Professional Documents
Culture Documents
GUIDED BY:
MR. PAVAN M. BHATT
SUBMITTED BY:
1 JAY P. PAREKH 126540319088
2 MITESH A. PRAJAPATI 126540319090
3 PRATIK B. MAHERIYA 126540319091
4 SAHIL I. MANSURI 126540319093
5 KIRTAN TALAVIYA 126540319089
1
POWER HAMMER PROJECT REPORT 2015
CERTIFICATE
This is to certify that project work embodied in this report entitled
“Power hammer” was carried out by
1. Jay P. Parekh 126540319088
2. Kirtan R Talaviya 126540319089
3. Mitesh A. Prajapati 126540319090
4. Pratik B. Maheriya 126540319091
5. Sahil I. Mansuri 126540319093
Date:
Place:
V.P.M.P. Polytechnic-Gandhinagar
2
POWER HAMMER PROJECT REPORT 2015
ACKNOWLEDGEMENT
Last but not least I wish to avail myself of this opportunity, express a
sense of gratitude and love to my friend and my beloved parent for their
manual support, strength, and help and for everything.
Place: Gandhinagar
ABSTRACT
To design and fabricate a simple mechanical operated
power hammer by applying the principle of kinematic
arrangement and machine design concepts.
3
POWER HAMMER PROJECT REPORT 2015
INDEX
1. INTRODUCTION……………………………………………..6
2. HISTORY AND DEVLOPMENT OF POWER HAMMER…15
3. EXPERIMENTAL WORK…………………………………...20
4. DESIGN CALCULATIONS……………………………...…..25
5. OPERATION SHEETS……………………………………….31
6. COST ESTIMATION………………………………………....36
7. PART AND ASSEMBLY DRAWINGS……………………...38
8. CONCLUSION………………………………………………..39
9. REFERENCE………………………………………………….40
4
POWER HAMMER PROJECT REPORT 2015
1.INTRODUCTION
ABOUT OF PROJECT WORK
The Aim of course can achieve By learning in classroom and
laboratory. however, Threw the project something extra Knowledge
can achieve.
5
POWER HAMMER PROJECT REPORT 2015
APROJECT MEANS
TECHNIQUES
6
POWER HAMMER PROJECT REPORT 2015
7
POWER HAMMER PROJECT REPORT 2015
The simplest and the basic kinematic chain is a four bar chain
or quadratic cycle chain, as shown in below fig. It consists of four
links p, q, l and s, each of them forms a turning pair. The four links
may be of different lengths. According to Grasshof’s law for a four
bar mechanism, the sum of the shortest and longest link lengths
should not be greater than the sum of the remaining two link lengths
if there is to be continuous relative motion between the two links.
8
POWER HAMMER PROJECT REPORT 2015
9
POWER HAMMER PROJECT REPORT 2015
Applications:-
Forging
Forging refers as the process of plastically deforming metals
or alloys to a specific shape by a compressive force exerted by some
external agency like hammer, Press, rolls, or by an upsetting
machine of some kind. The portion of a work in which forging is
done is termed the forge and the work is mainly performed by means
of heavy hammers, forging machines, and presses. Forging
processes are among the most important manufacturing techniques
since forging is used in small tools, railroad equipment, automobile,
and aviation industries.
1
0
POWER HAMMER PROJECT REPORT 2015
Forging Processes
The processes of reducing a metal billet between flat-dies or
in a closed impression die to obtain a part of predetermined size and
shape are called smith forging and impression-die forging
respectively. Depending on the equipments utilized they are further
sub-divided as hand forging, hammer forging, press forging, drop
forging, mechanical press forging, upset or machine forging.
1
1
POWER HAMMER PROJECT REPORT 2015
Press
Press working involves production of final component from
sheet metal in cold condition. The machine which is used to apply
the required pressure of force in a short duration is called press. The
press consists of a frame, supporting bed and ram. The ram is
equipped with special punches and moves towards and into the die
block which is attached to a rigid body. The punch and die block
assemble are generally referred to as a die set or simply die.
A disadvantage of press working is that the operations are
carried out at room temperature and the metal is less deformable of
strain hardening.
Classification of Presses
Presses are classified in various ways as listed below.
(i) Mechanical press. (ii)
Hydraulic press.
1
2
POWER HAMMER PROJECT REPORT 2015
2.PROBLEM DEFINITION
The conceptual design was based on the principle of design by
analysis [Norton, 2006]. The methodology adopted was to examine
the most critical defects of conventional hammer mills and provide
solutions. Thus the following defects or problems were identified
and corresponding solutions were proffered. Problem 1
As a result of wear and corrosion the sieve screen holes enlarge or
burst thereby allowing larger than desired particles to pass through.
