A

PROJECT REPORT ON

STUDY AND FABRICATION

OF

BRUSH MAKING MACHINE

(MECHANICAL)

SUBMITTED BY

---------------

---------------

PROJECT GUIDE

PROF. --------------------

H.O.D. PRINCIPAL

PROF.------------ SHRI.------------------

-----------------
----------------
200----200---
CERTIFICATE

1
 Certified that this Report submitted by Shri/Kum --------------------

Roll/Seat No. ----------------------------a student of FINAL YEAR of the course in ---- IN

MECHANICAL ENGINEERING as a part of Seminar / Project work as prescribed by the

Board of Technical Examination for the subject -------------------------------- And that I have

instructed/guided him for the said work from time to time and I found him to be

satisfactorily progressive; And that following students were associated with him for his

work. However his Contribution was proportionate :

1. -------------------------------- 4.-------------------------

2.--------------------------------- 5.-------------------------

And that the said work has been assessed by me and I am satisfied that the same is upto the standard

envisaged for the level of the course. And that the said work may be promoted to the External

Examiner.

[NAME OF GUIDE & SIGN] [NAME OF H.O.D & SIGN] [NAME OF PRINCIPAL & SIGN]

DATE----------------- DATE-------------------- DATE---------------------

--------- --------------
------------- ( -- )
200-----200--------

2
 SUBMISSION

I, ( Full Name) Shri /Kum -----------------------Roll/ Seat No.-------------------- a student of

FINAL YEAR of the course in DEGREE IN MECHANICAL ENGINEERING humbly submit that

I have completed from the Seminar / Project work as described in this Report from time to time by

using my own skill and study between the period From AUGUST 200 TO APRIL 200 as per the

instruction / guidance of (Name of Teacher)----------------------------------

And that, following students were associated with me for this work. However,

the teacher has approved quantum of my contribution. And that, I have not

copied the Report or it’s an appreciable part from any other Literature in

contravention of the academic ethics.

1. -------------------------------- 4.-------------------------------------

2.--------------------------------- 5.-------------------------------------

3.---------------------------------

Date:----------------------

( Signature of the Student)

3
 Acknowledgement
We express esteemed gratitude and sincere thanks to our worthy lecturer

guide PROF. -------------- our vocabulary do not have suitable words benefiting

to high standard at knowledge and extreme sincerity, deviation and affection

with they have regularly encouraged us to put heart and soul in this work.

We are also thankful to our H.O.D. PROF. ----------- whose advices and

kind co-operation wrought out through discussion provide for completion of this

project and also thanks to our workshop superintendent and all the Assistants,

who helped a lot, for completion of this project.

We also convey great thanks to our Honorable Principal ----------------

who helped a lot for completion of this project.

Our parents and relatives who always bear with us in very critical

situation have contributed a great deal in making this for us. As we give

expression to our love and appreciation for them our heart infill.

Thanking.

INDEX

4
Sr.N Name the topics Page

10

11

12

13

14

15

CHAPTER –1

5
 INTRODUCTION

From the ancient age man always prefers to have cold water for drinking purpose. Also in
India, our country the weather is too hot. Particularly in summer season, the normal water
temperature in open space is 35 to380 C. The water is not suitable for drinking purpose. The
required temperature is at the most 250 C. Hence lowering down of the temperature is an
essential task.

CHAPTER – 2

LITERATURE REVIEW-
As we know that, the physical principles upon which modern thermoelectric coolers are
based actually date back to the early 1800's, although commercial thermo-electric (TE)
modules were not available until almost 1960.

into the p-type and drop into the holes, releasing the excess energy in the form of heat.

The n-type

Sr no. Title of paper Author name and date Conclusions

1.

Cu alloy exchanger used He

& Xe mixture results in
Optimizing the design B L.Minner, Braun, L.
shorter device a lower
2. of a TR Mongeau 1996
operating frequency as
compared to pure helium and
results were nearly optimal

6
 Thermo acoustic Thermo acoustic skill
Gregory Swift,1997
3. natural gas liquefier successfully implemented to
liquefy natural gas

Even after reducing the

Design of TR J.C.H.Zeegers,Nov2001 parameters results obtained
4.
were 95% accurate as that of
the original one

Resource letter on
thermo acoustic It does not matter if wave is
Garrett, Jan2004
5. engines and travelling or standing the
refrigerators heat that is pumped matters

Development of low Loudspeaker of 250W was

6. cost loudspeaker 2005 used for successful working
driven TR with MYLAR stack

Stack spacing affects stack

performance too low spacing
An overview of stack leads to higher viscous losses
Bhansali.P.S,JUNE2015
7. design for TR and too larger spacing results
in only a small volume of gas
involved in thermal
interaction

