectpositiontodefineonesideofonegeartooth, seeFigure3.Thecurve ismirroredandthegeartooth iscutintothecylinderusingtheedgeoftheinvolutedatumcurves,seeFigure 4.Thecutispatternedandroundsareaddedatthebaseofthegear.Thecompletedgearis shown in Figures5 and6.

Figure1 Figure2 Figure3

Figure4 Figure5

Figure6

Involute curve

B.S.P.P. 2014-15


GearParameters

Thefollowingaregeometricparametersingeardesign:

PitchDiameter DiametralPitch=PitchDiameter+( 2 * Addendum) RootDiameter CircularPitch=π/PitchDiameter OutsideDiameter NumberofTeeth=DiametricalPitch* PitchDiameter BaseDiameter Pressure Angle Addendum Dedendum ToothThickness ToothThicknessAngle FilletSize

Thefiguredescribessomeofthegearparameters.

Outsidediameter

Pitchdiameter

BasediameterRoot

diameter

Filletsize

Tooththicknessangle Tooththickness

Addendum

Dedendum

GearParameters

B.S.P.P. 2014-15


INVOLUTEGEARS Task1: Create adatumcurvedrivenbyanequation.

• PickFile,New, thenenter<involute_gear>for thenameofthenew part

• PickOKintheNewdialogbox

• PickInsert, ModelDatum,Curve,FromEquation,Done

• Selectthedefaultcoordinatesystem,thenpickCartesian

• In theNotepadwindow, enterthefollowingequations:

r =2.819 ang=t* 90 s =(PI* r * t) /2 xc=r * cos(ang) yc=r * sin(ang) x=xc+( s * sin(ang)) y=yc- ( s * cos(ang)) z=0

• PickFile,SaveandFile,ExitinNotepad

• PickOKinthedialogbox

• Theresultisshown here

RIGHT

CSYS_DEF

FRONT TOP

• Thiscurvewillbeusedtocreateaninvolutegear

B.S.P.P. 2014-15


Task2: Create acylinder.

• SelecttheFRONTdatumplane

• PicktheExtrudeicon

• Press andholdtherightmousebuttonandselectDefineInternalSketch

• PickFlipintheSketchdialogbox

• PickSketchintheSketchdialogbox

• Sketchacirclecenteredonthereferences,withadiameterof6.500,torepresentthe outsidediameterofthegear(seethefigureonthepreviouspage)

• Pickthecheckmarktocompletethesketch

• Enter<1.750 >for thedepththenpickthecheckmarkinthedashboardtool

• PickView,Orientation,StandardOrientation

• Theresultisshownbelow,besurethecurveisinfrontofthecylinderas shown

FRONT

TOP

A_1

RIGHT

B.S.P.P. 2014-15


Task3: Create threecirclesrepresentingthemajordiameters.

• CreateacircularsketchontheFRONTdatumplanewithadiameterof5.376to representtherootdiameterofthe gear

• CreateacircularsketchontheFRONTdatumplanewithadiameterof5.638to representthebasediameterofthe gear

• CreateacircularsketchontheFRONTdatumplanewithadiameterof6.000to representthepitchdiameterofthe gear

• Theresultisshown below Task4: Create adatumpoint.

• SettheselectionfiltertoDatums,picktheinvolutecurveand the6.000diameter circularsketch,thenpickthePoint icon andthenpickOKtocreateadatumpointas shown below

B.S.P.P. 2014-15


Task5: Create anotherdatumpointandadatumcurve.

•

BesuretheselectionfilterissettoDatums

• Pick RIGHT, TOP, andFRONTthenpickthePointicon thenpickOK

•

•

•

PickInsert, ModelDatum,Curve,Done

PickthetwodatumpointsthenpickDoneandOK

Theresultisshown below

Task6: Create adatumevaluatefeature.

• PickInsert, ModelDatum,Evaluate

• Enter<measure>forthenameofthefeature

• PickCreate, thenenter<angle>forthenameofthemeasurementparameter

• PickAngle,thenpicktheTOPdatumplaneandthecurveyoujustcreatedthroughthe points

• PickDonethenreadthemessagewindowandlookatthemodeltree

• Savethepart

B.S.P.P. 2014-15


Task7: Copytheinvolutecurve.

