Anda di halaman 1dari 73

A Project Report On

FABRICATION OF MULTI PURPOSE DRILLING,GRINDING,


CUTTING & SHAPING MACHINE
Submitted in partial fulfillment of the requirements
For the award of the degree of

BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted By
K.KRISHNA MOULI (13B21A0303)

G.GIRI SEKHAR (13B21A0319) T.V.N.MURTY (13B21A0313)


A.VAMSI KIRAN (13B21A0322) N.SRINIVAS (13B21A0328)
M.DURGA PRASAD(14B25A0310) K.LOKESH (13B21A0302)

Under the esteemed guidance of


Mrs. N.V.LAKSHMI., M.Tech.,( Ph.D)
Assistant Professor
Department of Mechanical Engineering

KAKINADA INSTITUTE OF ENGINEERING & TECHNOLOGY


(AFFLIATED TO J.N.T UNIVERSITY KAKINADA, A.P.)
YANAM ROAD, KORANGI-533461, A.P
2013-2017
KAKINADA INSTITUTE OF ENGINEERING & TECHNOLOGY
(AFFILIATED TO J.N.T UNIVERSITY KAKINADA, A.P.)
DEPARTMENT OF MECHANICAL ENGINEERING

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.

Signature of the External Examiner

Signature of the Guide Signature of the HOD


Mrs. N.V.LAKSHMI Dr.T.V.R.RAVI KUMAR
Asst. Professor
ACKNOWLEDGEMENT

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 extend our sincere gratitude to our principal, Sri. CH.SUBHASH CHANDRA,


M.TECH.,(Ph.D) who has made the atmosphere so easy to work.

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

We hereby declare that the project work “FABRICATION OF MULTI PURPOSE


DRILLING, GRINDING, CUTTING & SHAPING MACHINE” submitted to the JNTU
Kakinada is a record of an original work done by me under the guidance of Mrs.
N.V.LAKSHMI., M.Tech., (Ph.D) Assistant professor, Mechanical Engineering. This project
work submitted in partial fulfillment of the requirement for the award of the degree of Bachelor
of Technology in Mechanical Engineering. The results embodied in this project report have not
been submitted to any other University or Institute for the award of any degree or diploma.

