BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
K.KRISHNA MOULI (13B21A0303)
CERTIFICATE
This is to certify that the project report entitled “FABRICATION OF MULTI
PURPOSE DRILLING,GRINDING, SHAPING & CUTTING MACHINE” being submitted
by K.KRISHNA MOULI(13B21A0303), G.GIRI SEKHAR (13B21A0319), N.SRINIVAS
(13B21A0328), A.VAMSI KIRAN(13B21A0322), K.LOKESH(13B21A0302), M.DURGA
PRASAD (14B25A0310) in partial fulfillment of the requirement for the award of Degree of
Bachelor Of Technology in Mechanical Engineering, Kakinada Institute Of Engineering &
Technology, Korangi, is a record of bonafide work carried out by them under my guidance.
The results embodied in this project have not been submitted to any other University or
Institute for the award of any degree.
With profound sense of reverence and gratitude, we express our sincere thanks to our
revered project guide Mrs. N.V.LAKSHMI, M.Tech., (Ph.D) Asst. Professor, Kakinada
Institute of Engineering & Technology, J.N.T.U Kakinada, for her valuable guidance and support
in accomplishing this Project work.
Our deepest gratitude to Dr. T.V.R. RAVI KUMAR, Head of the Department, Mechanical
Engineering, Kakinada Institute of Engineering & Technology, J.N.T.U Kakinada, for his
extended support.
We wish to express our gratitude to all the Teaching and Non-Teaching Staff of
Mechanical Engineering Department, Kakinada Institute of Engineering & Technology, JNTUK
for their Direct and Indirect aid provided to us in completing the Project.
Finally, we would like to thank one and all who have helped us in successfully completing
this project.
With Regards :
K.KRISHNA MOULI (13B21A0303)
G.GIRI SEKHAR (13B21A0319)
T.V.N.MURTY (13B21A0313)
N.SRINIVAS (13B21A0328)
A.VAMSI KIRAN (13B21A0322)
K.LOKESH (13B21A0302)
M.DURGA PRASAD (14B25A0310)
DECLARATION
With Regards :
K.KRISHNA MOULI (13B21A0303)
G.GIRI SEKHAR (13B21A0319)
T.V.N.MURTY (13B21A0313)
N.SRINIVAS (13B21A0328)
A.VAMSI KIRAN (13B21A0322)
K.LOKESH (13B21A0302)
M.DURGA PRASAD (14B25A0310)
CONTENTS
1.3 METHODOLOGY
1.3.1 SCOTCH YOKE MECHANISM 4
1.3.2 CONSTRUCTION 4
1.3.3 APPLICATIONS 5
2.1 DRILLING 7
2.2 CUTTING 10
2.3 SHAPING 11
2.3.1 OPERATION 11
2.3.2 ADVANTAGES 12
2.4 GRINDING 13
2.4.1 PROCESSES 13
6 COMPONENTS 19-48
6.7 HACKSAW 34
6.8 SHAPER 36
6.11 PULLEYS 44
6.12 BENCHVICE 46
6.13 SPRING 47
7 MANUFACTURING 49-51
8 ASSEMBLY 52-55
11 REFERENCE 64
LIST OF FIGURES
FIG NO TITLE PAGE NO
1.3.1 SCOTCH YOKE MECHANISM 4
This model facilitates us to get the different operations performed at one place
simultaneously as it is getting drive from the single power source. Objectives of this model are
conservation of electricity (power supply), reduction in cost associated with power usage,
increase in productivity and reduced floor space.
Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine
1. INTRODUCTION
Industries are basically meant for production of useful goods and services at low
production cost, machinery cost and low machinery cost. Today in this world every task have
been made quicker and fast due to technology advancement, but this advancement also demands
huge investments and expenditure, every industry desires to make high productivity rate
maintaining the quality and standard of the product at low average cost. In an industry a
considerable portion of investment is being made for machinery installation. At present
industries are using different machines for various operations according to their demands. These
machines takes lot of place for installations and also consume much of the electricity. The
production rate may vary from desired rate as the materials should be transported from one
operating machine to another.
Before starting our work we have undergone through many research papers which
indicates that for a production based industries machine installation is a tricky task as many
factor being associated with it such as power consumption (electricity bill per machine),
maintenance cost, no of units produced per machine i.e. capacity of machine, time consumption
and many more….
Some research papers which have led us to approach to the idea of a machine which
may give solution to all these factors are as follows:
These students designed and developed a multi purpose machine which is capable of
performing only three operations at a time i.e. drilling, sawing and shaping operations. This
machine is made of wood completely. So this machine is just a prototype and cannot bear high
vibrational forces when the machine is in working condition. The power required for this
machine is given through a single motor. This design is useful in this ideal world because of less
manufacturing cost as it is made of wood. And also it requires less work space and useful for
house hold purposes.
