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Transcript of vertical milling attachment
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ABSTRACT
The Project is based on attaching an additional VERTICAL MILLING ATTACHMENT to
the HORIZONTAL BORING MACHINE. The objective of project is to reduce the time required to
setting of the job this type of work is fatigue to the operator. Another objective is to produce jobs
having more accuracy.
All these results are accompanied by accurate design and
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COMPANY PROFILE
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COMPANY INFORMATION
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CHAPTER 1
COMPANY INFORMATION
NAME: GEAR TORQUE TRANSMISSIONS
ADDRESS: PLOT NO.W-48, Additional M.I.D.C., Satara, Maharashtra, (INDIA)
PRESENT PRACTICES & PROBLEMS
1. For machining the two mutually perpendicular face they machine 1st face & after that
they rotate the job & machine 2nd face
2. For heavy jobs it becomes fatigue to rotate the job
3. It is also time consuming for setting & clamping the job
SUGGESTIONS ON PROBLEM
1. Vertical Milling Attachment driven by same drive
2. Vertical Milling Attachment driven by same drive with gearing attachment
3. Vertical Milling Attachment driven by same drive with clutch system
4. Vertical Milling Attachment with independent driven drive
CHAPTER 2
LITERATURE REVIEW
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To complete our project design we refer following Design Data Books &
Reference Books.
1. PSG design data book:We use PSG design data book for the design of gear. We refer chapter bevel gear &
according to the formulae we complete our design.
2. CMTI design data hand book:
We refer material specification of gear & shaft, various stresses of material & also
design of gear from the CMTI hand book.
3. MACHINE DESIGN by V.B. BHANDARI:
For the calculation of forces acting on the gear & shaft we refer reference book of
machine design. We refer chapter bevel gear for gear design & force calculations.
4. MACHINE DESIGN by R.S. KHURMI:
For the calculations of the shafts, keys & also for the design of gear we use this book.
We refer chapter design of shaft for shaft & key design.
5.IS STANDARD FOR SELECTION OF BEARING
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CHAPTER 3.
DESIGN
SELECTION OF MOTOR
Required RPM: 500
Motor Specification: 3Phase Induction Motor
RPM: 1440
Torque:
We selected the available motor from company.
DESIGN OF BEVEL GEAR
Abbreviations:
m= Module
= Pitch Angle
i= Gear Ratio
b= Face Width
mt =Transverse Module
mn = Normal Module
Zp=No. of Teeth on Pinion
Zg=No of Teeth on Gear
R1= Cone Distance
dp= Reference Diameter For Pinion
dg= Reference Diameter For Gear
dpt= Tip Diameter Of Pinion
dpg= Tip Diameter Of Gear
Zcw= No of Teeth Crown Wheel
Zu = Minimum No of Teeth on Pinion to Avoid the Undercutting
m= Helix Angle
= Pressure Angle
ap= Addendum Angle For Pinion
ag = Addendum Angle For Gear
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c = Clearance
ap= Tip Angle For Pinion
ag= Tip Angle For Gear
rp= Root Angle For Pinionrg= Root Angle For Gear
ha= Tooth Height
hd= Tooth Height
DESIGN:
By considering required speed
We assume,
m=3, Zp=24, Zg=72
i=Zp/Zg
=20/60
=1/3
i =1:3
1. for ,Tan =i
Therefore, =tan-1 (i)
=tan-1(1/3)
=18.430
2. for mt,
mt=mm+
=3+
mt =3.1mm
3. for mm
mm= mtX cosm
=3.12Xcos0 .......... (since, m=0)
