CONTENTS

Sl.No NAME OF THE CONTENT PAGE NO.

1 ABSTRACT 4

2 INTRODUCTION 6

3 PROJECT PLANNING 11
4 FABRICATION DETAILS 19

5 MECHANISM FOR GEARLESS DRIVE 22

6 LIST OF MATERIAL 24

7 COST ESTIMATION 26

8 PLUMMER BLOCK 28
9 DRAWING 41

10 CONCLUSION 43

11 BIBLIOGRAPHY 46

12 PARTS OF DIAGRAM 48
13 ASSEMBLY OF DIAGRAM 50

6
ABSTRACT

Mechanical power may be transmitted directly using a solid structure such as a

driveshaft: transmission gears can adjust the amount of torque or force vs. speed in
much the same way an electrical transformer adjusts voltage vs current.

Hydraulic systems use liquid under pressure to transmit power： canals and
hydroelectric power generation facilities harness natural water power to lift ships or
generate electricity. Pneumatic systems use gasses under pressure to transmit
power： compressed air is commonly used to operate pneumatic tools in factories
and repair garages. A pneumatic wrench (for instance) is used to remove and install
automotive tires far more quickly than could be done with standard manual hand
tools.

In this project , the rotary power is transmitted at perpendicular direction through

four rods without using gear drive transmission.

It is made up of mild steel material. The whole construction of machine is

placed on the base plate. The grinding tool is screwed to the main spindle which is
driven through the gearless drive transmission from the motor. This motor with the
gearless drive mechanism are mounted in base plate.The stone is fixed in the
spindle and rotated by motor.

7
 INTRODUCTION
INTRODUCTION
This is a self - assessment test on the part of the students to assess his

competency in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on different

8
kinds of machines, so that he is exposed to various kinds of manufacturing

process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able to

design and fabricate a device.

This is the project work. That is the testimony for the strenuous training,

which the student had in the institute. This assures that he is no more a student,

he is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

9
11
PRECAUTION BEFORE SELECTION OF
THE PROJECT

12
PRECAUTION BEFORE SELECTION OF THE PROJECT

Before rushing out of buy the material for the component first determine

the Size of material required for gearless drive in order to transmit the load.

Obviously the first thing to look at is Whether the drive having an easier provisions

to attach the with the input and output devices or what extent we modify this. If

the drive having easier provision fit the devices to transmit the load or and them

try.

13
PROJECT PLANNING
PROJECT PLANNING

CONCEPT OF THE PROJECT

Before starting every project its planning is to be done. In planning

functions are life the functions of never in our body. planning a project is a very
important task and should be taken up with great care as the efficiency of the
whole project largely defends upon its planning, while planning a project each and
every details should be worked our in anticipation should be carefully considered
with all the relative provisions aspects.

PROJECT CAPACITY

The capacity of the project must be decided considering theamount of

14
money which can be invested. The availability of materialand machines and
usefulness of the project.

DESIGN AND DRAWING

Having decided about the project to be manufactured at must be designed.

Design work should be done very considering all the relevant factors. After design
the project detailed drawing are prepared. DetailedSpecification for raw material
and finished products should be decided Carefully along with the specification of
the machine required for the manufacture.
MATERIAL REQUIREMENTS

The list of material required for manufacture is prepared from the drawing.
The list is known as “Bill of materials”. Availability of these materials is surveyed
and purchased from the market.

OPERATION PLANNING

Next work of planning is to “select the best method” manufacture the product,
so that the wastage of materials, labour, machines and time can be eliminated by
considering various methods. The best method is to be selected for fabrication

15
and other works.

The proper method and proper person and the purposes of operation, necessity
operation, proper machine planning. The best method is the developed and is
applied to fabricate the project.

MACHINE LOADING
While planning proper care should be taken to find the machining time for the
operation as correct as possible. So that arrangement of full use of machines can
be made and the machine loading program can be decided.
PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the project

in the machine shop. In each case, we should decide whether tomake or buy
about a particular item. It is decided during the planning after making a complete
study of relative merits and demerits.