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

S.NO DESCRIPTION PAGE NO


1 INTRODUCTION 1-6

1.1 ECONOMICS OF MANUFACTURING 1

1.2 LITERATURE REVIEW 2

1.3 METHODOLOGY
1.3.1 SCOTCH YOKE MECHANISM 4
1.3.2 CONSTRUCTION 4
1.3.3 APPLICATIONS 5

2 OPERATIONS PERFORMED 7-14

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

3 ADVANTAGES & DISADVANTAGES 15-16

4 MULTI PURPOSE DRILLING,GRINDING, 17


CUTTING & SHAPING MACHINE
5 BLOCK DIAGRAM 18

6 COMPONENTS 19-48

6.1 BODY FRAME 19

6.2 INDUCTION MOTOR 20

6.3 BEVEL GEARS 23


6.4 PILLOW BLOCK BEARING 28

6.5 DRILLING CHUCK 30

6.6 DRILL BIT 31

6.7 HACKSAW 34

6.8 SHAPER 36

6.9 GRINDING WHEEL 39

6.10 BELT DRIVES 42

6.11 PULLEYS 44

6.12 BENCHVICE 46

6.13 SPRING 47

6.14 NUT AND BOLT 48

7 MANUFACTURING 49-51

8 ASSEMBLY 52-55

9 TESTING ON WOOD 56-62

9.1 DRILLING OPERATION 56

9.2 GRINDING OPERATIONS 58

9.3 CUTTING OPERATION 60

9.4 SHAPING OPERATION ON METAL 61

10 CONCLUSION & FUTURE SCOPE 63

11 REFERENCE 64
LIST OF FIGURES
FIG NO TITLE PAGE NO
1.3.1 SCOTCH YOKE MECHANISM 4

1.3.3 CHEBYSHEV LINKAGE 6

2.1.1 SPOT DRILLING 8

2.1.2 ORBITAL DRILLING 9

2.2.1 HACKSAW CUTTING TOOL 10

2.3.1 WHITWORTH QUICK RETURN MECHANISM 11

2.4.1 SURFACE GRINDING 14

4.1 MACHINE FRONT VIEW 17

4.2 MACHINE SIDE VIEW 17

6.1.1 DIMENSIONS OF FRAME 19

6.2.1 SINGLE PHASE INDUCTION MOTOR 21

6.3.1 BEVEL GEARS 24

6.4.1 PILLOW BLOCK BEARING 28

6.4.2 BALL BEARINGS 29

6.5.1 DRILL CHUCK 30

6.6.1 TWIST DRILL BIT 31

6.8.1 HORIZONTAL SHAPER 37

6.9.1 GRINDING WHEEL 39

6.10.1 TIMING BELT 42


FIG NO TITLE PAGE NO

6.11.1 FIXED PULLEY 42

6.11.2 BIGGER PULLEY 45

6.12.1 ENGINEER’S VICE 46

6.13.1 COMPRESSION SPRING 47

6.14.1 BOLT, NUT & WASHER 48

7.1.1 MEASUREMENT OF IRON BARS 49

7.1.3 COMPLETED BODY FRAME 50

7.2.2 SCOTCH YOKE ATTACHED TO MAINSHAFT 51

8.1.1 FRAME WITH BENCHWISE, DRILL TOOL 52

8.2.2 MEHANISM ON TOP OF FRAME 53

8.3.1 MOTOR ATTACHED TO FRAME 54

8.4.1 MULTI PURPOSE MACHINE 55

9.1.1 DRILLING OPERATION ON WOOD 56

9.1.2 GRINDING OPERATION ON METAL 58

9.1.2.1 SURFACE GRINDING MADE ON METAL 58

9.1.3 CUTTING OPERATION ON WOOD 60

9.1.4 SHAPING OPERATION ON WOOD 61


ABSTRACT

In an industry a considerable portion of investment is being made for machinery


installation. So in this project we have a proposed a machine which can perform operations like
drilling, cutting, shaping, grinding operations at different working centers at same place
simultaneously which implies that industrialist have not to pay for machine performing above
tasks individually for operating operation simultaneously. This project presents the concept of
Multi Purpose Drilling, Grinding, Cutting & Shaping Machine mainly carried out for
production based industries.

We have developed a conceptual model of a machine which would be capable of


performing different operations simultaneously and is also economically efficient. In this
machine we are actually giving drive to the main shaft through the D.C motor by using belt
drive. Scotch Yoke mechanism is directly attached to the main shaft which is used for cutting
and shaping operations. On the main shaft we have used bevel gear system for power
transmission at another location. Through bevel gear we will give drive to drilling centre.

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.

To avoid these difficulties we have proposed a machine which can perform


operations like drilling, cutting, shaping, grinding operations simultaneously at one place, which
implies that industrialists have not to pay for machines performing above tasks individually for
operating operations simultaneously.

1.1 ECONOMICS OF MANUFACTURING

According to some economists, manufacturing is a wealth-producing sector of an


economy, whereas a service sector tends to be wealth-consuming. Emerging technologies have
provided some new growth in advanced manufacturing employment opportunities in the
Manufacturing Belt in the United States. Manufacturing provides important material support for
national infrastructure and for national defense.

Department of Mechanical Engineering, KIET Page 1


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

1.2 LITERATURE REVIEW

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:

Dharwa Chaitanya Kirtikumar [1] :

He designed and developed a multipurpose machine which does not require


electricity for several operations like cutting, grinding etc. This is a human powered machine
runs on chain drives mainly with human efforts. But if you wanted to operate this machine by
electric power this machine can also does that. It has some special attachment so use both human
power as well as electric power. The design is ideal for use in the developing world because it
doesn’t require electricity and can be built using metal base, chain, pulley ,rubber belt, grinding
wheel, saw, bearing, foot pedal (for operated by human) ,electric motor, chain socket.