Solution 1
Eliminate sieve screens. Introduce an endless sieve that is a
dimensionally controlled “open gate”. Problem 2
After several hours of hammer mill operation, the sieve screen holes
are clogged thereby reducing its efficiency and capacity. Solution
2
The solution to problem 1 eliminates problem 2
Problem 3
Wet materials become elastic and therefore absorb most of the
impact energy of the hammer without breaking. This reduces the
efficiency of conventional hammer mills.
reduces the efficiency of conventional hammer mills. Solution
3
Introduce a fan to induce forced convection and rapid drying of
material
Problem 4
Adequately broken particles can be collected when they fall through
the sieve hole by gravity. Due to the relatively large gap between the
hammers and the screen, this will be inadequate and therefore
clearly inefficient.
1
3
POWER HAMMER PROJECT REPORT 2015
Solution 4
Solution 3 eliminates problem 4 as pressurized air can lift particles
of sufficient sizes through great distances. This is observed in
tornadoes and cyclones. Problem 5
Materials being crushed by conventional hammer mills cannot be
recycled until they are reduced to the required size before trying to
force them through the sieve holes. This is probably the greatest
cause of burst holes. Solution 5
A mechanical separator, which rotates at the same speed as the shaft
ensures that all solid particles above certain sizes are blown back
into the hammer mill chamber until they are ground or broken by
impact into fine particles. Problem 6
Some of the particles produced by hammer mills are in the form of
dust. They usually constitute 5- 10% of the raw materials and are
lost as dust into the atmosphere. They constitute serious health
hazard to the human operators of the hammer mills as they enter the
lungs (which can lead to cancer) and ears (which can lead to hearing
loss), eyes (which can lead to blindness), et cetera
2The dust particles escaping into the atmosphere would eventually
settle on roofs of buildings, leaves of trees, and on animals thus
causing pollution and damaging the ecology of the immediate
environment.
Solution 6
Install a large sedimentation chamber with long tubes so as to
virtually remove all the dust at the point of generation. This is
greatly aided by solution 3 as the fan generates the required suction
pressure. The design factors considered to be of utmost importance
in this design were function, maintenance, reliability, safety and cost
(Norton, 1999). The introduction of a sieve less screen for
separating the right size of particles from the unwanted ones ensures
1
4
POWER HAMMER PROJECT REPORT 2015
1
5
POWER HAMMER PROJECT REPORT 2015
1
6
POWER HAMMER PROJECT REPORT 2015
Pneumatic hammer
The hammer has two cylinders compressor cylinder and ram
cylinder. Piston of the compressor cylinder compresses air, and
delivers it to the ram cylinder where it actuates the piston which is
integral with ram delivering the blows to the work. The
reciprocation of the compression piston is obtained from a crank
drive which is powered from a motor through a reducing gear. The
air distribution device between the two cylinders consists of rotary
1
7
POWER HAMMER PROJECT REPORT 2015
valves with ports through which air passes into the ram cylinder,
below and above the piston, alternately. This drives the ram up and
down respectively.
Hydraulic hammer
In this hammers instead of air oil was used. The cost hydraulic
hammer is high as compared to the pneumatic hammers. Hydraulic
hammer is used in high force applications. These are noise less.
Power hammers
1
8
POWER HAMMER PROJECT REPORT 2015
1
9
POWER HAMMER PROJECT REPORT 2015
2
0
POWER HAMMER PROJECT REPORT 2015
3. EXPERIMENTAL WORK
Construction
As shown in above diagram it consists of 5 links, and one fixed
link. The five links are crank (link 1), link 3. Connecting rod
(link 4), Crank (link 5) and Ram die
(link 2).Column can be considered as a fixed link. The link 1 rotates
about a turning pair F, it is rotated by a pin joint axis, the link 3 and
link 1 is connected by a turning pair E. The connecting rod (link 4)
and link 3 are connected by a turning pair D. The crank (link 5) is
fixed at a turning pair A and oscillates about the pin joint axis.
Crank(link 5) and connecting rod (link 4) are connected by a turning
pair B.
2
1
POWER HAMMER PROJECT REPORT 2015
2
2
POWER HAMMER PROJECT REPORT 2015
Ram die
Mild steel material of required dimension is cut on power hack
saw. The material was fixed on the chuck in a lathe machine for
doing facing and turning operations. Polishing was done for good
surface finish. Chamfers were made for removing sharp corners. A
hole was drilled at the end of the ram of the required size for fixing
the slider pin. A slot was milled on the rod to insert the connecting
rod in the slot and fixing it in the slider pin. At the other end of
The ram a hole of required size was made and then later it was taped
at the same end to make the fixing adjustment of the punch with the
help of a screw.