EQUIPMENT PROCEDURE

Results obtained from “operation planning” and machine loading help in

calculating the equipment require Specification of the equipment should be laid
down by considering then drawings. Drawings will also help in deciding the
necessary requirement of tools and accessories.

16
FABRICATION DETAILS
FABRICATION OF PARTS DETAILS

1. BED

It is made up of mild steel L andle channel material. The motor is

engaged with base plate. All the parts for drive this mechanism are mounted on
base plate or bed.

2. GRINDING STONE

17
 The stone is fixed in the spindle and rotated by motor.

3. FOUR “ L “ RODS DRIVE TRANSMISSION

The power is transmitted from the motor , V belt drive to the grinding wheel
through the these four L shaped rods having 8mm diameter. These rods are
transmit the power in perpendicular directions and sliding in two cylinders.

4. V BELT DRIVE TRANSMISSION;

A belt is a loop of flexible material used to link two or more rotating shafts
mechanically. Belts may be used as a source of motion, to transmit power
efficiently, or to track relative movement. Belts are looped over pulleys. In a two
pulley system, the belt can either drive the pulleys in the same direction, or the belt
may be crossed, so that the direction of the shafts is opposite. As a source of
motion, a conveyor belt is one application where the belt is adapted to continuously
carry a load between two points. The power is transmitted from the motor to the
grinding wheel through four L shaped rods and V belt drive.The belt is a V belt of
B 45.The driving pulley is made in cast iron material of 25 mm diameter and the
driven is made in cast iron material having 100 mm diameter. The purpose of this V
belt drive is to reduce the speed from the motor.

Vee belts

Vee belts (also known as V-belt or wedge rope) solved the slippage and alignment
problem. It is now the basic belt for power transmission. They provide the best
combination of traction, speed of movement, load of the bearings, and long service

18
life. They are generally endless, and their general cross-section shape is trapezoidal
(hence the name "V"). The "V" shape of the belt tracks in a mating groove in the
pulley (or sheave), with the result that the belt cannot slip off. The belt also tends to
wedge into the groove as the load increases—the greater the load, the greater the
wedging action—improving torque transmission and making the V-belt an effective
solution, needing less width and tension than flat belts. V-belts trump flat belts with
their small center distances and high reduction ratios. The preferred center distance
is larger than the largest pulley diameter, but less than three times the sum of both
pulleys. Optimal speed range is 1000-7000 ft/min. V-belts need larger pulleys for
their larger thickness than flat belts.

For high-power requirements, two or more vee belts can be joined side-by-side in
an arrangement called a multi-V, running on matching multi-groove sheaves. This
is known as a multiple-V-belt drive (or sometimes a "classical V-belt drive").

V-belts may be homogeneously rubber or polymer throughout, or there may be

fibers embedded in the rubber or polymer for strength and reinforcement. The fibers
may be of textile materials such as cotton or polyester or, for greatest strength, of
steel or aramid (such as Twaron or Kevlar).

When an endless belt does not fit the need, jointed and link V-belts may be
employed. However they are weaker and only usable at speeds up to 4000 ft/min. A
link v-belt is a number of rubberized fabric links held together by metal fasteners.
They are length adjustable by disassembling and removing links when needed.

19
V pulley

5. AC INDUCTION MOTOR

This AC motor is working in 230 VAC supply.

An AC motor is an electric motor driven by an alternating current (AC).

It commonly consists of two basic parts, an outside stationary stator having coils

20
supplied with alternating current to produce a rotating magnetic field, and an inside
rotor attached to the output shaft that is given a torque by the rotating field.

There are two main types of AC motors, depending on the type of rotor used. The
first type is the induction motor, which runs slightly slower than the supply
frequency. The magnetic field on the rotor of this motor is created by an induced
current. The second type is the synchronous motor, which does not rely on
induction and as a result, can rotate exactly at the supply frequency or a submultiple
of the supply frequency. The magnetic field on the rotor is either generated by
current delivered through slip rings or by a permanent magnet. Other types of
motors include eddy current motors, and also AC/DC mechanically commutated
machines in which speed is dependent on voltage and winding connection.
Capacitor start motor

Schematic of a capacitor start motor.