S.G.Bahaley, Dr. A.U. Awate, S.V. Saharkar [2] :

They designed and fabricated a pedal powered multipurpose machine. It is a human


powered machine which is developed for lifting the water to a height 10 meter and generates 14
Volt, 4 ampere of electricity in most effective way. Power required for pedaling is well below the
capacity of an average healthy human being. The system is also useful for the work out purpose
because pedaling will act as a health exercise and also doing a useful work.

M.Prathyusha, P.Mounika, G.Kalyani, G.Prashanthi [3] :

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

Department of Mechanical Engineering, KIET Page 2


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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..

Department of Mechanical Engineering, KIET Page 3


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

1.3 METHODOLOGY

1.3.1 SCOTCH YOKE MECHANISM

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.

Fig.1.3.1 Scotch Yoke Mechanism

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.

Department of Mechanical Engineering, KIET Page 4


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Various other types of Straight line mechanisms are

1. Near straight line linkages

a. Watt’s linkage

b. Chebyshev linkage

c. Hoeckens linkage

d. Roberts Mechanism

2. Perfect straight line linkages

a. Hart’s inversor

b. Sarrus linkage

c. Tusi Couple

d. Quadruplanar - inversor

Department of Mechanical Engineering, KIET Page 5


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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

The Chebyshev approximate straight line mechanism is four bar linkage


mechanism. It is a double rocker and the mid point of the coupler is the point tracing the
approximate linear path.

Fig.1.3.3 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

The Sarrus linkage is a mechanical linkage which is used to convert a limited


circular motion to a linear motion without reference guide ways. The Sarrus linkage is of a
three-dimensional class sometimes known as a space crank.

Department of Mechanical Engineering, KIET Page 6


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

2. OPERATIONS PERFORMED

2.1 DRILLING

Drilling machine can be defined as an instrument which is used to drill holes.


Drilling machine plays an important role in mechanical workshops. A drilling machine comes in
many shapes and sizes, from small hand-held power drills to bench mounted and finally floor-
mounted models. The most advanced version-drilling machine is CNC (Computer Numeric
Control); it is used for drilling the PCB’s (Printed circuit boards). CNC Drilling is commonly
implemented for mass production.

 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.

Various types of drilling are :

a) Spot Drilling
b) Centre Drilling
c) Deep Hole Drilling
d) Gun Drilling
e) Trepanning
f) Micro Drilling
g) Vibration Drilling
h) Centre Interpolating

Department of Mechanical Engineering, KIET Page 7


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 2.1.1 Spot Drilling

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.

c) Deep hole drilling

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.

Department of Mechanical Engineering, KIET Page 8


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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

The main principle consists in generating axial vibrations or oscillations in addition


to the feed movement of the drill so that the chips break up and are then easily removed from the
cutting zone.

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.

Fig 2.1.2 Orbital Drilling

Department of Mechanical Engineering, KIET Page 9


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 2.2.1 Hack saw cutting tool

Department of Mechanical Engineering, KIET Page 10


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

2.3.1 NORMAL OPERATION

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).

Fig 2.3.1 Whitworth Quick Return Mechanism

Department of Mechanical Engineering, KIET Page 11


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Operations performed on shaping machine

 Horizontal Cutting
 Cutting of angular surfaces
 Vertical Cutting
 Irregular Cutting
 Keyway Cutting
 Machining of thin jobs

2.3.2 ADVANTAGES

 Keyways in the boss of a pulley or gear can be machined without resorting to a


dedicated broaching setup.

 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.

