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ACKNOWLEDGEMENT
I am very glad to represent project report on "PAPER CUTTING AND
REWINDING MACHINE" fully designed, fabricated and tested in our polytechnic
as part of our curriculum is awarding the Diploma in Engineering. I have tried my
level best to focus upon each and every parameter. In concern with this topic the
detail, necessary figure, definition, tabular analysis has been enumerated in very
easy, simple, compact and lucid manner.
Triprayar
03/13/2013
SEVENTH BATCH
Mechanical Engineering
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ABSTRACT
Paper Cutting & Rewinding Machine is one of the simplest machine which cuts
rolled paper in needed amount and re-winded form. The conventional paper rewinding
machine has complex mechanism and bulk size. We made some modification to the
conventional machine and eliminating its defects. The main peculiarity of machine is its
simplicity, reduced size, weight. And also reduces floor space. This project can be
directly implemented to paper cutting and rewinding machines in Paper mills. This
machine can also use in textile mills, plastic and rubber sheets cutting and rewinding
process in various industries by changing its cutting components.
By applying these modifications to the conventional machine reduce
maintenance and servicing cost, floor area and overhead expenditures. It is well suited
for small scale industries.
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CONTENTS
TOPIC NO.
TOPIC NAME
PAGE-NO.
1.
INTRODUCTION
2.
3.
FINANCIAL MANAGEMENT
12
4.
MARKET SURVEY
13
5.
17
6.
SITE SELECTION
20
7.
28
8.
COMPONENTS OF MACHINE
30
9.
MANUFACTURING PROCESS
35
10.
WORKING OF MACHINE
42
11.
PROCESS OF MANUFACTURING
43
12.
46
13.
SPECIFICATIONS OF MACHINE
46
14.
DRAWINGS
47
15.
52
16.
CONCLUSION
54
17.
BIBLIOGRAPHY
55
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INTRODUCTION
Definition Of Project :A project is a group of unique, inter-related activities that are planned
and executed in a certain sequence to create a unique product or service, within a
specific time frame, budget and the clients specifications. Some of the
characteristics of the task that qualify to be projects are:
1)
Unique Activities
2)
3)
Sequence of activities
4)
Specified time
5)
Interrelated activities
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A project is investment activities where resources are create some capital assets
that will produce some benefits over a spread of time. Every project will definitely have
the following characteristics.
1)
performance.
2)
3)
cost
benefits analysis.
The whole cycle of a project has to come through seven different stages
1) Containing of idea (identification of an activity)
2) Formulation of a scheme (here we prepare the project report)
3) Project reports Appraisal
4) Project monitoring
5) Implementation
6) Evaluation of the project implementation
7) Taking corrective measures for improvement
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Once a project has been identified the first step is to find out the price of
machinery and raw materials. Get the latest quotations for the machineries.
After ascertain the price of plant, machinery and raw materials. Find out the mages of
employees prevalent in the area. Now calculation regarding the profit return and breakeven point etc. has to be done.
A detailed market study had to be conducted and the same should be
incorporated into the project report (it is a must when the project cost is over 20 lakhs).
The market study should certain in the total demand for the product and present
manufacturers of the product, their installed capacities. Marketing arrangement
including channels of distribution, logistics, etc.
Technical area
II.
Economic area
III.
Commercial area
IV.
Financial area
V.
VI.
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I.
Topic covered:
1) Selection of the materials
2) Arc welding
3) Types of fits
4) Types of threading
5) Estimating and costing
6) Quality control
7) Production drawing
II.
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Procedure for Design of Machine Elements :The design of machine element is the most important step in the
complete procedure of machine design. In order to ensure the basic
requirement of machine elements, calculations are carried out to find out
the dimensions of the machine element. These calculations form an
integral part of the designing of machine elements. The basic procedure of
the design of element is as follows:
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ORGANISATION
FOR FINANCIAL
ASSISTANCE
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3.
KERALA STATE DEVELOPMENT CORPORATION
FOR SCHEDULED CASTE AND SCHEDULED TRIBES LTD.
1.
2.
3.
4.
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BANK
State bank of India operates a scheme of coordinate credit assistance to
small scale industries. The financial assistance is provided to craftsman and
technical qualified entrepreneurs who have sound project and are not able to
provide what is called owner equity of minimum capital usually required to
secure loan.
Other facilities available to the small scale industries in Kerala facilities
for incentives available from the state governments are :1.
2.
3.
4.
5.