By looking at all of the above research papers we have understood that Multi
Purpose Machines are made with either two or three operations working at a time. And also these
machines are made through work with human power with pedal operating. So these kind of
machines are not much efficient. So we fabricated a machine which can do four operations at a
time and works with a single motor. By this machine the time taken for machining will be less
and requires less space. Small scale industries are the one who are mostly benefited by this
machine..
1.3 METHODOLOGY
The Scotch yoke is a reciprocating motion mechanism, converting the linear motion
of a slider into rotational motion, or vice versa. The piston or other reciprocating part is directly
coupled to a sliding yoke with a slot that engages a pin on the rotating part. The location of the
piston versus time is a sine wave of constant amplitude, and constant frequency given a
constant rotational speed.
1.3.2 Construction
The scotch yoke mechanism is constructed with iron bars. Here the crank is
made in some length and the yoke is also made using the same material. It is noted that the
minimum length of the yoke should be double the length of the crank. The crank and yoke is
connected with a pin. Iron bars are welded to both sides of the yoke to get the reciprocating
motion. The yoke with the iron bars is fixed on the display board with the help of c clamp.
Now the crank is welded to the end of the shaft of the motor. Now the pin on the crank is
connected to the yoke. The pin used to connect yoke and crank is a bolt.
The term scotch yoke continues to be used when the slot in the yoke is shorter than
the diameter of the circle made by the crank pin. For example, the side rods of a locomotive
may have scotch yokes to permit vertical motion of intermediate driving axles.
1.3.3 Applications
This setup is most commonly used in control valve actuators in high-pressure oil and
gas pipelines.
Although not a common metal working machine nowadays, crude shapers can use
Scotch yokes. Almost all those use a Whitworth linkage, which gives a slow speed
forward cutting stroke and a faster return.
It has been used in various internal combustion engines, such as the Bourke engine,
and many hot air engines and steam engines.
The term scotch yoke continues to be used when the slot in the yoke is shorter than
the diameter of the circle made by the crank pin. For example, the side rods of a locomotive
may have scotch yokes to permit vertical motion of intermediate driving axles.
a. Watt’s linkage
b. Chebyshev linkage
c. Hoeckens linkage
d. Roberts Mechanism
a. Hart’s inversor
b. Sarrus linkage
c. Tusi Couple
d. Quadruplanar - inversor
Watt’s Linkage
Watt's linkage is a type of mechanical linkage in which the central moving point of
the linkage is constrained to travel on an approximation to a straight line. These linkages are
mostly used in Double – acting piston and automobile suspension.
Chebyshev linkage
Hart’s inversor
Hart's inversor is a mechanisms that provides a perfect straight line motion without
sliding guides. It can be used to convert rotary motion to a perfect straight line by fixing a
point on one short link and driving a point on another link in a circular arc.
Sarrus linkage
2. OPERATIONS PERFORMED
2.1 DRILLING
The drilling operation can also be accomplished in lathe, in which the drill is held in tail
stock and the work is held by the chuck.
The most common drill used is the twist drill.
It is the simplest and accurate machine used in production industries.
The work piece is held stationary i.e., clamped in position and the drill rotates to make a
hole.
Cutting fluid is commonly used to cool the drill bit, increase tool life, increase speeds
and feeds, increase the surface finish, and aid in ejecting chips. Application of these fluids is
usually done by flooding the work piece with coolant and lubricant or by applying a spray mist.
a) Spot Drilling
b) Centre Drilling
c) Deep Hole Drilling
d) Gun Drilling
e) Trepanning
f) Micro Drilling
g) Vibration Drilling
h) Centre Interpolating
a) Spot Drilling
The purpose of spot drilling is to drill a hole that will act as a guide for drilling the
final hole. The hole is only drilled part way into the work piece because it is only used to guide
the beginning of the next drilling process.
b) Centre Drilling
Center drill is a two-fluted tool consisting of a twist drill with a 60° countersink; used
to drill countersink center holes in a work piece to be mounted between centers for turning or
grinding.
Deep hole drilling is defined as a hole depth greater than ten times the diameter of
the hole. These types of holes require special equipment to maintain the straightness and
tolerances. Other considerations are roundness and surface finish.
d) Gun Drilling
Gun drilling was originally developed to drill out gun barrels and is used commonly
for drilling smaller diameter deep holes. The depth-to-diameter ratio can be even greater than
300:1. The key feature of gun drilling is that the bits are self-centering.
e) Trepanning
Trepanning is commonly used for creating larger diameter holes (up to 915 mm
(36.0 inches)) where a standard drill bit is not feasible or economical. Trepanning removes the
desired diameter by cutting out a solid disk.
f) Micro - Drilling
Micro drilling refers to the drilling of holes less than 0.5 mm (0.020 in). Drilling of
holes at this small diameter presents greater problems since coolant fed drills cannot be used and
high spindle speeds are required.
g) Vibration Drilling
It is the case of the self-maintained vibrations drilling: the eigen frequency of the tool
is used in order to make it naturally vibrate while cutting; vibrations are self-maintained by a
mass-spring system included in the tool holder.
h) Circle Interpolating
Orbital drilling is based on rotating a cutting tool with around its own axis and
simultaneously about a centre axis which is off-set from the axis of the cutting tool. The cutting
tool can then be moved simultaneously in an axial direction to drill or machine a hole.