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=3.1mm
4. For cone distance R
R=0.5Xmt Zp2+Zg2)
=0.5X3.12X 242 +722)
=117.636mm
5. Reference diameter,
dp=mt X Zp
=3.12X 24
=74.4mm
dg=mt X Zg
=3.12 X 72
=223.2mm
6. Tip diameter
dpt= mt X (Zp+ 2cosp)
= 3.12 X (24+2cos18.43)
= 80.28mm
dgt= mt X (Zg+ 2cosg)
= 3.1 X (72+2cos71.57)
=225.160mm
7. No of teeth on crown wheel
Zcw=2R/mt
=
=75.89mm
8. Minimum no of teeth on pinion to avoid undercutting
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Zu=
= .................... (=200)
=16.22
9. Addendum angle
tan ap= tan ag =
ap = ag = tan-1
ap = ag =1.50
10. dedendum angle
tan dp= tan dg =
dp = dg = tan-1
dp = dg =1.810
11. tip angle
ap = + ap
=18.43 + 1.5
=19.930
ag = + ap
= 71.57 + 1.5
= 73.070
12. Root angle
rp = dp
= 18.43 1.81
= 16.620
rg = dg
= 71.57 1.81
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= 69.760
13. Tooth height, h
h= ha + hd
ha = mt
=3.1mm
hd = 1.1236 mt ................. (Reinecker)
=3.50mm
GEAR TOOTH PROFILE
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FORCES ACTING ON GEAR TOOTH
Abbreviations:
b = Ultimate tensile stress
P = Power in kW
Np = Speed of pinion in rpm
Ng = Speed of gear in rpm
rm = Radius of pinion at midpoint of face-width
Ps = separating force between two meshing teeth
Pt = tangential or useful component
Mt = torque transmitted by gear
Pa = axial component on pinion
Pr = radial component on pinion
1. ultimate tensile stress
b =63kgf/mm2
= 63 X 9.81
= 618.03 N/mm2
= 620 N/mm2
2. power to be transmitted by the motor
1.5kW @ 1440 rpm
3. for radius of the pinion at midpoint of face width
rm =
=
=32.45mm
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4. Tangential or useful component
Pt=
But, mt= Pt X rm
Therefore
mt=
= 9947.18 N-mm
Pt=
=
= 306.53N
5. separating force between two meshing teeth
Ps=Pt tan
=306.53 tan20
=111.57 N
6. axial component on pinion
Pa=Pssin
=111.57 X sin18.43
=35.27 N
7. radial component on pinion
Pr=Ps cos
= 111.57 cos18.43= 105.84 N
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8. axial component on gear
Pa= Pttan tan
=376 X tan20 Xsin18.43=43.26 N
9. radial component on gear
Pr=Pt tan sin
= 306.63Xtan20Xsin18.43
=35.27N
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Strength of Bevel Gear:
Abbreviations:
Wt=strength of wear gear
o=shear start
yp= form factor for pinion
yg=form factor for gear
Zep=equivalent teeth of pinion
Zeg=equivalent teeth of gear
Cv=velocity factor
1. Wt=( o*Cv)*b**n*y*
o= 620/1.5
=413.34 N/mm2
`Form factor for pinion
Yp=0.154-
Zep=Zpsec
=20*sec18.43
=21.08
Therefore,
Yp=0.154-
=0.1107
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Vm=
=
=4.70 m/s
Therefore,
Cv=
=
=1.78
Wt=413.34 X 1.78 X 30 X X 3 X 0.1107 X
=17155.75117 N
2. form factor for gear
yg=0.154-( )
Zeg=Zg sec
=60sec18.43
=63.24
yg=0.154-
=0.139
Wt=413.34 X 1.78 X 30 X X 3 X 0.139 X
=21539.35 N
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WEAR STRENGTH:
Sw=wear strength
Q=
=
=1.80
k=0.16( )2
=0.0484 N/mm2
Wear strength
Sw=
=
=123.97 N
Effective loadPeffbetween two meshing teeth is given by
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Peff=
=
=264 N
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DESIGN OF SHAFT
d= 0.5R
= 0.5 X 117.63= 58.82mm
d1= 1.6 X d
= 1.6 X 58.82
= 94.1088mm
a= 0.2 X R
= 0.2 X 117.63
= 23.53mm
c= 0.3 X d= 0.3 X 58.82
= 17.64mm
l= 1.1 X d
= 1.1 X 58.812
= 64.70mm
TAPER BERINGS SELECTION
SELECTION OF BEARINGS