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FINANCIAL MANAGEMENT
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INTRODUCTION
Every business enterprise erective of its nature and scale of business
needs finance to carry out its activities and accomplish certain business
objectives. No business venture can assure can succeed unless it has enough
money to take advantage of any opportunities that may arise. Finance is the life
blood of any business.
The management of finance therefor plays a key role in the anticipation
of financial needs, acquiring financial resources and allocating funds in the
business. In fact it determines the success or failures of any business activity.
The economic objectives of a business organization are profitable, growth and
survival. The attainment of these objectives largely depends up on the efficient
management of finance.
Financial management basically deals with procurement of funds needed
by the enterprises on the most favorable terms in the light of their objectives. It
is only concerned with effective procurement of funds but also on the efficient
utilization of funds.
DEFINITION
The finance function is concerned with the process of acquiring and
efficiently utilizing the funds of a business system, with the objective of
maximizing the value of firm. Financial management involves the application of
general management principles to the financial function.
According to hog land, financial management deals with how the
corporation obtains the funds and how it uses them.
Financial management may also be defined as that part of management,
which is concerned mainly with raising the funds for the enterprises in the most
economical manner, utilizing those funds are profitably as possible for a given
risk level, planning future investments and controlling current performance and
the future development through financial statistics and other means.
FUNCTIONS OF FINANCIAL MANAGEMENT
The financial management begins a strategic and key area of
management involves variety of functions form the view point of effective
management of finance, the finance function can be categorized as
1.
Executive finance functions.
2.
Routine finance functions.
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Control on cash
Custody and safe guard of the document
Record keeping
Management reporting
INCREASE IN PROFILES
A firm should increase its revenues in order to maximize its value. The
profits of the firm are maximized, when the firm is in the equilibrium. At stage
in the average cost and the revenues are equal.
REDUCTION INCOST
A firm should make efforts to reduce the cost of the capital and to launch
its economy in its operation.
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CAPITAL
In order to start to run a business i.e.; to produce and to sell goods or
services, money has to be invested the money invested in the business in order to
yield an income is known as capital.
Capital is needed for the following purposes;
o Purchasing fixed assets (building, equipment, machinery, tools,
furniture etc.)
o Purchase raw materials and other supplies
o To meet the day expenditure such as wages of workers, selling
and distribution expenses, equipment and plant maintenance cost
etc.
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PROFITABITITY
Any product proposed to be manufactured should ensure reasonable return on
investment the manufacture of the product should be economical viable. The proposed
product should have come out from the laboratory levels to exploitation.
TECHNICAL FEASIBILITY
The proposed product should be technically feasible. It should be within the
technological competency of the entrepreneur.
STABILITY
The proposed product should have stable sails all the year round otherwise the
cost of production may go up and make product unstable. This may cause difficult to
plan May production and procurement program. In such cases it necessary to find out
alternatives uses for man machinery and equipments during the slack season.
REASONABLE GROWTH OVER TIME
The proposed product should give reasonable growth over a period of time in
order to ensure a progressive return to the entrepreneurs.
PROJECT CAPACITY
After conducting market survey the capacity of the project must be decided
considering the amount of money can be arranged i.e.; by partnership, through banks,
financial corporation or shares. While deciding the capacity of the project following are
the factors which should also be considered.
1)
2)
3)
4)
Demand product
Whether the demand is regular or fluctuating
Quality of powder, water, land, material available
Nature of product
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SITE SELECTION
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SITE SELECTION
Having taken a decision to start a factory it is important to select a suitable site
or location. The site has great effect on the success or failure of the operation of the
factory, so maximum importance should be given to the site selection. Therefore while
selecting a site the owner or management must consider technical, commercial and
financial aspects and then to select a site the owner or management must consider
technical. Sometimes it is not an easy affair to find a place where possess all
requirements. In such cases we have to analyses the merits and demerits of the place to
be selected and taken a favorable decision.
The problem of site selection of factory can be solved in the following two
stages
A.
B.
3. TRANSPORTATION FECILITIES
Transportation costs play a very important role then we have to see that the cost of
transportation should remain fairly small in production to the total cost depending upon
the order of raw materials and finished goods. A suitable method of transportation like
road, rail, air and water is selected and accordingly the plant location is decided.
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B.
1)
2)
3)
4)
5)
6)
7)
8)
The availability of cheap land to build and expand the plant in future.
The cost of leveling the land and providing foundation subsoil and drainage.
Cost of building materials like granite, bricks, literate sand and cement, lime.
Facilities for transport in getting and sending materials.
Facilities for housing the workers and if necessary,
Cost of installation of electricity, gas and other facilities.
Cost laying the water supply and providing the sewage.
