Abrasive Cutting Machine: Seminar ON

Abrasive Cutting Machine
SEMINAR ON
ABRASIVE CUTTING MACHINE
By : VARUN .V. TALWAR
[ AISSMSS COE, PUNE, 2003-2004 ]
ACKNOWLEDGEMENT
I take this opportunity to show over deep sense of gratitude towards our respected H.O.D. Prof. PHADKULE for this guidance and support. I also sincerely thank my Project & Seminar guide Prof Mrs. NENE for her support knowledge for the seminar on & guidance for preparing a seminar & departing ABRASIVE CUTTING NACHINE.
CERTIFICATE
This is to certify that the seminar entitled
ABRASUIVE CUTTING MACHINE

Submitted by
TALWAR VARUN VIJAY

is a bonafied work carried out under the supervisor & guidance of Prof. Mrs. A.A.NENE. And it in approved for the partial fulfillment of the requirement of university of Pune, for the award of degree of BACHELOR OF ENGINEERING (Mechanical)
Prof. A. A. NENE
Guide, Mech. Engineering deptt, A.I.S.S. M.S.S. C.O.E., Pune,
Prof. V.N. PHADKULE

H.O.D., Mech. Engg. Dept, A.I.S.S. M.S.S. C.O.E., Pune,
COMPONENTS
The list of basic & essential component used in this of a machine are1. 2. 3. 4. 5. 6. 7. 8. 3 A.C. Motor ABRASIVE WHEEL BELT & PULLEY DRIVE MECHANISM COLOUMN OF THE MACHINE SUPPORTING BRACKET FRAME BASE PLATE OPERATING LEVER / HANDLE SCREWS / PINS FOR ASSEMBLY PURPOSE
SPECIFICATION
ABRASIVE WHEEL
Selection of wheel A, 24, T, 8, B, 27R When A 24 7 8 B 27R symbolizes AL2O3 also called as the grey wheel grain size very hard grade density of the wheel Resinoid board suffix (companys trade sign, manufacturing reference) minimum operating speed 6790rpm size of wheel = 230 X 3X 22.23 Motor We require a 3 1HP motor for such purpose machine 1HP 736 w Belt and Pulley Type of left v type Number of groove -2 Cross sectional symbol of belt A
COLOUMN
Material t Function = (C40) 290 N/ mm2 It supports and guide the arm which carries the
bracket assembly.
F bracket
Material t LEVER Material t ARM BLOCK t 190 N/mm2 MS (C40) 290 N/ mm2 C.I. (FG-40) 190 N/mm2
Pin in used to fix the F-bracket on the arm block.
Cast iron (CI) (FG40)
COSTING
Such kind of machine are not readily available but are some special kind machines (SPM) used for specific purposes. These machines are tailor made to suit specific requirements & have dimensions & specifications for every customer machine would are different to suit their kind of work. Hence, the cost of such machine comes out to be more expensive. The cost of the machine comes to be lees if large number of such machines are manufactured in a lot. The different costs listed below are The raw material cost, which comes to about 2000/- Rs approximately for the photographed machine. The manufacturing cost comes to about 3000/- Rs approximately of such a
The cost of standard part, and overheads come to about 5000/approximately. So the total cost of such a machine comes to about 10-10.5 k if small number of these machine are manufactured.
MERITS & DEMERITS

As we know each and every process to be having its advantages & disadvantages this process of abrasive cutting also has some advantages & disadvantages listed below.
ADVANTGES
1) The machine is smaller than the band saw & hex saw machine & hence less luck bulky. 2) The cutting operation is much faster as compared to the hex saw machine. 3) Heat developed is less as compared to the gas cutting operation which distorts the chemical composition & mechanical properties of the metal. 4) The wheel used is cheaper than the hex saw blade as the wheel is an abrasive wheel & the hex saw blade is a H. S. S. blade. 5) Carbide wheels are available for cutting of had materials. Such wheel are also called as green wheel. 6) Life of the wheel depends upon the martial being cut, force applied and such different conditions.
7) Use of lubricant is limited to the different applications where as in the band saw or hex saw machine lubricant has to be used irrespective of the material be cut. 8) Machine time & power consumed is less as compared to parting on a lathe as a power saw. 9) Cheaper & more cost effective than the other compared processes like parting on lathe or power saw machine.
DISADANTAGES
1) The wheel lying approximately 3mm thick, hence about 3mm material is lost in every cut which links about a loss when a lot of cuts have to be undertaken in smaller lengths. 2) Operator should take care that the large number of sparks being generated dont harm him & his surroundings. 3) Accurate wheel mounting should be done which takes less time. 4) Extremely hard & thick sections take time to cut out & cause wheel wear.
INTRODUCTION
Every time on the shop floor, it is required to cut metal piece from bar stock the existing methods to work out the same are:-parting on lathe -sawing (either by band saw or power saw) -Gas cutting etc. In case of parting on lathe one can find that the length of job should not be more than distance between tail stalk and chuck, big diameter and odd shape object are difficult to part. The sawing operations make use of to and fro-motion of H.S.S. band saw blade. The power saw machine is very bulky and it is not an easy task to cut soft and thin jobs as heavy clamping is required to resist high cutting force. The hand sawing is quite time consuming and its accuracy is very poor. The gas cutting is comparative quicker, but it thermally distorts the material. Also there is always danger of oxidation. Thus each of above processes has certain merits and demerits and it needs to have a special purpose machine, which will be more efficient, effective and economical. The wheel rotating at 5000 rpm is progressed in the job. The operation is very fast and good finish and accuracy is obtained.
CONCEPT
The basic concept behind working of the machine is as shown in photograph. The job is kept at fixed position. The arrangement is made such that the cutting plane is always perpendicular to machine axis i.e. plane of rotation of abrasive edge always passes through the point on the job which exactly coincide with the machine axis. Thus we position the job on the work table in such a way that the point on the job form which we required cut coincide with the machine axis. Than by changing the position of wheel, we can adjust any angle exactly.
CONSTRUCTION AND WORKING