Department of Mechanical Engineering, KIET Page 12


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

2.4 GRINDING

Grinding, or abrasive machining, is the process of removing metal in the form of


minute chips by the action of irregularly shaped abrasive particles. These particles may be in
bonded wheels, coated belts, or simply loose. Grinding is a subset of cutting, as grinding is a true
metal-cutting process. Each grain of abrasive functions as a microscopic single-point cutting
edge (although of high negative rake angle), and shears a tiny chip that is analogous to what
would conventionally be called a "cut" chip (turning, milling, drilling, tapping, etc.). Lapping is
the subset of grinding.

A wide variety of machines are used for grinding:

 Hand-cranked knife-sharpening stones (grindstones).


 Handheld power tools such as angle grinders and die grinders.
 Various kinds of expensive industrial machine tools called grinding machines.
 Bench grinders often found in residential garages and basements

2.4.1 PROCESSES

Selecting which of the following grinding operations to be used is determined by the


size, shape, features and the desired production rate. They are

a) Surface Grinding
b) Cylindrical Grinding
c) Creep Feed Grinding
d) Centre less Grinding
e) Electrochemical Grinding
f) Electrolytic in-process dressing (ELID) grinding

Department of Mechanical Engineering, KIET Page 13


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 2.4.1 Surface Grinding

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.

Department of Mechanical Engineering, KIET Page 14


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

3. ADVANTAGES AND DISADVANTAGES

3.1 ADVANTAGES

1. All operations are performed by one motor :

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.

2. Low Manufacturing and Maintenance cost :

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.

5. Easy machinery used.

6. Power saving as all the operations are done at one place.

Department of Mechanical Engineering, KIET Page 15


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

3.2 DISADVANTAGES

1. Not fit for large scale production :

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.

2. Work piece movement is not automated

The work piece should be moved manually from one operating place to another. So
human effort is necessary which can be time consuming process.

Department of Mechanical Engineering, KIET Page 16


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

4. MULTI PURPOSE DRILLING,GRINDING,


CUTTING & SHAPING MACHINE

Fig 4.1 Front View

Fig 4.2 Side View

Department of Mechanical Engineering, KIET Page 17


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

5. BLOCK DIAGRAM

POWER SUPPLY

MOTOR

BELT
DRIVE

MAIN BEVEL
SHAFT GEARS

GRINDING SCOTCH YOKE BELT


WHEEL MECHANISM DRIVE

SHAPER HACK SAW DRILL


BIT

GRINDING SHAPING CUTTING DRILLING

Department of Mechanical Engineering, KIET Page 18


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6. HARDWARE COMPONENTS

6.1 BODY FRAME


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.

All dimensions are in cm Top view

Side View Top View

Fig 6.1.1 Dimensions of the Frame

Department of Mechanical Engineering, KIET Page 19


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.2 INDUCTION MOTOR


An induction motor is an AC electric motor in which the electric current in
the rotor needed to produce torque is obtained by electromagnetic induction from the magnetic
field of the stator winding. An induction motor can therefore be made without electrical
connections to the rotor. An induction motor's rotor can be either wound type or squirrel-cage
type. .

Types of Induction Motors :

 Single Phase Induction Motors


 3 phase Induction Motors

SINGLE PHASE INDUCTION MOTOR :

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

Department of Mechanical Engineering, KIET Page 20


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Types of Single Phase Induction Motor :

 Split – phase motor


 Capacitor Start Motor
 Permanent Capacitor run motor
 Capacitor start capacitor run motor
 Shaded pole motor

Capacitor Start Induction Motor :

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.

Fig 6.2.1 Single phase induction motor

Department of Mechanical Engineering, KIET Page 21


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

MOTOR SPECIFICATIONS

Model GF 4451

Type Single Phase Induction Motor

Input 180-240 Volts

H.P 0.25

Pole 4

Class B Class Insulated Contracting

R.P.M 1400

Running Capacity >12 Hrs

Protection Thermally Protected

Output 440 Volts

Winding Copper

Features High reliability and durability.Higher


performance. Consistence supply. Easy to
operate and long lasting.

Split Phase Induction Motor :

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.

Department of Mechanical Engineering, KIET Page 22


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.3 BEVEL GEARS

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.