8. David Bartos,2015 Best performing material is

Measuring the stainless steel followed by
performance of plastic and then paper
different stack
materials in thermo

7
 acoustic device

Performance The temperature difference

evaluation of TR across the hot end and cold
Ramesh Nayak,June 2015
9. using air as working end of the stack increases
medium with increase of acoustic
power for mean pressure of
10 bar

Pranav Mahamuni,FEB Parallel type stacks of

A study of TR system
10. 2015 thermoplastic gave satisfying
results

M.E.H.Tijani, Short stack approximation

Design of thermo
11. J.C.H.Zeegers, And for design of TAR gave
acoustic refrigerators
A.T.A.M.De Waele,2001 satisfactory results.

CHAPTER – 3

WORK DESIGN

3.1.5 Frame
The proper selection of material for the different part of a machine is the main objective in
the fabrication of machine. For a design engineer it is must that he be familiar with the effect,
which the manufacturing process and heat treatment have on the properties of materials. The
Choice of material for engineering purposes depends upon the following factors:

8
 1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
The mechanical properties of the metals are those, which are associated with the ability of the
material to resist mechanical forces and load. We shall now discuss these properties as
follows:

1. Strength : It is the ability of a material to resist the externally applied forces

2. Stress: Without breaking or yielding. The internal resistance offered by a part to an
externally applied force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses. The modules
of elasticity of the measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape after deformation
when the external forces are removed. This property is desirable for material used in
tools and machines. It may be noted that steel is more elastic than rubber.
5. Plasticity: It is the property of a material, which retain the deformation produced
under load permanently. This property of material is necessary for forging, in
stamping images on coins and in ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percent
reduction in area. The ductile materials commonly used in engineering practice are
mild steel, copper, aluminium, nickel, zinc, tin and lead.
7. Brittleness: It is the property of material opposite to ductile. It is the property of
breaking of a material with little permanent distortion. Brittle materials when
subjected to tensile loads snap off without giving any sensible elongation. Cast iron is
a brittle material.
8. Malleability: It is a special case of ductility, which permits material to be rolled or
hammered into thin sheets, a malleable material should be plastic but it is not essential
to be so strong. The malleable materials commonly used in engineering practice are
lead, soft steel, wrought iron, copper and aluminium.

9
 9. Toughness: It is the property of a material to resist the fracture due to high impact
loads like hammer blows. The toughness of the material decreases when it is heated.
It is measured by the amount of absorbed after being stressed up to the point of
fracture. This property is desirable in parts subjected to shock an impact loads.
10. Resilience: It is the property of a material to absorb energy and to resist rock and
impact loads. It is measured by amount of energy absorbed per unit volume within
elastic limit. This property is essential for spring material.
11. Creep: When a part is subjected to a constant stress at high temperature for long
period of time, it will undergo a slow and permanent deformation called creep. This
property is considered in designing internal combustion engines, boilers and turbines.
12. Hardness: It is a very important property of the metals and has a wide verity of
meanings. It embraces many different properties such as resistance to wear scratching,
deformation and mach inability etc. It also means the ability of the metal to cut
another metal. The hardness is usually expressed in numbers, which are dependent on
the method of making the test. The hardness of a metal may be determined by the
following test.
a) Brinell hardness test
b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test and
d) Share scaleroscope.
The science of the metal is a specialized and although it overflows in to realms of knowledge
it tends to shut away from the general reader. The knowledge of materials and their properties
is of great significance for a design engineer. The machine elements should be made of such
a material which has properties suitable for the conditions of operations. In addition to this a
design engineer must be familiar with the manufacturing processes and the heat treatments
have on the properties of the materials. In designing the various part of the machine it is
necessary to know how the material will function in service. For this certain characteristics or
mechanical properties mostly used in mechanical engineering practice are commonly
determined from standard tensile tests. In engineering practice, the machine parts are
subjected to various forces, which may be due to either one or more of the following.

 Energy transmitted
 Weight of machine
 Frictional resistance

10
  Inertia of reciprocating parts
 Change of temperature
 Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that are set up
during operation. The material selected should with stand it. Another criteria for selection of
metal depend upon the type of load because a machine part resist load more easily than a live
load and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn depends upon the
following factors.

 Reliabilities of properties
 Reliability of applied load
 The certainty as to exact mode of failure
 The extent of simplifying assumptions
 The extent of localized
 The extent of initial stresses set up during manufacturing
 The extent loss of life if failure occurs
 The extent of loss of property if failure occurs

Material used

 Mild steel

Reasons:

1. Mild steel is readily available in market.

2. It is economical to use.
3. It is available in standard sizes.
4. It has good mechanical properties i.e. it is easily machinable.
5. It has moderate factor of safety, because factor of safety results in unnecessary
wastage of material and heavy selection. Low factor of safety results in unnecessary
risk of failure.
6. It has high tensile strength.