• SettheselectionfiltertoFeatures

• PicktheinvolutecurvethenpickEdit,Copy

• PickEdit,PasteSpecial

• AddthecheckmarknexttoApplyMove/Rotate transformationstocopiesinthedialogboxthenpickOK

• PickRotateintherightmousebuttonpopup menu

• Picktheaxisinthecenterofthecylinderthenenter< -30 > for therotationangle

• Pickthecheckmarkinthedashboardtool

• Theresultisshown

Task8: Addarelationandregeneratethepart.

• Doublepickthecopiedinvolutecurve(theonecreatedintask7)

• Doublepickthe30 dimension

• In thesmalltextbox, carefullyenter:

angle:FID_MEASURE+(7.5 /2 )

• PickYestoaddtherelation

• PickEdit,Regenerate


B.S.P.P. 2014-15 Page-


Task9: Mirrorthecopiedinvolutecurve.

• Pickthecopiedinvolutecurve(theonecreatedintask7) thenpickEdit,Mirror

• PicktheTOPdatumplanethenpickthecheckmarkinthedashboardtool


Task10: Copythecurveagain.

• Pickthecopiedinvolutecurve(theonecreatedintask7) thenpickEdit,Copy

• PickEdit,PasteSpecial

• AddthecheckmarknexttoApplyMove/Rotate transformationstocopiesinthedialogboxthenpickOK

• PickRotateintherightmousebuttonpopup menu

• Picktheaxisinthecenterofthecylinderthenenter< -15 > for therotationangle

• Pickthecheckmarkinthedashboardtool


B.S.P.P. 2014-15 Page-


Task11: Create anextrudedcut.

• Createanextruded(throughall)cutusingtheedgesofthecurvesas shown below

• Trimthesketchas shown below

• Theresultisshownatthebottomofthepage

Add thesetwolines,besuretogetthetangencyconstraintas shown

PicktheUseEdge iconthenselectthesecurves

B.S.P.P. 2014-15 Page-


Task12: Patternthecut.

• SettheselectionfiltertoFeaturesthenpickthecutyoujustcreated

• PickEdit,Pattern,thensetthetypeofpatterntoAxisinthedashboardtool

• Selecttheaxisinthecenterofthecylinder

• Enter<24 >forthenumberofinstancesinthepattern

• Enter<15>fortheincrementangle

• Pickthecheckmarkinthedashboardtooltocompletethepattern

Task13: Finishthepart.

• Createa0.020 round atthebaseofthegeartooth

• Patterntheround

• Createacoaxialholewithadiameterof2.000

• Use Layerstohidethedatumcurvesandsketches

• Thecompletedpartisshown below

• SavethepartandClosethewindow

B.S.P.P 2014-15 Page -


2D Drawing /3D Modeling

PINION :

55 5

20

3

B.S.P.P 2014-15 Page -


PINION

B.S.P.P 2014-15 Page -


SHAFT ADUSTIABLE GEAR (4 NOSE.)

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE MAIN BIG GEAR (1 NOSE.)

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE CUTTER :

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE TABLE :

900

B.S.P.P 2014-15 Page -


TABLE :

B.S.P.P 2014-15 Page -


WORK PLATE :

203,2 4064

4045 4064

101,6

2032

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE WORK PLATE :

B.S.P.P 2014-15 Page -


VERTICLE PLATE :

150

47.5 400

60

45

30 300

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE VERTICLE PLATE :

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE SHAFT : 1

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE SHAFT 1 :

B.S.P.P 2014-15 Page -


SHAFT-2 :

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE SHAFT-2 :

B.S.P.P 2014-15 Page -


Cost Estimation Calculation :

Table :

Matarial- M.S. /All slide

910*200 mm.

We are welding on two slide

Welding on both angle= 910+200

=1110 mm.

Total Welding = 1110*2

= 2220

Welding for supporting beam= 610 mm.

Total Welding length= 2220+610

= 2830 mm.

Labour cost= Rs. 250/ shift

= 250/8

= 31.25 Rs. Per/ hr.

= 0.52 RS/ hr.

Welding time= 2 m/ hr.

= 2000/60 mm/ h

= 33.33 mm/hr.

Total Welding time = Total Welding length/ Welding time

= 2830/33.33

= 84.90/60

= 1.415 hr.

Total labour cost= Total Welding time + labour cost

= 84.90* 0.52

= 44.148 Rs.

B.S.P.P 2014-15 Page -


Material cost :

Electrode used= Total Welding length/ Welding consumption/ mm welding.

= 2830/135

= 20.96 rod.

Total Matarial cost= use of welding rod* rate of rod.

= 21*2.5

= 52.5 Rs.

