Machine required for completion of above project

1. ARC Welding Machine,

2. Drilling Machine, Grinder,

Parts lists

1. Motor =1
2. gear box =1
3. battery supply =1
4. Operator switches as required
5. Mounting Fabrication =1
Welding

Arc welding is one of several fusion processes for joining metals. By applying
intense heat, metal at the joint between two parts is melted and caused to
intermix - directly, or more commonly, with an intermediate molten filler metal.
Upon cooling and solidification, a metallurgical bond is created. Since the
joining is an intermixture of metals, the final element potentially has the same
strength properties as the metal of the parts. This is in sharp contrast to non-
fusion processes of joining (i.e. soldering, brazing etc.) in which the mechanical
and physical properties of the base materials cannot be duplicated at the joint.
In arc welding, the intense heat needed to melt metal is produced by an electric
arc. The arc is formed between the actual work and an electrode (stick or wire)
that is manually or mechanically guided along the joint. The electrode can either
be a rod with the purpose of simply carrying the current between the tip and the
work. Or, it may be a specially prepared rod or wire that not only conducts the
current but also melts and supplies filler metal to the joint. Most welding in the
manufacture of steel products uses the second type of electrode.

Equipment
The equipment for the shielded metal arc welding process consists of a power
source, welding leads, electrode holder, and work clamp or attachment. A
diagram of the equipment is shown below.

Composition carbon 0.20 % - 0.25 %

Manganese max 0.8%

Sulphur, max 0.05%

Phosphorus, max 0.05%

Silicon, max 0.25 %

Iron remainder
Yield stress : 280 N/mm^2

Hardness : 170 BHN

1) Cast iron

Composition
carbon: 2.0 % -
4.0 %

Manganese max: 0.4% -1.0%

Sulphur, max: 0.05% -0.1%

Phosphorus, max : 0.07%

Silicon, max : 0.1 % - 4%

Iron : remainder

Tensile strength : 100 to 200 N/mm ^2

Yield stress : 28 kgf/mm^2

Compressive strength: 400 TO 1000 N/MM^2

Shear stress : 120 N/MM^2

 COST ESTIMATION
Cost estimation may be defined as the process of casting the expenses
that must be incurred to manufacture a product. These expenses take into a
consideration all expenditure involved in design and manufacturing with all
related services facilities such as pattern making , tool , making as “well as a
portion of the general administrative and selling cost.

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 company.

2) Check the quotation supplied by venders.

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 OF TWO
TYPES.

1. Material cost.
2. Machining cost.

 MATERIAL COST ESTIMATION :

Material cost estimation gives the total amount required to collect material which the
raw has to be processed or fabricated to desired size and functioning of the
components.
These materials are divided into two categories.

1. Material for fabrication :

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

finished size for proper functioning of the components .

2. Standard purchased parts.

This includes the part which was readily available in the market like
Allen screws etc. A list in for chard by the estimation stating the quality ,
size and standard parts , the weight of raw material and cost per kg for
the fabricated parts.

 MACHINING COST ESTIMATION:

This cost estimation is an attempt to forecast the total expenses that may include
manufacturing part from material cost. Cost estimation of manufacturing parts
can be considered as judgment on and after careful consideration which
includes labor, material and factory services required to produce the required
parts.
PROCEDUER 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 divided into two Categories

a. Fabricated components
b. Standard purchase components.
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchase taken and added up

Material cost:

Sr no Part name material cost

1 angle frame M.S 850/-
2 Plate(75*20*0.7) M.S 200/-
3 tyres - 550/-
4 Motor - 950/-
5 Wiring - 250/-
6 Ply - 550/-
7 Gear C.I 850/-/-
11 shaft M.S 700/-
13 other - 1000/-

TOTAL ------/-

Machining cost
Here we have to work on the different m/c for operation. So the machine is
being hired For that much period of time. Considering the depreciation and
the electric light bill along with the rent of work shop or the initial
investment, the machining cost is calculated as the cost in Rs / hr
 Sr operation rupees
no.
1 Boring 400/-
3 painting 200/-
4 welding 500/-
6 drilling 500/-
7 cutting 500/-
---/-
Total