A capacitor start motor is a split-phase induction motor with a starting capacitor

inserted in series with the startup winding, creating an LC circuit which produces a
greater phase shift (and so, a much greater starting torque) than a split-phase motor.
The capacitor naturally adds expense to such motors.

21
PLUMMER BLOCK
STRUCTURE

22
HANDLING THE PLUMMER BLOCK AND BEARING

Rolling bearings are precision components. To maintain accuracies, they

must be handled very carefully. In particular, they must be kept clean, not be
subjected to long impact, and be protected against possible rusting. Plummer blocks
also need similar handling practices.

I. INSPECTION BEFORE INSTALLATION

Before installation a bearing and a plummer block, the blowing point must be
thoroughly checked and inspected.

INSPECTION BEFORE INSTALLATION

♦ Prepare installation tools, measured instruments, oil stone, lubricant and
factory cloth. Before the installation work, remove dust and impurities from
these tools

23
♦ Make sure that the shaft is free from bends or other damages and that it has
been dimensioned and formed as specified.

♦ Remove dent marks even through very small from the mating faces with an
oil stone or fine emery paper. Check that the contact face to the seal has
specified surface roughness. Wipe dust away from the shaft with clean
factory cloth.

♦ Remove possible dust and metal chips from the inside of plumber block.

24
 ♦ Check the flatness of the mounting face of the plummer block. When placed
on a frame, the plummer block must be stably seated.

II. PREPARATION FOR INSTALLINT THE BEARING

♦ Unpack the bearing just before the installation work.

《♦If the bearing is to be grease-lubricated, the rust-proof coating on it may

remain unremoved. If it is to be oil- lubricated, remove the coating with
benzene or kerosene.

Preparation for Installing the Bearing

♦ For a bearing with an adapter, check its radial clearance before the
installation work. To do so, place it on a flat work bench, and fit a
thickness gage between the uppermost roller and the raceway surface on
the outer ring to measure the clearance . Do not force the thickness gage in
or turn the bearing. Otherwise, the resultant clearance measurement will be
greater than the actual clearance.

25
III. INSTALLATION OF THE BEARING AND ASSOCIATED
COMPONENTS

Once careful checking is complete, install the bearing and associated

components. For the positional relationship.

26
 Sea

Bearing
■ ■oi.sing

INSTALLATION OF THE BEARING AND ASSOCIATED COMPONENTS

When a bearing is installed onto a shaft or into a housing. Do not directly hit
its end face with a hammer. Otherwise, its design performance can be lost. Always
evenly exert force around the entire bearing ring face. Also, do not apply force to
one bearing ring.

o EXAMPLE; Outer ring

27
To convey the force via the rolling elements to the other bearing ring inner ring to
install the latter. Otherwise, a dent mark or other damage can occur on either or
both rings.

When installing a cylindrical bore bearing, whose interference is relatively

small, its whole inner rings can be uniformly press- fitted at an ordinary
temperature as illustrated .Usually, the inner ring is press-fitted by tapping the
sleeve with a hammer. However, when many bearings must be installed at a
time, a mechanical or hydraulic press will be helpful.

28
 When installing a non-separable bearing to the shaft and housing at a time,
apply a press-fitting force to both the inner and outer rings by using a pressure
distribution pad.

IV. ASSEMBLING THE PLUMMER BLOCKS

When installing two or more plummer blocks on a shaft, use one block to
locate the outer ring of a bearing in the axial direction, and arrange the other block
⑻ so that the outer ring ⑻of bearing (s) in the latter block (s) can more freely in
the axial direction.

ASSEMBLING THE PLUMMER BLOCKS

Once the bearing has been installed to the shaft and the associated
components have been inserted over the shaft, assemble the plummer blocks
according to the following procedure.