2.2 CUTTING
A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame,
used for cutting materials such as metal or plastics. Hand-held hacksaws consist of a metal arch
with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade.
A screw or other mechanism is used to put the thin blade under tension. The blade
can be mounted with the teeth facing toward or away from the handle, resulting in cutting action
on either the push or pull stroke. On the push stroke, the arch will flex slightly, decreasing the
tension on the blade, often resulting in an increased tendency of the blade to buckle and crack.
Cutting on the pull stroke increases the blade tension and will result in greater control of the cut
and longer blade life.
2.3 SHAPING
A shaper is a type of machine tool that uses linear relative motion between the
work piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous to
that of a lathe, except that it is linear instead of helical. A wood shaper is a similar wood working
tool, typically with a powered rotating cutting head and manually fed work piece, usually known
simply as a shaper in North America and spindle moulder in the UK.
The work piece mounts on a rigid, box-shaped table in front of the machine. The
height of the table can be adjusted to suit this work piece, and the table can traverse sideways
underneath the reciprocating tool, which is mounted on the ram. Table motion may be controlled
manually, but is usually advanced by an automatic feed mechanism acting on the feed screw.
The ram slides back and forth above the work. At the front end of the ram is a vertical tool slide
that may be adjusted to either side of the vertical plane along the stroke axis. This tool-slide
holds the clapper box and tool post, from which the tool can be positioned to cut a straight, flat
surface on the top of the work piece.
The ram is adjustable for stroke and, due to the geometry of the linkage, it moves
faster on the return (non-cutting) stroke than on the forward, cutting stroke. This action is via
a slotted link (or Whitworth link).
But in this machine we are using Scotch yoke mechanism in order to get the forward
and return stroke. In this mechanism the ratio of two strokes are equal i.e. strength of forward
stroke is equal to backward stroke. The motion of the stroke is by connecting it to a shaft which
is powered through single motor.
Horizontal Cutting
Cutting of angular surfaces
Vertical Cutting
Irregular Cutting
Keyway Cutting
Machining of thin jobs
2.3.2 ADVANTAGES
Dovetail slides
Internal splines and gear teeth.
Keyway, spline, and gear tooth cutting in blind holes.
Cam drums with tool paths of the type that in CNC milling terms would require 4- or 5-
axis contouring or turn-mill cylindrical interpolation.
It is even possible to obviate wire EDM work in some cases. Starting from a drilled or
cored hole, a shaper with a boring-bar type tool can cut internal features that don't lend
themselves to milling or boring (such as irregularly shaped holes with tight corners).
Smoothness of a rough surface.
2.4 GRINDING
2.4.1 PROCESSES
a) Surface Grinding
b) Cylindrical Grinding
c) Creep Feed Grinding
d) Centre less Grinding
e) Electrochemical Grinding
f) Electrolytic in-process dressing (ELID) grinding
a) Surface Grinding
Surface grinding uses a rotating abrasive wheel to remove material, creating a flat
surface. The tolerances that are normally achieved with grinding are ± 2 × 10−4 inches for
grinding a flat material, and ± 3 × 10−4 inches for a parallel surface. The surface grinder is
composed of an abrasive wheel, a work holding device known as a chuck.
b) Cylindrical grinding
Cylindrical grinding (also called center-type grinding) is used to grind the cylindrical
surfaces and shoulders of the work piece. The work piece is mounted on centers and rotated by a
device known as a drive dog or center driver. The abrasive wheel and the work piece are rotated
by separate motors and at different speeds.
c) Creep-Feed Grinding
It is used primarily to finish surfaces, CFG is used for high rates of material
removal, competing with milling and turning as a manufacturing process choice. Depths of cut of
up to 6 mm (0.25 inches) are used along with low work piece speed.
d) Centerless Grinding
Centerless grinding is when the work piece is supported by a blade instead of by
centers or chucks. Two wheels are used. The larger one is used to grind the surface of the work
piece and the smaller wheel is used to regulate the axial movement of the work piece.
3.1 ADVANTAGES
Since all the operations are present at one work place only one Induction motor is
necessary for performing all operations at once. This machine consumes only little amount or
electricity.
There will be no transportation cost to transfer the work pieces from one place to
another place, so the manufacturing cost will be reduced. And also this machine requires only
lubrication at only certain places like bevel gears and scotch yoke mechanism. So the
maintenance cost is greatly reduced.
3. Time saving
The time required for manufacturing a product is greatly decreased as all the
machining operations can be done at one place.