Labour cost

the Labour cost consists of the amount increased on the wages paid to the
operators. The cost is calculated based on the calculation of the hourly wages,
paid to the operators. Here the operators are considered as the skilled operator.
 Testing of Machine Parts

1) Testing of Body or frame

The testing of whole body or frame of the machine which the whole weight of
machine with respect to ground is essential. Because the angles of the body
should be at right angle to ground and flywheel, shafts and other parts are
installed on the body. Alignment of frame must be accurate which in turn
depends on perpendicularity of vertical & horizontal angles. Bush mountings
should be put on the mounting plate parallel to ground and shaft will be passing
through it. For paddle and control lever should be mounted by proper
adjustment on body. Distance of centre of shaft with ground should be maintain
constant and should avoid blocking of motion of shaft.

1) Roundness of shaft

The shaft which is used as the main power transmission member in the machine
should be in perfect round condition. The roundness of the shaft should be
checked properly by using V block and height gauge and also by micrometer so
that the standard deviation should not more than +0.05 mm. The precision
should maintain all over the surface of the shaft and outer face of the shaft
should be harden to the RC30 to RC45 so that it should not wear out easily and
not to lose its circularity.

4)Error in alignment :
The testing of alignment of shaft with the flywheel and all the other parts with
each other should be checked properly so that the mechanism should work
properly. Misalignment may give rise to the cyclic fatigue set up in related parts
and parts may undergoes severe fatigue which results in sudden failure of the
machine parts without any pre symptoms.

To avoid this all parts should be checked to ± 0.05 mm standard deviation

which is much more in some cases' So much care should be taken in assembly
of all members of the mechanism.

6) Noise

The noise level in the working model should not more so that to disturb
others. More noise means more friction being taken place in the mechanism
which
could be minimize by proper oiling and greasing and proper alignment of all
parts
where noise generation taken place.
 Testing of Machine Parts

2) Testing of Body or frame

The testing of whole body or frame of the machine which the whole weight of
machine with respect to ground is essential. Because the angles of the body
should be at right angle to ground and flywheel, shafts and other parts are
installed on the body. Alignment of frame must be accurate which in turn
depends on perpendicularity of vertical & horizontal angles. Bush mountings
should be put on the mounting plate parallel to ground and shaft will be passing
through it. For paddle and control lever should be mounted by proper
adjustment on body. Distance of centre of shaft with ground should be maintain
constant and should avoid blocking of motion of shaft.

2) Roundness of shaft

The shaft which is used as the main power transmission member in the machine
should be in perfect round condition. The roundness of the shaft should be
checked properly by using V block and height gauge and also by micrometer so
that the standard deviation should not more than +0.05 mm. The precision
should maintain all over the surface of the shaft and outer face of the shaft
should be harden to the RC30 to RC45 so that it should not wear out easily and
not to lose its circularity.

4)Error in alignment :
The testing of alignment of shaft with the flywheel and all the other parts with
each other should be checked properly so that the mechanism should work
properly. Misalignment may give rise to the cyclic fatigue set up in related parts
and parts may undergoes severe fatigue which results in sudden failure of the
machine parts without any pre symptoms.

To avoid this all parts should be checked to ± 0.05 mm standard deviation

which is much more in some cases' So much care should be taken in assembly
of all members of the mechanism.

6) Noise

The noise level in the working model should not more so that to disturb
others. More noise means more friction being taken place in the mechanism
which
could be minimize by proper oiling and greasing and proper alignment of all
parts
where noise generation taken place.
 BIBLOGRAPHY:

MACHINE DESIGN SIR VINOD THOMBRE

PATIL
PRODUCTION HAZRA AND
TCHHNOLOGY CHAUDHARY
WORKSHOP R.K. JAIN
TECHNOLOGY
MACHINE AUTOMOBILE KRIPAL SING
ENGEERING