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STANDARD TABLE FOR BEARING
Selected bearings- SKF DESIGNATION 32208 & 32210
CHAPTER 4
ASSEMBLY AND PART DRAWINGS
1) PART DRAWINGS
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GEAR DESIGN:
PINION DESIGN:
BASE PLATE:
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INPUT SHAFT:
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OUTPUT SHAFT:
VERTICAL BEARING FLANGE:
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HORIZONTAL CASING:
45O ATTACHMENT
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VERTICAL CASING:
HORIZONTAL BEARING FLANGE:
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ASSEMBLY DRAFTING
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CHAPTER 5
CRITICAL PATH METHOD DIAGRAM
Activity Name of Activity Immediate
Predecessor
Duration(in
days)A Project search - 20
B Project finalization A 5
C Documentation B 30
D Design C 30
E Analysis and force calculation D 15
F Manufacturing of pinion E 1H Manufacturing of gear F 2
G Manufacturing of input shaft H 2
I Manufacturing of output shaft G 3
J Manufacturing of bearings H,I 1
K Manufacturing of flanges J 3
L Manufacturing of horizontal casing K 2
M Manufacturing of vertical casing K 3
N Manufacturing of 450attachment L,M 4
O Nut and bolts L 0
P Manufacturing of support O 4Q Motor selection P 1
R Assembly Q 15
S Testing R 10
T Painting S 5
U Attachment T 5
TOTOL DAYS= 161
days
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Critical path-
1-2-3-4-5-6-8-9-10-11-13-14-15-16-17-18-19-20
Total duration= 133 Days.
Activity Duration Earliest time Latest time Total floatStart Finish Start Finish
1-2 20 0 20 0 20 0
2-3 05 20 25 20 25 0
3-4 7 25 32 20 32 0
4-5 30 32 62 32 62 05-6 15 62 77 62 77 0
6-7 1 77 78 79 80 2
6-8 2 77 79 77 79 0
7-9 2 78 80 80 82 2
8-9 3 79 81 79 82 0
9-10 1 82 83 82 83 0
10-11 3 83 86 83 86 0
11-12 2 86 88 90 92 4
11-13 3 86 89 86 89 012-14 1 88 89 92 93 4
13-14 4 89 93 89 93 0
14-15 4 93 97 93 97 0
15-16 1 97 98 97 98 0
16-17 15 98 113 98 113 0
17-18 10 113 123 113 123 0
18-19 5 123 128 123 128 0
19-20 5 128 133 128 133 0
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CHAPTER 6
BILL OF MATERIAL
Sr. No. Part name Material No off Make/buy1 SUPPORT MS 1 Make
2 BEVEL GEAR
a) PINION
b) GEAR
EN 353
EN353
1
1
Make
Make
2 HORIZONTAL CASING MS 1 Make
3 INPUT SHAFT EN 36 1 Make
4 OUTPUT SHAFT EN 36 1 Make
5 BEARING SUPPORT FLANGE
a) INPUT SHAFT
b) OUTPUT SHAFT
MS
MS
1
1
Make
Make
6 TAPER BEARING
a) INPUT SHAFT
b) OUTPUT SHAFT
B.S.
B.S.
1
1
Buy
Buy
7 45 ROTATION
ATTACHMENT
MS
(HARDENED)
1 Make
8 BOLT
a) M 12
b) M 16
EN 8
EN 8
28
06
Buy
Buy
9 NUT
a) M 16 EN 8 06 Buy
EN 353 Case Hardened Steel - 251570
MATERIAL COMPOSITION - 15Ni 2Cr 1Mo 15
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CHAPTER 7
CONCLUSION
After completion of design of VERTICAL MILLING ATTACHMENT for
horizontal boring machine, a final design is submitted to the company. The company is
satisfied with our work and also we had a great experience working with the company.
The cost of purchasing of new machine for milling is very high. By using our
attachment the cost is reduces. Also at one time we not only bore but also mill the same job
as per requirement.
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CHAPTER 8
REFERANCES
1. DESIGN DATA BOOK (PSG)
2. MACHINE DESIGH BY V.B. BHANDARI
3. CMTI
4. MACHINE DESIGN BY KHURMI GUPTA
5. ISO STANDARD
6. MACHINE TOOL DESIGN BY N.K. MEHTA