4. Size is compact
The size of the machine is very small and requires less space than other machines
presently in use.
3.2 DISADVANTAGES
This machine is basically designed for machining small objects since all operations
are done at one place. Also the size of the machine is small, so it is possible for machining small
objects and therefore not fit for large scale production.
The work piece should be moved manually from one operating place to another. So
human effort is necessary which can be time consuming process.
5. BLOCK DIAGRAM
POWER SUPPLY
MOTOR
BELT
DRIVE
MAIN BEVEL
SHAFT GEARS
6. HARDWARE COMPONENTS
As the name suggests, these motors operate on single phase AC supply. Single
phase induction motors are extensively used in low power applications such as domestic
appliances as mentioned above. These are small in size and less expensive to manufacture.
These motors are also called as fractional KW motors, because most of these motors are
constructed in fractional kilo-watt capacity. Single phase induction motors consist of two main
parts; stator and rotor. The construction of these motors is more or less similar to a three-phase
squirrel-cage induction motor.
The stator is a stationary part and it has laminated construction, which is made up of
stampings. These stampings consists of slots on its periphery to carry the stator winding. This
winding is excited with a single phase AC supply. The rotor is a rotating part and its
construction is of squirrel cage type. The rotor consists of uninsulated aluminum or copper
bars which are placed in the slots. These rotor bars are permanently shorted at both ends with
the help of end rings.
OPERATING PRINCIPLE
When the stator of a single phase motor is fed with single phase supply, it
produces alternating flux in the stator winding. The alternating current flowing through stator
winding causes induced current in the rotor bars (of the squirrel cage rotor ) according
to Faraday's law of electromagnetic induction. This induced current in the rotor will also
produce alternating flux. Even after both alternating fluxes are set up, the motor fails to start
(the reason is explained below). However, if the rotor is given a initial start by external force
in either direction, then motor accelerates to its final speed and keeps running with its rated
speed. This behavior of a single phase motor can be explained by double-field revolving
theory.
This motor is similar to the split phase motor, but in addition a capacitor is
connected in series to auxiliary winding. This is a modified version of split phase motor. Since
the capacitor draws a leading current, the use of a capacitor increases the phase angle between
the two currents (main and auxiliary) and hence the starting torque. This is the main reason for
using a capacitor in single phase induction motors.
MOTOR SPECIFICATIONS
Model GF 4451
H.P 0.25
Pole 4
R.P.M 1400
Winding Copper
This is one of the most widely used types of single phase induction motors. The
essential parts of the split phase motor include main winding, auxiliary winding and a
centrifugal switch. The auxiliary or starting winding carries a series resistance such that its
impedance becomes highly resistive in nature.
Bevel gears are used to transmit power between two non-parallel shafts. The shafts
may be intersecting or non-intersecting. Bevel gears can be described as conical gears as they are
cut on conical blanks (tapered). They are not interchangeable and always designed pairs.
A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh
with another toothed part in order to transmit torque, in most cases with teeth on the one gear
being of identical shape, and often also with that shape on the other gear. Two or more gears
working in tandem are called a transmission and can produce a mechanical advantage through a
gear ratio and thus may be considered a simple machine.
Geared devices can change the speed, torque, and direction of a power source. The
most common situation is for a gear to mesh with another gear; however, a gear can also mesh
with a nonrotating toothed part, called a rack, thereby producing translation instead of rotation.
The gears in a transmission are analogous to the wheels in a crossed belt pulley system. An
advantage of gears is that the teeth of a gear prevent slippage.
Straight bevel gears are used for speed ratio 1:1. Their precision is as good as parallel
helical gears, but higher than crossed helical gears, spiral bevel gears, hypoid bevel gears and
worm gears.
Specifications
= 16
10
Gear Ratio = 8
5
= 8:5
Applications :
Straight bevel gears are used primarily for low speed application with pitch line
velocities up to 300 m/min. They are widely used in textile machines. Few of applications are
listed below :
These gears are mounted on shaft whose axes are intersecting. The pitch surface is
conical as shown in Figure below. Spiral bevel gears have curved oblique teeth (spiral), which
allow contact to develop gradually and smoothly. They have more contact length and area and
less power transmission efficiency compared to straight bevel gears. They are useful for high-
speed applications and others requiring less noise and vibration.
Hypoid bevel gears are used to connect shafts whose axes do not intersect. They are
very similar to spiral gears. However, their pitch surfaces are hyperpoloids rather than cones. As
a result, their pitch axes do not intersect. They permit certain amount of sliding action along the
direction of tooth element, which requires good lubrication.
In majority of bevel gear drives, the shafts of the meshing gears are 90º to each other.
If the angles between the shafts are 90°, and the two gears of a pair are having the same number
of teeth, then it is called as “Miter Gear”.