V. MAINTENANCE AND INSPECTION

To be able to use a bearing to its design life and avoid by accident, check the
following points at regular servals.

1. Running sound on bearing.

29
2. Temperature on bearing or plummer block.

3. Vibration on shaft.

4. Leaking grease or worn oil seal.

5. Loose tightening and mounting bolts.

6. Trouble- free operation of the lubrication system, and loosening or leakage with
piping.

The bearing arrangement must be inspected while it is a standstill, check it for

the following points:

1. Check appearance the of bearing for any irregularity.

2. Fouling of grease ,or contaminants in grease.

3. Loose adapter sleeve.

4. Worn or damage seal.

VI. BEARING DISASSEMBLY

Straighten the bent tab on the washer, and loosen the nut by two or three
turns. Place a drift to a face of the nut. Sightly tap the drift to turn the sleeve. Once
be sleeve is shifted in the axial can be direction, the bearing easily removed.

30
 Note,however,when the nut as been excessively loosened and only a
few ridges remain engaged,and if the nut is further tapped,the threading on the
sleeve or nut may be stripped.

VII. CYLINDRICAL BORE BEARING

Usually, a cylindrical bore bearing is interference-fitted. Thus, the
bearing is simply drawn out by placing a jig to yhr face of the inner ring and
exerting a forces illustied with a hand press. However,be careful not to apply a
force to the outer ring. When using this tool, make sure that the jig is fully engaged

31
with the face of the inner ring.

VIII. CLEANING THE BEARING

Clean the removed bearing with diesel oil or kerosene.

USE TWO VESSELS.

One for rough cleaning and the other for finish cleaning. Prepare a cleaning
station that has a metal screen as illustrated. So that the bearing does not directly
contact the fouling on the bottom of vessel. In rough cleaning, virtually all oil and
foreign matters should be removed from the bearing which should be immediately
transferred to the finish vessel. The finish vessel must be provide with a filter unit
to maintain the cleaning agent clean.

Once cleaned, the bearing must be immediately rust-proofed.

The bearings (which have been carefully removed) must be checked whether
they can be reused. The judging criterion for reuse should be determined
considering the following criteria through a trial-and-error basis.

1. Scheduled operating duration to next regular inspection.

2. Importance of the machine that uses the bearing in question
3. Operating conditions such as loading and bearing speed.

4. Severity of damage on the rolling contact surface.

5. Tendency of increasing bearing clearance and wear on the cage.

6. Loss in accuracy, etc.,

32
IX. STORING THE BEARING

When storing a bearing, pay particular attention to rust prevention. Note that
the rust-proofing grease in the bearing will run away at a temperature of 50 to 60 C.
Therefore, store a bearing in a dry, cool location at a height at least 30cm above the
floor. Remember that wooden crate attracts moisture. Thus, immediately unpack the
delivered bearings, and store them on shelves.

33
 Introduction to Grinding wheel

Grinding wheels

A grinding wheel is an expendable wheel that is composed of an abrasive

compound used for various grinding (abrasive cutting) and abrasive machining
operations. They are used in grinding machines.

The wheels are generally made from a matrix of coarse particles pressed and
bonded together to form a solid, circular shape, various profiles and cross sections
are available depending on the intended usage for the wheel. They may also be
made from a solid steel or aluminium disc with particles bonded to the surface.

The manufacture of these wheels is a precise and tightly controlled process, due not
only to the inherent safety risks of a spinning disc, but also the composition and
uniformity required to prevent that disc from exploding due to the high stresses

34
produced on rotation.

Characteristics

There are five characteristics of a cutting wheel: material, grain size, wheel grade,
grain spacing, and bond type. They will be indicated by codes on the wheel's label.

Material, the actual abrasive, is selected according to the hardness of the material
being cut.