Machine construction is as shown in the photograph. The main components are listed below: Circular column Base Machine arm and block Pin F bracket Spindle, bearing Pulleys and belts Motor 3 , 1HP 2880 rpm , foot mounted Abrasive wheel The column is mounted on the base exactly perpendicular to it. The column itself is a guide way form the arm. The block is linked with the column by means of arm carrying tensing spring mechanism. The block is having a vertical bore to pass the pin, about which the F bracket assembly swivels . The F- bracket used here, serves two purpose. It carries the motor as well as provide hub to spindle and accessories. The accessories include two bearing, spacer, bearing cap etc.
The wheel is mounted on the spindle in between two flanges. Belt drive is used here for transmission. Two double groove pulleys having A reduction ratio of 1:2. are employed.
INSTRUCTION
Following instruction should be followed by the operator while with the machine for safe operation. 1. As the rpm of cutter is very high, the abrasive wheel is guarded with a guard, so do not remove the guard and dont start the machine without them in position. 2. The abrasive wheel guard also provides protection against the spark of cutting. 3. Direction of rotation of abrasive wheel should be anti clock wise from the front. 4. While changing the direction of any particular job, check the lock nut on spindle. 5. Do not give feed to the cutter against the job instantly after starting, allow sufficient time to rotate the wheel with full speed. 6. Clamp the job properly on the lathe table so that it does not vibrate or move while cutting which in turn may cause breaking of the wheel. 7. Feed depends upon the type of material to be cut, give feed carefully smooth and continuous for proper cutting. Excessive
feed
may
cause jamming of wheel which in turn may cause wheel.
failure of
8. Do check every day the pulley, spindle bolts. 9. Clamp and unclamp the job when machine is in stop condition. 10. 11. Replace the wheel periodically when it gets worm out. Periodically, apply lubrication for the parts having relative For proper and safe operation of the machine, above instruction should be kept in mind. The machine will perform wonderfully well when we follow all guidelines and do proper maintenance of the machine.
motions.
COMPARISON
1) 2) 3) 4) 5) 6) 7) 8) As compared to the band saw machine. The process is very fast. Faster & more cost effective than hex saw machine. Power consumption is less as compared to the hex saw machine. Machine is for as cheap as compared to the lathe. Process is faster than hand sawing. Hard orders & material can be cut as compared to hand saws. Gas cutting is faster but chemical distortion takes place. Too much of heat generation takes place & hence lots of lubricant is used.
WORKING
1. 3. Job positioned on the base below the machine axis is clamped. Then by unlocking the pin, set the required degree. Here we are changing the position of whole assembly fixed with the pin. Tighten the screw to lock it with the arm block. 4. Start the motor to obtain the spindle rpm more than 500 rpm. 5. Give feed gradually with the help of the lever. 5. The frame of the machine is lowered on the job against the spring action and brought down till the grinding wheel touches the workpiece. Then the lever is pressurized even more so as to facilitate the cutting action. 6. 7. 8. After cutting stop the motor and then let the assembly reach its original position by means of the spring action. Unclamp the cut job and position next piece. For next cut repeat the same procedure for the rest of the cycles.
2. The job is held between the vice and clamped tightly.
9. If very hard and thick material has to be cut, lubrication should be taken care of.
ERGONOMIC & AESTHETIC CONSIDERATIONS

In brief aesthetic is the response of a human about a particular machine. While ergonomic is easy and convenient for use. There are various provisions on the machine, which make machine pleasant and give safety feeling while working on it. The column is rigidly fixed on the base. Also the base is having T slots as well as vice on it to hold the job securely. Three holes are also provided for the installation of the machine. The shape of F bracket and arm block is such that it gives a feeling of rigidly in the first sight. The F bracket is the cast part, which increases the damping capacity of the machine against vibrations.
The abrasive Wheel is mounted on the spindle shaft with taking aid of two flanges, which is rigid. Two roller bearings are provided, separated spacer in order to prevent the deflecting of the spindle. Fearing can is also be provided to protect the bearings from the dust, chips and foreign piracies. Various locking arrangements are also on the machine. The feed of the machine also can be constrained with help of the feed pin. One can lock the downward feed motion or the arm with help of the screw provided on the rear side of the machine when it is not in use. The 3 ph I H.P. 288O rpm motor is foot mounted on the robust looking upper plate of the F bracket. The power is transmitted through a double groove pulley and V belt mechanism.
The abrasive cutting wheel is covered in a strong safety guard. Grey paint is applied to make the mood of operator & also gives the machine rigid & unwearing look.
REFERENCES
1. Mechanical Engineering design. - By J. E. Shigley. 2. Machine Design - By R. S. Khurmi 3. 4. P. S. G. Design Data Book Production Technology - By H.M.T. Tata McGraw Hill Publication. 5. Material Science and Metallurgy
- By Dr. V. D. Kodgire.

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