Spur Gears
Worm Gears
Racks
Helical Gears
SPUR GEARS
Spur gears are the most commonly used gear type. They are characterized by teeth
which are perpendicular to the face of the gear. Spur gears are by far the most commonly
available, and are generally the least expensive. Spur gears generally cannot be used when a
direction change between the two shafts is required. Spur gears are easy to find, inexpensive, and
efficient.
WORM GEARS
Worm gears are special gears that resemble screws, and can be used to drive spur
gears or helical gears. Worm gears, like helical gears, allow two nonintersecting 'skew' shafts to
mesh. Normally, the two shafts are at right angles to each other. A worm gear is equivalent to a
V-type screw thread. Another way of looking at a worm gear is that it is a helical gear with a
very high helix angle.
RACKS
Racks are straight gears that are used to convert rotational motion to translational
motion by means of a gear mesh. (They are in theory a gear with an infinite pitch diameter). In
theory, the torque and angular velocity of the pinion gear are related to the Force and the velocity
of the rack by the radius of the pinion gear, Perhaps the most well-known application of a rack is
the rack and pinion steering system used on many cars in the past. They are limited usefulness,
difficult to find.
HELICAL GEAR
Helical gears are similar to the spur gear except that the teeth are at an angle to the
shaft, rather than parallel to it as in a spur gear. The resulting teeth are longer than the teeth on a
spur gear of equivalent pitch diameter.
A pillow block bearing, also known as a plumber block or housed bearing unit, is a
pedestal used to provide support for a rotating shaft with the help of compatible bearings &
various accessories. Housing material for a pillow block is typically made of cast iron or cast
steel.
OPERATION
A pillow block refers to any mounted bearing wherein the mounted shaft is in a
parallel plane to the mounting surface, and perpendicular to the center line of the mounting
holes, as contrasted with various types of flange blocks or flange units. A pillow block may
contain a bearing with one of several types of rolling elements, including ball, cylindrical roller,
spherical roller, tapered roller, or metallic or synthetic bushing. Split type housings are usually
two-piece housings where the cap and base may be detached, while others may be single-piece
housings. Various sealing arrangements may be provided to prevent dust and other contaminants
from entering the housing.
Plain Bearing
Ball bearing
Roller bearing
Jewel bearing
Fluid bearing
Magnetic bearing
Flexure bearing
BALL BEARINGS
A ball bearing is a type of rolling-element bearing that uses balls to maintain the
separation between the bearing races.
The purpose of the ball bearing is to reduce the rotational friction and
support radial and axial loads. It achieves this by using at least two races to contain the balls and
transmit the loads through the balls. In most applications, one race is stationary and the other is
attached to the rotating assembly (e.g., a hub or shaft). As one of the bearing races rotates it
causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient
of friction than if two flat surfaces were sliding against each other.
Many chucks have jaws, (sometimes called dogs) that are arranged in a radially
symmetrical pattern like the points of a star. The jaws are tightened up to hold the tool or work
piece. Often the jaws will be tightened or loosened with the help of a chuck key, which is
a wrench-like tool made for the purpose.
1. Jawed Chucks
2. Independent Chucks
a. Self – Centering
b. Spiders
Drill bits are cutting tools used to remove material to create holes, almost always
of circular cross-section. Drill bits come in many sizes and shape and can create different kinds
of holes in many different materials. In order to create holes drill bits are attached to a drill,
which powers them to cut through the work piece, typically by rotation.
Low-carbon steel
High-speed steel (HSS)
Cobalt steel
high-carbon steel
Twist drill bits are the most common type of drill bit and are used for everyday
drilling in all types of material. They are also the most confusing due to the sheer number of size,
tip, and material specifications. It comprises a cutting point at the tip of a cylindrical shaft with
helical flutes; the flutes act as an Archimedean screw and lift swarf out of the hole.
Specifications
Diameter - 5 mm
A step drill bit is a drill bit that has the tip ground down to a different diameter. The
transition between this ground diameter and the original diameter is either straight, to form a
counter bore, or angled, to form a countersink.
2. Unbit
A unibit (Steep drill bit) is a roughly conical bit with a stairstep profile. Due to its
design, a single bit can be used for drilling a wide range of hole sizes. Some bits come to a point
and are thus self-starting. The larger-size bits have blunt tips and are used for hole enlarging.
Center drill bits, occasionally known as Slocombe drill bits, are used in metal
working to provide a starting hole for a larger-sized drill bit or to make a conical indentation in
the end of a work piece in which to mount a lathe center.
A bit used to enlarge an existing hole is called a core drill bit. The existing hole may
be the result of a core from a casting or a stamped (punched) hole.
Used almost exclusively for deep hole drilling of medium to large diameter holes
(approximately 3⁄4–4 in or 19–102 mm diameter). An ejector drill bit uses a specially designed
carbide cutter at the point.
Indexible drill bits are primarily used in CNC and other high precision or production
equipment, and are the most expensive type of drill bit, costing the most per diameter and length.