• Aluminium Oxide (A)

• Silicon Carbide (S)

• Ceramic (C)

• Diamond (D, MD, SD)

• Cubic Boron Nitride (B)

Grain size, from 8 (coarsest) 1200 (finest), determines the physical size of the
abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but
poor surface finish. Ultra-fine grain sizes are for precision finish work.

Wheel grade, from A (soft) to Z (hard), determines how tightly the bond holds the
abrasive. Grade affects almost all considerations of grinding, such as wheel speed,
coolant flow, maximum and minimum feed rates, and grinding depth.

Grain spacing, or structure, from 1 (densest) to 16 (least dense). Density is the

ratio of bond and abrasive to air space. A less-dense wheel will cut freely, and has a
large effect on surface finish. It is also able to take a deeper or wider cut with less
coolant, as the chip clearance on the wheel is greater.

35
Wheel bond, how the wheel holds the abrasives, affects finish, coolant, and
minimum/maximum wheel speed.

• Vitrified (V)
• Resinoid (B)

• Silicate (S)

• Shellac (E)

• Rubber (R)

• Metal (M)

• Oxychloride (O)

Types

Straight wheel


Straight wheel

To the right is an image of a 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.

36
Straight Wheels are generally used for cylindrical, centreless, and surface grinding
operations. Wheels of this form vary greatly in size, the diameter and width of face
naturally depending upon the class of work for which is used and the size and
power of the grinding machine.

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" in 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.

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.

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.

Dish cup

A very shallow cup-style grinding wheel. The thinness allows grinding in slots and
crevices. It is used primarily in cutter grinding and jig grinding.
Saucer wheel

A special grinding profile that is used to grind milling cutters and twist drills. It is

37
most common in non-machining areas, as sawfilers use saucer wheels in the
maintenance of saw blades.

Diamond wheel

£3

Diamond wheel

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. The saw pictured to the right is a slitting saw and is
designed for slicing hard materials, typically gemstones.

Diamond mandrels

Diamond mandrels are very similar to their counterpart, a diamond wheel. They are
tiny diamond rasps for use in a jig grinder doing profiling work in hard material.

Cut off wheels

Cut off wheels, also known as parting wheels, are self-sharpening wheels that are
thin in width and often have radial fibres reinforcing them. They are often used in
the construction industry for cutting reinforcement bars (rebar), protruding bolts or
anything that needs quick removal or trimming. Most handymen would recognise

38
an angle grinder and the discs they use.

Use

To use the grinding wheel it must first be clamped to the grinding machine. The
wheel type (e.g. cup or plain wheel below) fit freely on their supporting arbors, the
necessary clamping force to transfer the rotary motion being applied to the wheels
side by identically sized flanges (metal discs). The paper blotter shown in the
images is intended to distribute this clamping force evenly across the wheels
surface.

Dressing

Grinding wheels are self sharpening to a small degree; for optimal use they may be
dressed and trued by the use of wheel or grinding dressers. Dressing the wheel
refers to removing the current layer of abrasive, so that a fresh and sharp surface is
exposed to the work surface. Trueing the wheel makes the grinding surface parallel
to the grinding table or other reference plane, so that the entire grinding wheel is
even and produces an accurate surface.

39
WORKING PRINCIPLE

40
WORKING PRINCIPLE
This drive consists of

1. Ac capacitor start type induction motor

2. V belt drive transmission

3. Four L shaped rods drive transmission

4. Plummer block support bearings with shaft drive for grinding

wheel. This drive mechanism is shown below

The power is transmitted from the motor , V belt drive to the grinding wheel
through the these four L shaped rods having 8mm diameter. These rods are transmit

41
the power in perpendicular directions and sliding in two cylinders.

The power is transmitted from the motor to the grinding wheel through four L
shaped rods and V belt drive.The belt is a V belt . The purpose of this V belt drive
is to reduce the speed from the motor.