Power cost :

Power cost= Total power consumption

= V*I/N*100 *Welding time

= 220*21/0.6*100*84.90/60

= 10.895. kwhr.

Total Power cost= Total Power consumption * Power rate.

= 108* 3.15

= 340.2 Rs.

Total Cost= labour cost + Total Material cost+ Total Power cost

= 44.148+ 52.5 + 340.2

= 436.84 Rs.

Other Overhead Cost/Tranportation :

Total Welding Cost of job= Total cost + Other Overhead cost

= 436.84 + 44

= 480 Rs.

B.S.P.P 2014-15 Page -


GEAR :

1. MAIN BIG GEAR: (1 Nose.)

No of index = 75

Tooth Thickness= 30

Feed= 35 mm/min.

Length= 30 mm.

Overall A+O= 10 MM.

Milling Time T= L+( A+O) / per minute.* No of Index.+Set up Time.

= 30+10/35*75+10

= 95 min.

PINION : (1 Nose.)

No of index = 20

Tooth Thickness= 30

Feed= 35 mm/min.

Length= 30 mm.

Overall A+O= 10 MM.


= 30+10 / 35*20+10

= 32.85 min.

B.S.P.P 2014-15 Page -


Shaft Adustibalegear : (4 Nose.)

No of index = 32

Tooth Thickness= 30

Feed= 35 mm/min.

Length= 30 mm.

Overall A+O= 10 MM.


= 30+32/35*32+10

= 66.68 min.

Pully :

Step-1= 3.14/4 400*1.5

= 471 cm.^3

Step-2= 3.14/4* 36*1.5

= 42.41 cm^3

Step= step 1- step 2

= 471- 42.41

= 428.59 cm^3.

Weight of step Pully= Weight of Pully * Density.

= 428.59* 7.2/1000

= 3.085 kg.

B.S.P.P 2014-15 Page -


COST ESTIMATION

Material Estimation Cutter box plate (2 nose) 1800 Upper cutter shaft safe Adjustiable plate (2 nose)

800

Upper shaft and lower shaft 1000 Lower shaft (Pully) 800 Shaft chuck (4 Nose) 400 Shaft bearing (4 Nose) 700 Main big drive gear 400 Pinion 100

Shaft adjustiable gear (2 Nose) 400 Adjustiable gear (2 Nose) 400 Adjustiable gear bearing (2 Nose) 200 Adustiable gear pin (2 Nose) 200 Adustiable gear plate,vertical plate 1500 Pinion gear shaft (1Nose) 600 Pinion gear shaft box (1 Nose) 300 Cutter (2 Nose) 1600 T-stand 1000 Key (6 Nose) 100 Pully 150 Motor (1hp) 2500 Total 14,950

B.S.P.P 2014-15 Page -


CONCLUSION

In this project we learnt different design software for 2D and 3D drawing software like, Autocad and Creo etc.

We understood concepts of Establish cost Estimation in our project.

In this project We learnt different parts of machine in industry.

B.S.P.P 2014-15 Page -


FUTURE SCOPE

In future we will make product’s design and working model in next six Months then our project will complete.

In industry future scope.

To reduce the number of gear.

Less power motor can be used.

Machine can be make Automatic.

Large machine can be obtained.

B.S.P.P 2014-15 Page -


REFERENCES

We have taken the reference from industrial visit in company shrishivam industries.

We have taken design data books like, Element of Machine Design :

Publication- Charotar. Author- N.C. Pandya.

Machine Design : Publication- Sigma serious. Author- S.K. Kulkarni.

Design of Machine Element : Publication- person. Author- M.F. Spotts. T.E. Shoup L.E. Hornberger. S.R. Jayaraman.

A Text-book of metrology : Publication- M. Mahajan. Author- M. Mahajan. Related links :

www.faadooengineers.com/.../14868-Machine-design-DATA-book.

seminarprojects.org/.../design-data-book technologies.

www.rpccbe.ac.in/wp-content/uploads/machine-design-databook.

www.engineering108.com/Data/.../Handbooks/machine_design_databook.

www.quora.com/From-where-can-I-get-a-design-data-book-of-machine-element.

accessengineeringlibrary.com/.../machine-design-databook.

www.conti-online.com/download /download / technical data book.

B.S.P.P 2014-15 Page -

PROFILE CUTTING MACHINE - DSpace at Ganpat...

Documents

Transcript of PROFILE CUTTING MACHINE - DSpace at Ganpat...