Like indexible lathe tools and milling cutters, they use replaceable carbide or ceramic inserts as a
cutting face to alleviate the need for a tool grinder.
Black Oxide
Bronze Oxide
Titanium Nitride (TiN)
Titanium aluminum nitride (TiAlN)
Diamond powder
Zirconium nitride
6.7 HACKSAW
A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame,
used for cutting materials such as metal or plastics. Hand-held hacksaws consist of a metal arch
with a handle, usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or
other mechanism is used to put the thin blade under tension.
The blade can be mounted with the teeth facing toward or away from the handle,
resulting in cutting action on either the push or pull stroke. On the push stroke, the arch will flex
slightly, decreasing the tension on the blade, often resulting in an increased tendency of the blade
to buckle and crack. Cutting on the pull stroke increases the blade tension and will result in
greater control of the cut and longer blade life.
BLADES
Blades are available in standardized lengths, and with anywhere from three to thirty-
two teeth/inches (tpi). The blade used is based on the thickness of the material being cut, with a
Minimum of three teeth in the material. Hacksaw blades are normally quite brittle, so care needs
to be taken to prevent brittle fracture of the blade. Bi-metal blades are meant to minimize this
risk.
The pitch of the teeth can be anywhere from fourteen to thirty-two teeth per inches
(tpi) for a hand blade, with as few as three tpi for a large power hacksaw blade. The blade chosen
is based on the thickness of the material being cut, with a minimum of three teeth in the material.
As hacksaw teeth are so small, they are set in a "wave" set. As for other saws they are set from
side to side to provide a kerfs or clearance when sawing.
The most common blade is the 12 inches or 300 mm length. Hacksaw blades have
two holes near the ends for mounting them in the saw frame and the 12 inches / 300 mm
dimension refers to the center to center distance between these mounting holes.
Inch Blade
6.8 SHAPER
A shaper is a type of machine tool that uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear toolpath. Its cut is analogous to that of
a lathe, except that it is (archetypally) linear instead of helical.
1. Based on type of mechanism employed for the movement of the cutting tool i.e. tool carrying
ram the shapers are classified in to three types
a. Crank type
b. Gear type
c. Hydraulic type
2. According to position and movement of ram the shapers are classified in to three types
a. Horizontal type
b. Vertical type
c. Travelling head type
3. Shapers are classified in to two types based on design of the work table
a. Standard shaper
b. Universal shaper
a. Push type
b. Draw type
Horizontal Shaper
As the name indicates these shapers have the motion of ram along the horizontal
axis. This type of shapers is generally used for generation of fine and flat surfaces.
Specifications :
Height - 70 mm
Width - 12 mm
In these shapers the reciprocating ram is driven by crank mechanism. In this a single
point cutting tool is employed to do the operation. A crank is connected to the ram and the bull
gear to which the power is given through an individual motor. These are most common type of
shapers being used.
These are the rarely used shapers. In these shapers a rack and pinion are employed
the rack is attached to the lower part of the ram and on which the pinion moves. The power is
transmitted from the bull gear. A grain train is engaged for the transfer of power from the bull
gear to pinion.
These shapers run on hydraulic power. The end of the ram is connected to a piston
fitted in to a cylinder. Oil is fed in to the cylinder initially the oil acts in one direction and the
ram moves in one direction. A varying pressure is applied on the oil so as to obtain the
reciprocating motion of the ram.
Vertical Shaper
In these shapers the tool containing ram has its motion in vertical direction. In some
of the shapers a provision of 100 rotation of the ram is also provided. In vertical shaper the ram
may be driven by various types like crank driven, screw driven, gear driven, or by hydraulic
power.
This type of shaper is generally employed for machining very large objects that
cannot be mounted on the table of the machine and cannot be moved. In this machine the ram
having reciprocating movement also provides crosswise movement simultaneously.
It is just a converse of the push type shaper. In these machines the metal is removed
from the work piece when the ram is moving towards the column. So due to this the work piece
takes a force in the direction towards the column of the work piece.
It is one of the most commonly used shaper. In this the metal is removed when the
ram is moving away from the column. This type of shaper pushes the work piece while removing
the work piece away from it so this shaper is called as push type shaper.
ABRASIVE GRAIN
The abrasive aggregate is selected according to the hardness of the material being cut.
Straight Wheel
These are by far the most common style of wheel and can be found on bench or
pedestal grinders. They are used on the periphery only and therefore produce a slightly concave
surface (hollow ground) on the part. This can be used to advantage on many tools such as
chisels. Straight Wheels are generally used for cylindrical, centreless, and surface grinding
operations.
Specifications
Material - Carborundum
Diameter - 100 mm
Cylinder wheels provide a long, wide surface with no center mounting support
(hollow). They can be very large, up to 12" inch width. They are used only in vertical or
horizontal spindle grinders. Cylinder or wheel ring is used for producing flat surfaces, the
grinding being done with the end face of the wheel.