11
 7. Low co-efficient of thermal expansion.

Properties of Mild Steel:

M.S. has a carbon content from 0.15% to 0.30%. They are easily wieldable thus can be
hardened only. They are similar to wrought iron in properties. Both ultimate tensile and
compressive strength of these steel increases with increasing carbon content. They can be
easily gas welded or electric or arc welded. With increase in the carbon percentage weld
ability decreases. Mild steel serve the purpose and was hence was selected because of the
above purpose

THE VARIOUS MACHINING OPERATIONS CONDUCTED AFTER MATERIAL

SELECTION ARE AS FOLLOWS

ABRASIVE SAW-
An abrasive saw, also known as a cut-off saw or metal chop saw, is a power tool which is
typically used to cut hard materials, such as metals. The cutting action is performed by an
abrasive disc, similar to a thin grinding wheel. Technically speaking this is not a saw, as it
does not use regularly shaped edges (teeth) for cutting. The abrasive saw generally has a
built-in vise or other clamping arrangement, and has the cutting wheel and motor mounted on
a pivoting arm attached to a fixed base plate.

12
 FIGURE- ABRASIVE CUTTING MACHINE

They typically use composite friction disk blades to abrasively cut through the steel. The
disks are consumable items as they wear throughout the cut. The abrasive disks for these
saws are typically 14 in (360 mm) in diameter and 7⁄64 in (2.8 mm) thick. Larger saws use
410 mm (16 in) diameter blades. Disks are available for steel and stainless steel. Since their
introduction, portable metal cutoff saws have made many building site jobs easier. With these
saws, lightweight steel fabrication previously performed in workshops using stationary power
band saws or cold saws can be done on-site. Abrasive saws have replaced more expensive
and hazardous acetylene torches in many applications, such as cutting rebar.

DRILLING MACHINE-
Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of circular cross-
section in solid materials. The drill bit is a rotary cutting tool, often multipoint. The bit is
pressed against the workpiece and rotated at rates from hundreds to thousands of revolutions
per minute. This forces the cutting edge against the workpiece, cutting off chips (swarf) from
the hole as it is drilled. Exceptionally, specially-shaped bits can cut holes of non-circular
cross-section; a square cross-section is possible.

13
 FIGURE- DRILLING MACHINE

WELDING MACHINE-
Welding is a fabrication or sculptural process that joins materials, usually metals or
thermoplastics, by causing fusion, which is distinct from lower temperature metal-joining
techniques such as brazing and soldering, which do not melt the base metal. In addition to
melting the base metal, a filler material is often added to the joint to form a pool of molten
material (the weld pool) that cools to form a joint that can be as strong, or even stronger, than
the base material. Pressure may also be used in conjunction with heat, or by itself, to produce
a weld. Although less common, there are also solid state welding processes such as friction
welding or shielded active gas welding in which metal does not melt.

FIGURE- ARC AND WELD IN SHEILDED METAL ARC WELDING

14
1. Coating Flow
2. Rod
3. Shield Gas
4. Fusion
5. Base metal
6. Weld metal
7. Solidified Slag

FIGURE- ELECTRODE ARC

Some of the best known welding methods include:

Shielded metal arc welding (SMAW) also known as "stick welding or electric welding", uses
an electrode that has flux around it to protect the weld puddle. The electrode holder holds the
electrode as it slowly melts away. Slag protects the weld puddle from atmospheric
contamination.
Gas tungsten arc welding (GTAW) also known as TIG (tungsten, inert gas), uses a non-
consumable tungsten electrode to produce the weld. The weld area is protected from
atmospheric contamination by an inert shielding gas such as argon or helium.
Gas metal arc welding (GMAW) commonly termed MIG (metal, inert gas), uses a wire
feeding gun that feeds wire at an adjustable speed and flows an argon-based shielding gas or
a mix of argon and carbon dioxide (CO2) over the weld puddle to protect it from atmospheric
contamination.