Cheap possibilities of disposing of trade waste efficient treatment.
REGISTRATION OF PLANT
The next step is to ensure the implementation of the project. If in case, the
entrepreneur is interested in getting financial assistance from institutional agencies, it is
necessary for him to prepare and submit a feasible project report for their acceptance.
To apply and avail of the various facilities, incentives and assistance available from
various instructions like district industrial Centre, national small scale Industries
Corporation and various financial institutions. It is necessary for the unit to itself
registered with director of industries and commerce. The registration of the unit is done
in two stages via
1)
2)
Provisional registration
Regular registration
PROVISIONAL REGISTRATION
Provisional registration is meant to enable party to make necessary steps during the unit
into existences. A provisional registration is valid up to six months and it can convert to
regular registration later on. The provisional registration entities the part to
i.
Apply for a shed in an industrial state, developed site in an industrial area/
material for the construction of the shed, as the case may be.
ii.
Apply to corporation, municipal/ panchayath other local authorities for construct
the establish a unit.
iii.
Apply for power connection
iv.
Apply for the financially institution on the basis of a project may require by
them
v.
Apply to the N.S.L.C/S.S.L.C/ other institution for procuring machinery in hire
purchase basis.
vi.
Obtain sales tax, exercise, and duties etc. registration whenever required.
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REGULAR REGISTRATION
When the party has taken all steps for establishing the unit, i.e.; when the factory
building is ready, power connection is given the machinery has been installed etc. and
he can apply for the machinery has been installed etc. and he can apply for the regular
registration of the unit. Within the seven days on the receipt of application, the district
industries officer or other designed officer will inform the party to the date and time for
inspection of the unit. On being satisfied that the unit is capable of production activity, a
registration certificate is issued by the directorate of industries and commerce.
MANAGEMENT
It is easier to a new unit, than to manage it successfully managing a unit is a
continuous process; the entrepreneur should have initiative, drive clarity of ideas and
should be in a position to enlist the cooperation of the workers to achieve the common
goals in order to achieve this goal, the entrepreneur must be in a position to manage all
this firm i.e. manage all the things come in action successfully. His success depends
upon the attention that the entrepreneur pays to the various things, problem like
arrangement of raw materials, scheduled production, proper management of labor,
timely arrangement of finance, to the scheduled and asserting to cost of production.
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MARKET SURVEY
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INTRODUCTION
Market survey is a scientific study of all problems relate to the transfer
and sale of goods produced from producers to consumers. Market survey
provides necessary statistics helpful for forecasting and planning a project before
starting a business, market survey is very essential to know about what must be
produced, how much be produced, who are the purchasers, and where they are
located, margins of profit etc.
Thus the main object of market survey is find out the future of the
proposed products in the initial stage preliminary survey is done by some
experienced analyst and if this preliminary survey supplies sufficient
information that there is no profitable market for the product to be manufactured
then further detailed survey is not required. If preliminary survey provides some
hope then only detailed survey is done.
The following points area of the most importance while making market
survey.
1)
2)
3)
4)
5)
Helps the entrepreneur to know the market potential for his products(s).
To know other competitions producing the same product(s).
Fix the production rate proportional to consumers demand.
Helps in fixation of price in accordance with demand.
Accelerate sales.
Helps to discover new market opportunities
Induces confidence in entrepreneur to make investments in production.
Helps in predicting changes in market. I.e. Sales position or
expansion/shrinkage for a particular product.
Reveals customers requirements, tastes, purchasing capacity,
preferences for a particular brand, buying motives and habits etc.
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MARKET RESEARCH
All industries enterprises it develops product for direct market applications
without having any idea in advance of consumer acceptance of the product takes
quicker risk.
On the country another concern lends to learn consumer action to product prior
to manufacturing the same.it does not involve any risk associating high
expenditures.
Market research may be defined as organized approach which includes all our
research activities involved in the market.
1) Gathering recounting and analyzing the activity and marketability of the
Product.
2) The nature of the demand
3) The nature of completion
4) The method of marketing
5) Other aspects of movements of problems from the stage of production to the
point where they consumed.
Market research provides an effective sales forecast. It also promotes soundness
of marketing decisions.
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Stress Reliving Of Welded Joints:Welded joints are subjected to residual stresses due to non-uniform
heating of parts being joined. There is always possibility that localized
thermal stresses may result from uneven heating and cooling during fusion
and subsequent cooling. This is also results in distortion. The magnitude of
residual stresses cannot be predicted with any degree of certainty. This is the
major disadvantage of welded joints. Following two methods can reduces
the residual stresses.
a) Preheating of the weld area to retarded cooling of the metal in the
vicinity of the joint.
b) Stress reliving of weld area by using proper heat treatment such as
normalizing and annealing in temperature range of 550 C to 675 C.