2. Tapered Wheel
A straight wheel that tapers outward towards the center of the wheel. This
arrangement is stronger than straight wheels and can accept higher lateral loads. Tapered face
straight wheel is primarily used for grinding thread, gear teeth etc.
3. Straight Cup
Straight cup wheels are an alternative to cup wheels in tool and cutter grinders,
where having an additional radial grinding surface is beneficial.
4. Cup Wheel
They are used in Tool and Cutter grinders where orientation of the wheel and a slim
profile are required. These wheels are used (and dressed) on the side face and have the advantage
of producing a truly flat surface on the side of lathe tools. They are used in jig grinders to
produce flat surfaces or counterbores.
5. Saucer Wheels
A special grinding profile that is used to grind milling cutters and twist drills. It is
most common in non-machining areas, as sawfilers use saucer wheels in the maintenance of saw
blades.
6. Diamond Wheels
Diamond wheels are grinding wheels with industrial diamonds bonded to the
periphery. They are used for grinding extremely hard materials such as carbide cutting tips,
gemstones or concrete. This is a slitting saw and is designed for slicing hard materials, typically
gemstones.
A belt is a loop of flexible material which is used to link two or more rotating
shafts mechanically, most often parallel. Belts may be used as a source of motion, to transmit
power efficiently, or to track relative movement. Belts are looped over pulleys and may have a
twist between the pulleys, and the shafts need not be parallel. In a two pulley system, the belt can
either drive the pulleys normally in one direction, or the belt may be crossed, so that the direction
of the driven shaft is reversed.
We are using total two belt drives in this machine. They are
1. Location : Between the motor and the pulley which is connected to the main shaft
Diameter : 210 cm
Grade : A 2070 A 80
2. Location : In between the shaft connected to the bevel gear and pulley of the drill chuck
Diameter : 90 cm
Grade : SYN
An open belt drive is used to rotate the driven pulley in the same direction of driving
pulley. In the motion of belt drive, power transmission results make one side of pulley more
tightened compared to the other side. In horizontal drives, tightened side is always kept on the
lower side of two pulleys because the sag of the upper side slightly increases the angle of folding
of the belt on the two pulleys.
FLAT BELTS
The flat belt is a simple system of power transmission that was well suited for its
day. It can deliver high power at high speeds (500 hp at 10,000 ft/min or 373 kW at 51 m/s), in
cases of wide belts and large pulleys. Flat belts were traditionally made of leather or fabric.
Today most are made of rubber or polymers.
TIMING BELTS
Flat belts were traditionally made of leather or fabric. Today most are made of rubber
or polymers. Grip of leather belts is often better if they are assembled with the hair side (outer
side) of the leather against the pulley. They can bear up to 200 hp (150 kW) at speeds of
16,000 ft/min (4,900 m/min).
Disadvantages
6.11 PULLEY
A pulley is a wheel on an axle or shaft that is designed to support movement and
change of direction of a taut cable, supporting shell is referred to as a "block."
Fixed Pulley
1. Movable : A movable pulley has an axle in a movable block. A single movable pulley is
supported by two parts of the same rope and has a mechanical advantage of two.
2. Compound : A combination of fixed and a movable pulleys forms a block and tackle. A block
and tackle can have several pulleys mounted on the fixed and moving axles, further increasing
the mechanical advantage.
We are using a total of 4 pulleys in this project. Three pulleys are of the same size
but the other pulley is of the larger dimeter.
Reason for using the bigger pulley at the end of main shaft
The size and weight of the main shaft is too high and also the dimensions of the
Scotch yoke mechanism is bigger. In order to rotate the mechanism greater force is required
through the pulley. But if we keep a small diameter pulley higher force is necessary through
motor in order to rotate. So if we keep a bigger wheel due the weight of the wheel itself the shaft
can be easily rotated. This principle is known as Regenerative Energy.
Woodworking vice
Engineer’s vice
Machine vice
Pipe vice
Clamp - on
Engineer’s Vice
Quantity - 3
6.13 SPRING
Compression Spring
Torsion spring
Tension spring
NUT
A nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction
with a mating bolt to fasten two or more parts together. The two partners are kept together by a
combination of their threads' friction (with slight elastic deformation), a slight stretching of the
bolt, and compression of the parts to be held together.
BOLT
A bolt is a form of threaded fastener with an external male thread. Bolts are thus closely
related to, and often confused with, screws. Bolts are for the assembly of two unthreaded
components, with the aid of a nut.
WASHER
A washer is a thin plate with a hole that is normally used to distribute the load of a threaded
fastener, such as a screw or nut. Other uses are as a spacer, spring etc. Washer usually have an
outer diameter about twice larger than their inner diameter.
