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A Project Seminar on Click to edit Master subtitle style
Design & fabrication of sample holder & low rpm rotary motion mechanism for lapping machine to polish fatigue/tensile test sample
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Project team
Amrit Kumar Meher Kumar P
(1JS08ME008) (1JS08ME033) (1JS07ME009)
Nilesh
Chethan
Under the Guidance of: Dr. Shankargoud N
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introduction
Lappingis
aprocess in which two surfaces are rubbed together with anabrasivebetween them. can take two forms. first type (grinding), involves rubbing a brittle surface against another brittle surface with an abrasive in between them. produces microscopic conchoidal fractures as the abrasive rolls about
This The
This
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introduction
The other form involves a softer material for the lap, which is "charged" with abrasive lap is then used to cut a harder materialthe work piece abrasive embeds within the softer material which holds it and permits it to score across and cut the harder material
The The
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Problem definition
Our
aim is to achieve rotary motion of the holder at lower rpm value. We need to design and fabricate a mechanism for rotary motion of the sample at low rpm.
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objective
To
design suitable mechanism to simulate the hand lapping of fatigue/ tensile test sample. achieve proper result sand paper should move in a direction perpendicular to tool marks produced in the previous machining process (Turning on the lathe). have uniform surface finish, sample should be rotated at a low rpm, for this
To
To
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Design of individual part
Female Block Material Used = Mild Steel (EN8)
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Male Block Material Used = Mild Steel (EN8)
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Rocker Plate Material Used = Mild Steel (EN8) Hole is drilled for lift
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Fixture Material Used = Mild Steel (EN8) Made from 6mm sheet metal
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CALCULATION
Design of V Belt: d1 = Diameter of driver d2 = Diameter of driven 1. Selection of belt c/s Equivalent pitch diameter of smaller pulley
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CALCULATION
2. Velocity of belt V = (* d1 * n1)/60,000 V = 3.84 m/s 3. Power capacity N* = v((0.45/v0.09)) (19.62/ de ) ((0.765*
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CALCULATION
= 2cos-1 ((d1 d2)/ (2C)) = 104.73 0 From value in Table 22.26 Fd = 0.77
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CALCULATION
Speed of driven pulley: We Know, n1/n2 = d2/d1 n2 = 411rpm Gear box reduction ratio:
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Components and specification
Machine Stand Length = 675mm Width = 675mm
Fixture Thickness = 6mm Material =
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Gear Box 3Litre Wet Grinder
Motor Single Phase motor Power = 1HP Volt = 200/220V
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Pulley Diameter = 14inch
Drill Chuck 5mm-20mm Arbor and Chuck key
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Pulley Diameter = 7inch
Pulley Diameter = 2 inch Double Pulley
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Bearing with housing Inner dia = 20 mm Outer dia = 40 mm
Bearing Connected to shaft
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A32
A64
Belt
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Assembly showing Rocker Plate, Connecting rod, male and female block
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Rectifier Used in motor for DC to AC Conversion
DC Motor 3000rpm 12 volt
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Transformer 24 volt output Used for step down of voltage
Bush Material = Silicon Carbide Size = Inner dia =27
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Sanding Belt Grade 60, 120,240 available 60 grade used inch Width belt
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Machine 5
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1 2 3 4 5 6 7
Diameter = 185 mm Thickness = 4 mm Height = 159 mm
12V,3000 rpm Length= 800 mm
8 9
Male Female Block
DC Motor Shaft
COSTING DETAILS
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Input Materials(Direct Costs)
SL. NO 1 2 3 4 5 6 7 8 9
PART QUANTITY PRICE IN RUPEES
Motor Gear Box Drill Chuck DC Motor 14 Pulley 7 pulley Transformer Rectifier Paint
1 1 1 1 1 1 1 1
3800 2500 1000 1400 680 400 300 50 200
COSTING DETAILS
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Input Materials(Direct Costs)
SL. NO 10 11 12 13 14 15 16 17 18
PART QUANTITY PRICE IN RUPEES
A32 V belt A64 V belt Sand belt Bearing Bearing housing Shaft Bush Bearing(small) 2 Double
1 1 1 2 2 1 3 1 1
50 75 55 125 800 500 600 75 200
Assembly Costs (Indirect Costs)
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Sl . NO. 1 2 3 4 5 6 7 8 9
FABRICATION
PRICE IN RUPEES
Male and Female block Cutting, Drilling, Slot Cutting etc Connecting rod Fixture Rocker Plate Labor cost Transportation cost Frame Miscellaneous (bolts, nut
400 200 150 350 300 2000 1500 1700 300
Assembly Costs (Indirect Costs)
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Sl . NO. 10 11 12
FABRICATION
PRICE IN RUPEES
Electrical Over Costs Sub Total TOTAL
250 1000 8,150 Rs. 20,960/-
CONCLUSION
Simple
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in design Economical Less space requirements Less skilled man power required
SCOPE FOR FUTURE WORK
Speed can be decreased by using 3 phase motor and connecting to vfd(variable frequency drive) qNoise reduction in machine can be achieved by using more rigid design and by using damper and rubber pads etc. qSample holder can be designed for holding different sizes of sample.
q
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Bibliography
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BOOKS
Design of Machine element, JBK Das Dr. K Lingaiah, Machine Design Data Handbook, Suma Publishers, 4th Edition, 2006
WEBSITES
www.google.com www.wikipedia.com www.sciencedirect.com www.ebay.in
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THANK YOU