Brief Description About Gears

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.

Types of Bevel Gears

 Straight Bevel Gears


 Spiral Bevel Gears
 Hypoid Bevel Gears
 Miter and Angular Bevel Gears

Straight Bevel Gears


The straight bevel gears are the simplest types of bevel gears. They are the
important gears to transmit power between intersecting shafts. Straight bevel gears are shown in
Figure below. The teeth are cut straight, have a taper, and if extended inward, would intersect
each other on the axis of shaft. The meshing gears have line contact. Hence, they are not smooth
in operation; generate more vibrations and noise at high-speed. They produce thrust load on shaft
bearings.

Department of Mechanical Engineering, KIET Page 23


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Fig 6.3.1 Bevel Gears

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

Number of teeth in the Drive Gear = 16

Number of teeth in the Driven Gear = 10

Material = Cast Iron

Angle between the Gears = 90 Degrees

Gear Ratio (Speed Ratio)

Gear ratio = Number of teeth in the drive gear


Number of teeth in driven gear

= 16
10

Gear Ratio = 8
5

= 8:5

Department of Mechanical Engineering, KIET Page 24


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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 :

 Drive to bobbin rail on roving machine


 Drive between the doffer and feed roller on low speed carding machines.
 Drive from calender roller to coiler rollers, top coiler to bottom coiler plates in card,
comber and drawing machine.
 Drive between calender roll and lap stop mechanism-lever in lap former of conventional
blow room.

Spiral Bevel Gears

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.

Fig 6.3.2 Spiral Bevel Gear

Hypoid Bevel Gears

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.

Department of Mechanical Engineering, KIET Page 25


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Mitel and Angular Bevel Gears

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”.

Comparison with Other Drive Mechanisms

 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.

Fig 6.3.3 Worm gears

Department of Mechanical Engineering, KIET Page 26


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 6.3.4 Racks

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.

Department of Mechanical Engineering, KIET Page 27


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.4 PILLOW BLOCK BEARING

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.

Fig 6.4.1 Pillow Block Bearing

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.

Total plumber blocks used in this machine - 9

Different types of bearing are

 Plain Bearing
 Ball bearing

Department of Mechanical Engineering, KIET Page 28


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

 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.

Fig 6.4.2 Ball Bearing

Department of Mechanical Engineering, KIET Page 29


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.5 DRILLING CHUCK

A chuck is a specialized type of clamp. It is used to hold an object with radial


symmetry, especially a cylinder. In drills and mills it holds the rotating tool whereas in lathes it
holds the rotating work piece. On a lathe the chuck is mounted on the spindle which rotates
within the headstock. For some purposes (such as drilling) an additional chuck may be mounted
on the non-rotating tailstock.

Fig 6.5.1 Drill Chuck

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.

Different types of chucks are

1. Jawed Chucks

2. Independent Chucks

a. Self – Centering

b. Spiders

Department of Mechanical Engineering, KIET Page 30


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.6 DRILL BIT

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.

Materials used for Drill Bits

 Low-carbon steel
 High-speed steel (HSS)
 Cobalt steel
 high-carbon steel

Twist Drill Bits

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.

Fig 6.6.1 Twist Drill Bit

Specifications

Type - High Speed Steel

Diameter - 5 mm

Department of Mechanical Engineering, KIET Page 31


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Different types of Drill bits are

 Twist Drill bits


 Step Drill bits
 Unbits
 Centre and spotting drill bits
 Core drill bit
 Counter sink bit
 Ejector drill bit
 Indexible drill bit

1. Step Drill Bits

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.

3. Centre and spotting Drill Bits

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.

4. Core Drill Bit

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.

Department of Mechanical Engineering, KIET Page 32


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

5. Counter Sink Bit

A countersink is a conical hole cut into a manufactured object; a countersink bit


(sometimes called simply countersink) is the cutter used to cut such a hole. A common use is to
allow the head of a bolt or screw, with a shape exactly matching the countersunk hole, to sit flush
with or below the surface of the surrounding material.