One of the methods of stress reliving is 'hand peening'. It consists of
hammering the weld along the length with peen of hammer while joint is
hot. It reduces residual stress and induced residual compressive stress on
surface. This improves fatigue strength of joint.
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1) BASIC FRAME
The entire unit is mounted on a rigid frame. The frame is made of
mild steel C- Channels (75X40 mm) connected in rectangular form and weld
at their joints.
2) ROLLERS
The paper rotating element in this device is the 89 mm outer
diameter rollers with 40 mm outer diameter journals, which made up of
three components.
1) G. I Hollow Pipe of 89 mm outer Diameter.
2) M.S Rod of 40 mm Diameter.
3) M.S Circular Plate of 81 mm Diameter.
The rotation of motor is transferred to the one of the four rollers on which
cut paper is mounting in operation. The rotating roll makes all other three rollers
to rotate. The roller is supported at its two ends by Plummer block with ball
bearing blocks. The main functions of roller are to favor the cutting operation by
moving paper and rewind it to rolls.
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4) PLUMMER BLOCK
The roller is supported at the two
ends with the help of Plummer block fitted
with 40 mm diameter Ball bearings. The
bearings are cleaned and greased for easy
rotation of roller.
5) BEARINGS
Ball bearing is a type of rolling-element bearing that uses balls to
maintain the separation between the bearing races.
The purpose of a ball bearing is to reduce 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 in Plummer block and the other is
attached to rollers journal. 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.
Ball bearings tend to have lower load capacity for their size than other
kinds of rolling-element bearings due to the smaller contact area between the
balls and races. However, they can tolerate some misalignment of the inner and
outer races.
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6) INDUCTION MOTOR
An induction or asynchronous
motor is an AC motor in which all
electromagnetic energy is transferred by
inductive coupling from a primary winding
to a secondary winding, the two windings
being separated by an air gap.
The machine is powered by 1 Hp motor with 1440 rpm. This makes
one roll rotates and rotating roll makes other rollers to rotate and not only
wound the paper but also pull the paper to make the operation going.
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MANUFACTURING PROCESS
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MANUFACTURING PROCESS
I.
Step One:
First cut the c-channel in pieces of length 71" (i.e. 6 feet [180 mm]- two pieces)
and in 36" (i.e. 3 feet[91.5 mm] - three pieces). Then Put the two lengths of 6 feet
parallel to each other at a distance of 3 feet from each other. Then put the lengths of 3
feet on either end of two parallel lengths and weld them as shown below. The two
diagonals must be same.
Step Two:
Then cut four pieces of c-channel of length 24" (i.e. 2 feet[61 mm]) and weld
two of them on one end of rectangular structure vertically using engineers block. Then
weld remaining two pieces vertically at a distance of 30" from previous pieces.
Step Three:
Then brought the two pieces of flat of size 75 X 12 X 760 mm and weld them on
the top of four columns as shown.
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Step Four:
Then cut another two pieces of
length 48" (i.e. 4 feet[122 mm]) and
weld them vertically at a distance of
16" from previously welded columns.
Afterwards weld the previously cut
piece of 36"[41 mm] on top and in
between the upper ends of these
columns.
Step Five:
Then cut two pieces of C-channel of
length 15". And four pieces of 4" length. Then
at a distance of 4.5" from nearest end weld
them to form a frame as shown below.
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II.
Roll is mead up of hollow pipe, solid circular plates & solid shaft journal.
So we have to manufacture each part as per required size and then assemble it as
a roll. Steps in this task are:-
Step one:
First, brought the hollow pipe of required dimensions. I.e. of required outer,
inner and length. If it not available, then cut it on hacksaw machine.
Step two:
Then brought two circular plates of 10 mm thickness, face them from both
sides by holding them on lathe machine. And turn out to the diameter as equal to
inner diameter of hollow pipe so they can fit into pipe for welding purpose.
Step three:
Take solid bar of M.S. of 50 mm diameter cut it to length 110 mm. Hold
this bar on lathe chuck and turn it out up to the diameter 38 mm so that it can be fit
in pedestal self-aligning bearing block.
Step four:
Now, weld the turned solid bar to each of two s o l i d circular plates axially.