These four rods are slide inside the cylindrical barrel and simultaneously transmit
the power from the motor to grinding wheel.
Gearless drive specification;

1. L angle --- 40 x 3

2. shaft dia-…20mm x 550 length

3. sliding shaft --------- 10mm dia/100mm length

4. flange with 4 holes -------- 115 mm dia. 100mm length

5. plummer block bearings ------- ucp 204

(20mm bore dia)

42
 LIST OF MATERIALS
LIST OF MATERIALS

Sl.No COMPONENT MATERIAL QUANTITY No.

1 L-ANGLE CAST IRON 1

2 PLUMBER BLOCK CAST IRON 4

3 PULLEY CAST IRON 2

4 SPINDLE (SHAFT) MILD STEEL 2

5 END GRINDING STONE ABRESIVE 1

43
 ADVANTAGES
ADVANTAGES

■ Gearless mechanism is used to reduce the maintenance cost

■ Quick response is achieved

■ Simple in construction

■ Easy to maintain and repair

■ Cost of the unit is less when compared to other Machines

■ No fire hazard problem due to over loading

■ Comparatively the operation cost is less

■ The speed of forward and reverse stroke is varied

■ Continuous operation is possible without stopping

44
APPLICATIONS
APPLICATIONS

• Small and Medium load transmission

• It is very useful in machine shop

45
Industrial Application

46
LIMITATIONS

LIMITATIONS

47
■ High torque cannot be obtained

■ Load carrying capacity of this unit is not very low

48
FINISHING AND
PAINTING

49
 FINISHING AND PAINTING

JOB PREPARATION;

50
 Before welding, remove any bend in the L angle with the sludge hammer
on the anvil block. Then it is cut to the required length with the hacksaw blade
and fabricated to required dimensional shape with arc welding.

FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the chipping
hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed
with the emery sheet.

Metal primer is applied on the surfaces with the brush .After drying the metal
primer, the second coating is applied with the paint.

51
COST ESTIMATION

COST ESTIMATION
Sl.No COMPONENT MATERIAL QUANTITY COST

L-ANGLE MILD STEEL 4800

1 1
FABRICATION
MOTOR
2 1 2200

3 GRINDING ABSERIVE 400

STONE 6

52
4 V-BELT ABSERIVE
1 600

5 PLUMMER CAST IRON 4 2400

BLOCK
SPINDLE (SHAFT) MILDSTEEL 900
6 1

7 BOLDS & NUTS ALLOY STEEL

200

PULLEYS (TWO) CAST IRON 900

8 2
~ ~~

9 PAINT 2 LT 300

PLUG WIRE
10 1 100

TOTAL —— 13600

53
DRAWINGS

54
55
CONCLUSION

56
CONCLUSION

57
 We are assembling the gearless drive to enable the machine to perform one
additional operation. At present this attachment is purely operated and
controller by means of mechanical.

The present made can eliminate the rescue work of the geared drive and at
the same time reduce the maintenance cost of the same machine.

We present out idea for mechanism in manual assisted or operated type

attachment. We have decided an equipment namely “Gearless Attachment”
has been completed successfully to our entire satisfaction While processing his
project, we happen to visit number of libraries and industries to collect
information. We got an opportunity to meet a few experienced person in this
field. This experience have also enriched our knowledge both theoretically and
practically creating confidence. Which would be useful in my future span of
life.

58
BIBLOGRAPHY

BIBLOGRAPHY

59
WORKSHOP W.J. CHAPMAN

PRODUCTION TECHNOLOGY R.K.JAIN

PRODUCTION TECHNOLOGY R.K. JAIN & S.C. QUPTA

METAL FORMING PROCESS R.S. KURMI

MANUFACTURING PROCESS K. RAMACHANDRAN

MACHINE SHOP TECHNOLOGY S.S. MANIAN &

RAJAGOPAL &

G. BALAJI SINGH
DESIGN OF MACHINE ELEMENTS
R.S. KURMI &

P.N. VENKATESAN

DESIGN OF MACHINE ELEMENTS RAMACHANDRAN

DESIGN DATA BOOK
P.S.G. COLLEGE OF

TECHNOLOGY

60
PHOTO VIEW

61
PHOTO VIEW

62
65