6. Ejector Drill Bit

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.

7. Indexible Drill Bit

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.

Coating used in Drill Bits are

 Black Oxide
 Bronze Oxide
 Titanium Nitride (TiN)
 Titanium aluminum nitride (TiAlN)
 Diamond powder
 Zirconium nitride

Department of Mechanical Engineering, KIET Page 33


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 6.7.1 Hacksaw

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.

Department of Mechanical Engineering, KIET Page 34


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Blades are available in standardized lengths, usually 10 or 12 inches for a standard


hand hacksaw. "junior" hacksaws are half this size. Powered hacksaws may use large blades in a
range of sizes, or small machines may use the same hand blades.

Recommended Teeth per 25mm (tpi) for each material type

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.

Hacksaw blade Specifications

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

Hole to Hole : 11 7/8 inches / 300 mm

Overall Blade Length : 12 3/8 inches / 315 mm (not tightly controlled)

Blade Width : 7/16 to 33/64 inches / 11 to 13 mm (not tightly controlled)

Blade Thickness : 0.020 to 0.027 inches / 0.5 to 0.70 mm

Department of Mechanical Engineering, KIET Page 35


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

A wood shaper is a similar woodworking 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.

Shapers are classified according to various aspects.

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

4. Based on type of cutting stroke employed these are classified in to

a. Push type
b. Draw type

Department of Mechanical Engineering, KIET Page 36


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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 :

Material - Stainless steel

Height - 70 mm

Width - 12 mm

Angle of cut - 30 degrees

Fig 6.8.1 Horizontal Shaper

Crank Type Shaper

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.

Gear Type Shaper

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.

Department of Mechanical Engineering, KIET Page 37


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Hydraulic Type Shaper

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.

Travelling head Type Shaper

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.

Draw Type Shaper

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.

Push Type Shaper

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.

Department of Mechanical Engineering, KIET Page 38


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.9 GRINDING WHEEL

A grinding wheel is a wheel composed of an abrasive compound and used for


various grinding (abrasive cutting) and abrasive machining operations. Such wheels are used
in grinding machines. The wheels are generally made from a composite material consisting of
coarse-particle aggregate pressed and bonded together by a cementing matrix to form a solid,
circular shape. They may also be made from a solid steel or aluminium disc with particles
bonded to the surface.

ABRASIVE GRAIN

The abrasive aggregate is selected according to the hardness of the material being cut.

 Aluminum oxide (A)


 Silicon carbide (S)
 Ceramic (C)
 Diamond (D, MD, SD)

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.

Fig 6.9.1 Grinding Wheel

Department of Mechanical Engineering, KIET Page 39


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Specifications

Material - Carborundum

Diameter - 100 mm

Different types of Grinding Wheels

 Cylinder or Wheel Rig


 Tapered Wheel
 Straight Cup
 Cup Wheel
 Saucer Wheel
 Diamond Wheels

1. Cylinder or Wheel Ring

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.

Department of Mechanical Engineering, KIET Page 40


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 6.9.2 Grinding wheel

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.

Department of Mechanical Engineering, KIET Page 41


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.10 BELT DRIVE

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

Type : Flat belt drive

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

Type : Timing Belt

Diameter : 90 cm

Grade : SYN

Fig 6.10.1 Timing belt


Department of Mechanical Engineering, KIET Page 42
Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

OPEN BELT DRIVE

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).

Advantages of Timing belts

 Less noise is produced


 Lubrication is not necessary
 They can bear high speeds
 They need the least tension of all belts

Disadvantages

 Relatively high purchase cost


 Fixed lengths which do not allow length adjustment unlike flat belt

Department of Mechanical Engineering, KIET Page 43


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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

A fixed pulley has an axle mounted in bearings attached to a supporting structure. A


fixed pulley changes the direction of the force on a rope or belt that moves along its
circumference. Mechanical advantage is gained by combining a fixed pulley with a movable
pulley or another fixed pulley of a different diameter.