7. MANUFACTURING
Four rectangular iron bars of dimensions 3.2 feet and 2.6 feet are taken. These bars
are welded in the shape of rectangle by using arc welding. To this rectangle four bars, each at
one vertex are welded perpendicularly. These vertex bars acts as legs to the rectangular frame.
From the middle of the chassis a horizontal bar is welded in order to support the main shaft
attached to the Scotch Yoke Mechanism. From this horizontal bar two bars are welded
perpendicularly in order to support the bevel gear attachment.
Another two vertical iron bars are welded in such a way, so as to fix the drilling
mechanism beside the gear shaft. Holes are drilled at particular positions in order to place the
plumber blocks. The uneven surfaces left over after welding are grinded for obtaining a good
surface finish.
The scotch yoke mechanism is constructed with iron bars. Here the crank is made in
some diameter and the yoke is also made using the same material. The crank and yoke is
connected with a pin. Iron bars are welded to both sides of the yoke to get the reciprocating
motion. Now the crank is welded to the main shaft to which pulley is attached at the other end.
Bevel gears are welded in the middle of the shaft.
8. ASSEMBLY
STEP 1 :
At first the bench vices are attached to the frame. Now the vertical bevel gear
attachment is fixed to the centre bars with the help of two plumber blocks. Drill tool arrangement
is attached to the left of frame. The vertical bevel gear rod and the drill tool arrangement are
connected with the help of toothed belt drive. Feeding rod is connected to the centre bars and
placed above the drill tool arrangement. The assembly of the first step is shown below :
STEP 2 :
Now the hacksaw blade arrangement is fixed to the right side of Scotch yoke
mechanism and shaper to the left of it. Pulley and grinding wheel are fixed to the other end of the
main shaft. Now this full mechanism is attached to the body frame with plumber blocks on top of
it. The assembly of this arrangement is shown in the figure below :
Fig 8.2.1 Scotch yoke mechanism with shaper, blade, grinding wheel
STEP 3 :
Now the motor is attached at the bottom of the frame with the help of nuts and
bolts. The motor is attached to the main pulley with the help of flat belt drive. This are the final
attachments made to the machine. All the connections are made through nut and bolt assembly
except the frame. The assembly is shown below :
STEP 4 :
The assembly of all the operations is now completed. Appropriate grease is applied
to the bevel gear and Scotch Yoke mechanism in order to provide smooth movement. Now the
motor is connected to the power supply with the help of wired connections. The completed Multi
Purpose Machine is shown in the figure below :
9. TESTING
WORKING
This Multi Purpose Machine consists of a single phase motor. When the power is
supplied to the motor, the pulley which is connected to the motor through belt drive starts
rotating. The main shaft which is connected to the bigger pulley starts rotating and gives drive to
the scotch yoke mechanism. Cutting operation is done on the right side while the shaping
operation is done on the left side of the scotch yoke mechanism. The base of the shaping
operation can be moved forward or backward for accurate cuttings. Bevel gear arrangement is
placed at the middle of the main shaft in order to transfer the power to the drilling operation
through belt drive. Feeding should be given in order to control the depth of the drill with the help
of feeding rod, which is placed above the drill chuck rod. Grinding wheel which is placed on the
other end of the main shaft rotates itself when the power supply is given to motor. Thus all the
operations are performed by using a single motor at a time and more importantly these are done
at one place.
OBSERVATIONS :
= 3.14*5*690
1000
= 10.838 metre/minute
Depth of drill = 22 mm
= 3.14*1*690*(5)2
4
= 135.48 mm3/minute
OBSERVATIONS :
= 3.14*100*561
1000
OBSERVATIONS :
Dimensions of wood
Width = 36 mm
Height = 24 mm
OBSERVATIONS :
Where,
L = Stroke length
= 0.12
0.08
= 1.5
Now,
= 150*168*2.5
1000
We can see that all the production based industries wanted low production cost and
high work rate which is possible through the utilization of Multi Purpose Drilling,Grinding,
Cutting & Shaping Machine. It requires less power as well as less time, since this machine
provides working at one work center. It really reduced the time consumption up to appreciable
limit. It can be used for light duty cutting and drilling operations of plywood and also the
grinding operation can be used to sharp the tools edges as well as to remove extra materials. Its
working can be done in less floor space. Unskilled labor can also handle it efficiently because of
this we can reduce the cost of production which is the most important factor in production
industry. This is one of the most reliable and simple machine in the work shop.
FUTURE SCOPE :
In future operations can be done with materials of higher density and sizes by fabricating
a bigger machine.
By placing a high speed motor operations can be done more quicker than of now.
The shaper can be designed in order to give the depth of cut which is not present in the
current machine.
Implementations like each operation can be controlled in such a way that unnecessary
operations are stopped in order to transfer all the energy to one machining operation can
be done.
11. REFERENCE
Publications :
Text Books :
Web References :
http://en.wikepedia.org/wiki
www.Howstuffworks.com