Composite Bush
It was manufactured by two different materials one of Mild
steel and other was liner made up of Gun metal. The outer one is
made up of Mild steel on which facing and turning operations were
done on a lathe and then the inner one was made up of Gun metal on
which facing and turning were carried out of the required size then
2
3
POWER HAMMER PROJECT REPORT 2015
the liner was inserted in the outer bush by the application of a press
fit.
Column
The Column is made up of Mild Steel of required dimension.
First the marking for the holes to fix the links were done on the
column. The outer profile was marked and then made to cut on a gas
cutter, and then it was milled to the required size and then finally
chamfering was done to remove unnecessary sharp corners and
edges. Drills were drilled on the column for bearings, turning pairs
F and A. Then the composite bush was welded on the column. Vice
was fitted on the column by the application of welded joints for
holding the work piece.
2
4
POWER HAMMER PROJECT REPORT 2015
2
5
POWER HAMMER PROJECT REPORT 2015
4.DESIGN CALCULATIONS
2
6
POWER HAMMER PROJECT REPORT 2015
=6000/75
∴Effective area (A) =80 mm²
The formula for the minimum effective area is obtained as bt – (dt)
it can be observed in the link as in the fig2.1
Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross
sectional area in the entire mechanism. We know that stress is
inversely proportional to the area, so the minimum area leads to
increase the stress. So it is always preferred to design any machine
by taking minimum cross sectional area as effective area.
2
7
POWER HAMMER PROJECT REPORT 2015
The below diagram is for the finite width plate with a transverse
hole.
2
8
POWER HAMMER PROJECT REPORT 2015
σmax
σnom=σ max
kt
5886 =150
(20 - a)6 2.3
5886 =65.22
(20 - 6a)
5886 = 65.22(120-6a)
5886 = 7826.5 – 391.32a
5886 – 7826.5 = - 391.32a
- 1940.5 = - 391.32a
2
9
POWER HAMMER PROJECT REPORT 2015
Therefore, a=1940 .5
391 .32 a = d
(diameter) = 4.99mm
Due to dynamic characteristics of links the diameter of pin is
selected as 6 mm.
3
0
POWER HAMMER PROJECT REPORT 2015
= 180 N/mm² τY
≥load
shear area
τY ≥6000
shear
area
3
1
POWER HAMMER PROJECT REPORT 2015
5. OPERATION SHEETS
1. CRANK (LINK 1) Description
: Crank 1
Part No :1
2. RAM DIE
Description : Die
Part No :2
Material : Mild Steel.
Required size : 20mm x 420mmɸ
3
2
POWER HAMMER PROJECT REPORT 2015
3. LINK 3 Description :
LINK 3
Part No :3
3
3
POWER HAMMER PROJECT REPORT 2015
3
4
POWER HAMMER PROJECT REPORT 2015
5. CRANK (LINK 5)
3
5
POWER HAMMER PROJECT REPORT 2015
6. COMPOSITE BUSH
Description : composite bush
Part No :6
Bush .
Material : Mild steel
Required size : ɸ38mmx 100mm
SL. NO MACHINE OPERATION TOOL GAUGE
1 Power saw Cutting Hacksaw Vernier
caliper,
steel
rule
2 Lathe Facing Single Vernier
point caliper
cutting
3
6
POWER HAMMER PROJECT REPORT 2015
tool
3
7
POWER HAMMER PROJECT REPORT 2015
6. COST ESTIMATION
3
8
POWER HAMMER PROJECT REPORT 2015
3
9
POWER HAMMER PROJECT REPORT 2015
4
0
POWER HAMMER PROJECT REPORT 2015
1. CRANK (LINK 1)
4
1
POWER HAMMER PROJECT REPORT 2015
2. RAM DIE
4
2
POWER HAMMER PROJECT REPORT 2015
3. LINK 3
4. CONNECTING ROD
5. CRANK (LINK 5)
4
3
POWER HAMMER PROJECT REPORT 2015
6. COMPOSITE BUSH
4
4
POWER HAMMER PROJECT REPORT 2015
7. ELECTRIC MOTER
4
5
POWER HAMMER PROJECT REPORT 2015
DETAIL DRAWING
4
6
POWER HAMMER PROJECT REPORT 2015
4
7
POWER HAMMER PROJECT REPORT 2015
4
8
POWER HAMMER PROJECT REPORT 2015
ASSEMBLY DRAWING
4
9
POWER HAMMER PROJECT REPORT 2015
8. CONCLUSION
5
0
POWER HAMMER PROJECT REPORT 2015
9. REFERENCE
• www.slideshare.com
• www.wikipedia.org
• www.nptel.in
• www.google.com
5
1