Fig 6.11.1 Fixed Pulley

Various other types of pulley systems are

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.

Department of Mechanical Engineering, KIET Page 44


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Diameter of the Pulley’s

Diameter of the smaller pulley’s ( 3 ) = 8 cm

Diameter of the bigger pulley’s ( 1 ) = 44 cm

Fig 6.11.2 Bigger pulley

Department of Mechanical Engineering, KIET Page 45


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.12 BENCH VICE

A vise is a mechanical apparatus used to secure an object to allow work to be


performed on it. Vises have two parallel jaws, one fixed and the other movable, threaded in and
out by a screw and lever.

Different types of vices

 Woodworking vice
 Engineer’s vice
 Machine vice
 Pipe vice
 Clamp - on

Engineer’s Vice

An engineer's vise, also known as a metalworking vise or machinist's vise, is used to


clamp metal instead of wood. It is used to hold metal when filing or cutting. It is sometimes
made of cast steel or malleable cast iron, but most are made of cast iron. The jaws are often
separate and replaceable, usually engraved with serrated or diamond teeth. An engineer's vise is
bolted onto the top surface of a workbench, with the face of the fixed jaws just forward of its
front edge.

Material - Cast Iron

Quantity - 3

Fig 6.12.1 Engineer’s vice

Department of Mechanical Engineering, KIET Page 46


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.13 SPRING

A spring is an elastic object used to store mechanical energy. When a spring is


compressed or stretched from its resting position, it exerts an opposing force approximately
proportional to its change in length Springs are usually made out of spring steel. Spring is used
in our machine in order to give the feeding which is required for the drilling operation. Spring is
kept between the drilling chuck and the feeding rod.

Fig 6.13.1 Compression Spring

Compression Spring

Compression springs are open-coil helical springs wound or constructed to oppose


compression along the axis of wind. Helical Compression Springs are the most common metal
spring configuration. Generally, these coil springs are either placed over a rod or fitted inside a
hole. When you put a load on a compression coil spring, making it shorter, it pushes back against
the load and tries to get back to its original length. Compression springs offer resistance to linear
compressing forces (push), and are in fact one of the most efficient energy storage devices
available.

Other types of springs are

 Torsion spring
 Tension spring

Department of Mechanical Engineering, KIET Page 47


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

6.14 NUT AND BOLT

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.

Bolts used for plumber blocks - M15

Bolts used for other purposes - M13

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.

Fig 6.14.1 Nut,bolt&washer

Department of Mechanical Engineering, KIET Page 48


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

7. MANUFACTURING

7.1 BODY FRAME

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.

Fig 7.1.1 Measurements of Iron bars

Fig 7.1.2 Welding of the frame

Department of Mechanical Engineering, KIET Page 49


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

Fig 7.1.3 Completed Body Frame

Department of Mechanical Engineering, KIET Page 50


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

7.2 Scotch Yoke Mechanism Attached To Main Shaft

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.

Fig 7.2.1 Attachment of iron bars to Yoke

Fig 7.2.2 Scotch Yoke Mechanism attached to Main shaft

Department of Mechanical Engineering, KIET Page 51


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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 :

Fig 8.1.1 Body frame with bench vice, drill tool

Department of Mechanical Engineering, KIET Page 52


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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

Fig 8.2.2 Mechanism attached on top of the frame

Department of Mechanical Engineering, KIET Page 53


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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 :

Fig 8.3.1 Motor attached to frame

Fig 8.3.2 Motor connected to pulley through belt drive

Department of Mechanical Engineering, KIET Page 54


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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 :

Fig 8.4.1 Multi Purpose Drilling,Grinding,Cutting&Shaping Machine

Department of Mechanical Engineering, KIET Page 55


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

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.