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Step five:
Step six:
The roll is completed, but because of welding different parts it
need to be turned again using lathe machine. Hold the journal on one
side in chuck and turn the other journal as well as hollow pipe part of
roll. Do the same operation by holding other journal in chuck so the roll
will rotate along its axis accurately.
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III.
The c-clamp with the two bolts to clamp and one extended piece of flat for
mounting of cutter is welded. It is used to hold the cutter.
Step One:
First take the flat of 25 X 10 and cut it by bend saw in size of 90 mm,
65mm, 60 mm and 40 mm.
Step Two:
Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of 40 mm
in length and weld it on the 65 mm side of clamp.
Step Three:
By using drilling machine, make three holes of 10 mm at the points shown below in
the complete assembly of cutter. Afterwards perform the tapping operations using
tap of inch.
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IV.
DRIVING MECHANISM
As our project as a demo and also designed for small weight
we use the 1 Hp A.C. motor. It is having the 1440 rpm speed. We use
two pulleys of three [7.62 mm] & eight [20.32] inch diameter
respectively on motor and roller. One on the motor shaft and another
is on the shaft of roll. The numbers of belts required for given
application is one. V-belt is used for
this purpose.
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V.
WORKING OF MACHINE
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PROCESS OF MANUFACTURING
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Marking :This is the process of dimensioning the raw material to the required
size. This is usually done by scriber and steel rule. After marking, the lines
are punched by using a dot punch.
Cutting :Cutting is used for the separation of parts. This operation has
been adopted on the following items:
C-Channel, M.S Flat, M.S Rod, G.I Pipe, M.S Circular Plate,
Cast Iron Block.
Grinding :Grinding operation are used for finishing the surfaces which are
previously file or cut by a hack saw. Grinding is also for removing
excess material and foe smoothing the sharp curves of the welded
portion. A grinding machine which is either fixed or flexible is used for
the above operations.
Drilling :It is the process of making holes in the desired position. For
fixing clamp to the frame by bolts has been done.
Department of Mechanical Engg.
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Lathe operations :The most essential part of the manufacturing of Paper Cutting &
Rewinding machine is the lathe work. The roller making and boring
pulleys are done by lathe work. The main operations included in the
lathe work are turning, drilling, chamfering etc.
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Advantages
1)
2)
3)
4)
Disadvantages
6) When the winding and cutting operation is going on there is no
way to find that how much paper had been wound and how
much is remained.
SPECIFICATIONS OF MACHINE
Length
6 feet ( 152.4")
= 387.096 mm
Width
Height
Components
Motor
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DRAWINGS
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DESCRIPTION
QTY.
760 X 89 mm G.I
Pipe(4 Nos )
25 Kg.
M.S. Rod
135 mm X 50 mm
24 Kg.
Rs. 1392.00
7 Kg.
Rs. 406.00
M. S. Flat 12 X 75 X
760
(2 No
11 Kg.
Rs. 638.00
C-channel
75 X 40 ( 12.2 meter )
76 Kg.
Rs.4400.00
8 No.
Bearings 40 mm
Inner
8 No.
Pulleys 3"
1 No.
Rs. 150.00
Pulley 8"
1 No.
Rs. 540.00
V- Belt of B-type
1 No.
Rs.180.00
10
Paper
4.1 kg
Rs.131.00
11
Motor 1 Hp Induction
Motor (2nd Hand)
1 No.
Rs. 2500
Rs. 2500
12
Travelling Charge
---
------
Rs.1,160.00
Total
Rs.14,962.00
Plummer Blocks
6
No 208 i.e. 40 mm
RATE
AMOUNT
Rs. 2025.00
Rs.1600.00
Rs. 240.00
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CONCLUSION
The matters discussed in the earlier pages just have a broad outline for starting
and managing an industry in small scale sector. We have tried our level best to give a
clear picture about the needs, and requirement of industries which produces. We have
been made an attempt to reduce handling cost and material movement. The main
consideration in the layout and planning is practical rather than the accuracy of facts and
figures. It is hoped that the report will be an immersed us to all investigator Interested in
preparing the project. However it shall be always born business and practical standpoint
We hope that we can be proud of the efforts. We employing in getting this
project work completed. It helped us to study a lot of things and practice in various
techniques. We hope that this project will helpful to the students in polytechnic to
understand the working of Paper Cutting & Rewinding Machine. We will be grateful
those who have co-operated with us once again thanking them.
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BIBLIOGRAPHY
Forbes Marshall- Engineering Data Book
Workshop Technology- B.S. Raghuwanshi (Vol. I & II)
Production Management- ICFAI University
Elements of machine design- V. B. Bhandari
Strength of materials- R. K. Bansal
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