3.2 &3.

3​ Housing and baseframe

Different components being manufactured can’t work freely in air , will need some
outer cover where in planned spaces the gear, pinion shafts , shaft , bearings will
be placed perfectly. This cover is generally fabricated in fabrication shop in two or
three parts.

- Housing is the upper part of the cover (it may be divided into two parts upper and
lower housing)

- Baseframe is lower part of the cover which remains on the ground and gets joint to
housing.

Different steps followed

- At first the process starts at fabrication shop where bigger sheets of metal of
desired thickness gets cut through cnc laser cutter or manual laser cutter machines.
Flame used in the process is mainly lpg- oxygen flame or plasma flame.

- After marking on the sheet and cutting through the flame the small sheet parts are
sent for welding where the welder joins the pieces according to the given drawing.
Mostly MIG welding is used over arc welding because of more strength, no gap, no
flux formation.

-Before the welding process the pieces of sheets gets grinded according to
requirement . After the welding too grinding can be done if required.

- Now the housings and baseframes are sent to stress relieving furnace where it is
heated upto desired temperature to remove the internal stresses generated during
the fabrication process.

Stress relieving
Stress Relieving is a heat treating process that consists of heating the steel to a
temperature below the critical range to relieve the residual stresses resulting from
hot rolling, welding shearing, or gas cutting. Stress relieving does not change the
material properties as does annealing and normalizing.

Since the critical temperture remains around 900 to 950 °c ,the stress relieving is
done at around 600 °c.
Stress relieving furnace

Stress Relief Furnaces​ relieve stresses in materials generated by welding,

machining, or heat processing.
The purpose of a Stress Relief Furnace is to raise the temperature of a component to
slightly below the transformation temperature. This elevation in temperature eliminates
internal stresses caused by secondary processes such as welding, machining, or cold
forming. Upon reaching completion of the heat-up and hold cycle, the parts are then
cooled at a controlled rate.

​Stress relieving furnace

- After stress relieving the housing and base frame are sent to ​shot blasting​ unit
where through steel ball shots the cleaning , deburring of the housing surface.

- ​Shot blasting

Shot blasting is a method used to clean, strengthen (peen) or polish metal. Shot
blasting is used in almost every industry that uses metal, including aerospace,
automotive, construction, foundry, shipbuilding, rail, and many others. There are
two technologies used: wheelblasting or airblasting .

Airblast machines can take the form of a blast cabinet ​,​the blast media is
pneumatically accelerated by compressed air and projected by nozzles onto the
component. For special applications a media-water mix can be used, this is called
wet blasting.
In both air and wet blasting the blast nozzles can be installed in fixed positions or can be
operated manually or by automatic nozzle manipulators or robots.
The blasting task determines the choice of the abrasive media,in our case the abrasive
material was steel balls.

​ Steel balls shooting the parts

- after this step the warnish is applied on the surface of the parts and sent for
machining.

Machining

Machining​ is any of various processes in which a piece of raw material is cut into a
desired final shape and size by a controlled material-removal process. The
processes that have this common theme, controlled material removal, are today
collectively known as ​subtractive manufacturing.

Different processes of machining

Boring​ - In machining, boring is the process of enlarging a hole that has already
been drilled(or cast) by means of a single- point cutting tool (or of a boring head
containing several such tools), such as in boring a gun barrelor an engine cylinder.
Boring is used to achieve greater accuracy of the diameter of a hole, and can be
used to cut a tapered hole.

Turning- ​Turning operations are operations that rotate the workpiece as the
primary method of moving metal against the cutting tool. Lathes are the principal
machine tool used in turning

Milling- ​Milling operations are operations in which the cutting tool rotates to bring
cutting edges to bear against the workpiece. Milling machines are the principal
machine tool used in milling.
Drilling​- Drilling operations are operations in which holes are produced or refined
by bringing a rotating cutter with cutting edges at the lower extremity into contact
with the workpiece. Drilling operations are done primarily in drill presses but
sometimes on lathes or mill.

Shaping or planing- Planing​ is a manufacturing process of material removal in

which the workpiece reciprocates against a stationary cutting tool producing a plane
or sculpted surface. Planing is analogous to shaping. The main difference between
these two processes is that in shaping the tool reciprocates across the stationary
workpiece. Planing motion is the opposite of shaping. Both planing and shaping are
rapidly being replaced by milling.
- Different cncs , vncs , vtls are used depending on the process to be carried out ,
tolerance required ,size of the workpiece etc.
Different machines in the machine shop and there specifications were already
explained earlier.

3.4 ​Bearings

A bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may,
for example, provide for free linear movement of the moving part or for free rotation
around a fixed axis or, it may prevent a motion by controlling the vectors of normal
forces that bear on the moving parts.

Types of bearing

There are at least 6 common types of bearing, each of which operates on different
principles:
plain bearing ,​ consisting of a shaft rotating in a hole. There are several specific
styles: bushing, journal bearing, sleeve bearing, rifle bearing, composite bearing;
R​olling-bearing element,​ in which rolling elements placed between the turning and
stationary races prevent sliding friction. There are two main types:
Ball bearing​ in which the rolling elements are spherical balls;
Roller bearing​, in which the rolling elements are cylindrical,taper and
spherical rollers;
Jewel bearing​ , a plain bearing in which one of the bearing surfaces is made of an
ultrahard glassy jewel material such as sapphire to reduce friction and wear;
Fluid bearing ​, a noncontact bearing in which the load is supported by a gas or
liquid.
Magnetic bearing​ in which the load is supported by a magnetic field ;
Flexure bearing,​ in which the motion is supported by a load element which bends.

The bearings which were used in the project were

- Cylindrical roller bearing
- Ball bearing
3.5 ​other parts

Different other parts used in the assembly were:-

-spacers
-covers
-blind covers
-Air breather