9.1 TESTING WITH WOOD

9.1.1 DRILLING OPERATION

Fig 9.1.1 Drilling Operation on wood

Department of Mechanical Engineering, KIET Page 56


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

OBSERVATIONS :

Diameter of Drill bit = 5 mm

Speed (r.p.m) = 690 r.p.m

Cutting Speed = π * Diameter of drill bit * r.p.m


1000

= 3.14*5*690
1000

= 10.838 metre/minute

Depth of drill = 22 mm

Total cutting time taken = 24.5 sec

Feed rate (f) = 1 mm (Suppose)

Metal Removing Rate = πfN(Diameter of bit)2


4

= 3.14*1*690*(5)2
4

= 135.48 mm3/minute

Department of Mechanical Engineering, KIET Page 57


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

9.1.2 GRINDING OPERATION

Fig 9.1.2 Grinding operation on metal

Fig 9.1.2.1 Surface grinding made on a metal


Department of Mechanical Engineering, KIET Page 58
Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

OBSERVATIONS :

Diameter of grinding wheel = 100 mm

Speed (r.p.m) = 561 r.p.m

Length of work piece = 45 mm

Width of work piece = 40 mm

Cutting Speed = π*Diameter of wheel*N


1000

= 3.14*100*561
1000

Cutting Speed = 17.62 meter/minute

Cutting time = 1 min 36 sec

Department of Mechanical Engineering, KIET Page 59


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

9.1.3 CUTTING OPERATION

Fig 9.1.3 Cutting Operation on wood

OBSERVATIONS :

Dimensions of wood

Width = 36 mm

Height = 24 mm

Time taken = 1 min 5 sec

Time taken by hand sawing = 2 min 28 sec

Department of Mechanical Engineering, KIET Page 60


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

9.1.4 SHAPING OPERATION

Fig 9.1.4 Shaping operation on wood

OBSERVATIONS :

Stroke length = 150 mm

Length of work piece = 80 mm

Width of work piece = 20 mm

Total strokes taken to complete the work = 168

Time taken for Forward stroke = 0.12 sec

Time taken for Return stroke = 0.08 sec

Department of Mechanical Engineering, KIET Page 61


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

Cutting Speed = LN(1+k)


1000

Where,

L = Stroke length

N = Total strokes taken

k = Time taken for Forward stroke


Time taken for Return stroke

= 0.12
0.08

= 1.5

Now,

Cutting Speed = 150*168*(1+1.5)


1000

= 150*168*2.5
1000

Cutting Speed = 46 metre/minute

Department of Mechanical Engineering, KIET Page 62


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

10. CONCLUSION & FUTURE SCOPE

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.

The multi purpose Drilling,Grinding,Cutting&Shaping machine that we developed as


a part of our project performed well in doing all the four operations with specific accuracy.

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.

Department of Mechanical Engineering, KIET Page 63


Fabrication of Multi Purpose Drilling,Grinding,Cutting & Shaping Machine

11. REFERENCE

Publications :

 [1]. Dharwa Chaithanya Kirthikumar, “A Research on Multi Purpose Machine”,


International Journal for Technological Research in Engineering (Vol.1, Issue.1,
ISSN:2347-4718) (2013).
 [2]. S.G.Bahaley,Dr.A.U.Awate,S.V.Saharkar, “Performance Analysis of Pedal Powered
Multipurpose Machine”, International Journal of Engineering Research and Development
(IJERD) (Vol.1, Issue.5, ISSN:2278-0181) (2012).
 [3]. M.Prathyusha, P.Mounika, G.Kalyani, G.Prashanthi, “Multi Purpose Machine
(Drilling, Sawing, Shaping)”, International Journal & Magazine of Engineering
Technology, Management and Research (Vol. 1, Issue.1, ISSN NO: 2348-4845).

Text Books :

 Theory of Machines by S.S. Rattan, TMH.


 Machine Design By V. Bandari, TMH Publishers.
 Manufacturing Technology, R.K. Jain.

Web References :

 http://en.wikepedia.org/wiki
 www.Howstuffworks.com

Department of Mechanical Engineering, KIET Page 64

Anda mungkin juga menyukai