15
Flux-cored arc welding (FCAW) almost identical to MIG welding except it uses a special
tubular wire filled with flux; it can be used with or without shielding gas, depending on the
filler.
Submerged arc welding (SAW) uses an automatically fed consumable electrode and a blanket
of granular fusible flux. The molten weld and the arc zone are protected from atmospheric
contamination by being "submerged" under the flux blanket.
Electro slag welding (ESW) a highly productive, single pass welding process for thicker
materials between 1 inch (25 mm) and 12 inches (300 mm) in a vertical or close to vertical
position.
Many different energy sources can be used for welding, including a gas flame, an electric arc,
a laser, an electron beam, friction, and ultrasound. While often an industrial process, welding
may be performed in many different environments, including in open air, under water, and in
outer space. Welding is a hazardous undertaking and precautions are required to avoid burns,
electric shock, vision damage, inhalation of poisonous gases and fumes, and exposure to
intense ultraviolet radiation.
Until the end of the 19th century, the only welding process was forge welding, which
blacksmiths had used for centuries to join iron and steel by heating and hammering. Arc
welding and oxy-fuel welding were among the first processes to develop late in the century,
and electric resistance welding followed soon after. Welding technology advanced quickly
during the early 20th century as the world wars drove the demand for reliable and
inexpensive joining methods. Following the wars, several modern welding techniques were
developed, including manual methods like SMAW, now one of the most popular welding
methods, as well as semi-automatic and automatic processes such as GMAW, SAW, FCAW
and ESW. Developments continued with the invention of laser beam welding, electron beam
welding, magnetic pulse welding (MPW), and friction stir welding in the latter half of the
century. Today, the science continues to advance. Robot welding is commonplace in
industrial settings, and researchers continue to develop new welding methods and gain
greater understanding of weld quality.

THREADING OPERATION-
Taps and dies are tools used to create screw threads, which is called threading. Many are
cutting tools; others are forming tools. A tap is used to cut or form the female portion of the
mating pair (e.g., a nut). A die is used to cut or form the male portion of the mating pair (e.g.,
a bolt). The process of cutting or forming threads using a tap is called tapping, whereas the

16
process using a die is called threading. Both tools can be used to clean up a thread, which is
called chasing.

FIGURE- VARIOUS TAPS

FIGURE- VARIOUS TAP HANDLE

Bottoming tap or plug tap

The tap illustrated in the top of the image has a continuous cutting edge with almost no taper
between 1 and 1.5 threads of taper is typical. This feature enables a bottoming tap to cut
threads to the bottom of a blind hole. A bottoming tap is usually used to cut threads in a hole
that has already been partially threaded using one of the more tapered types of tap; the
tapered end ("tap chamfer") of a bottoming tap is too short to successfully start into an
unthreaded hole. In the US, they are commonly known as bottoming taps, but in Australia
and Britain they are also known as plug taps.

Intermediate tap, second tap, or plug tap

17
The tap illustrated in the middle of the image has tapered cutting edges, which assist in
aligning and starting the tap into an untapped hole. The number of tapered threads typically
ranges from 3 to 5. Plug taps are the most commonly used type of tap.[citation needed] In the
US, they are commonly known as plug taps, whereas in Australia and Britain they are
commonly known as second taps.

Taper tap
The small tap illustrated at the bottom of the image is similar to an intermediate tap but has a
more pronounced taper to the cutting edges. This feature gives the taper tap a very gradual
cutting action that is less aggressive than that of the plug tap. The number of tapered threads
typically ranges from 8 to 10. A taper tap is most often used when the material to be tapped is
difficult to work (e.g., alloy steel) or the tap is of a very small diameter and thus prone to
breakage.

The above illustrated taps are generally referred to as hand taps, since they are, by design,
intended to be manually operated. During operation, it is necessary with a hand tap to
periodically reverse rotation to break the chip (also known as swarf) formed during the
cutting process, thus preventing an effect called "crowding" that may cause breakage. The
most common type of power driven tap is the "spiral point" plug tap, whose cutting edges are
angularly displaced relative to the tap centre-line. This feature causes the tap to continuously
break the chip and eject it forward into the hole, preventing crowding. Spiral point taps are
usually used in holes that go all the way through the material, so that the chips can escape.
Another version of the spiral point plug tap is the spiral flute tap, whose flutes resemble those
of a twist drill. Spiral flute taps are widely used in high speed, automatic tapping operations
due to their ability to work well in blind holes.
Whether manual or automatic, the processing of tapping begins with forming (usually by
drilling) and slightly countersinking a hole to a diameter somewhat smaller than the tap's
major diameter. The correct hole diameter may be determined by consulting a drill and tap
size chart, a standard reference item found in many machine shops. If the hole is to be drilled,
the proper diameter is called the tap drill size.

GRINDING OPERATION-
Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.
 A wide variety of machines are used for grinding:
18
  Hand-cranked knife-sharpening stones (grindstones)
 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding machines
 Bench grinders often found in residential garages and basements

FIGURE- WORKING OF ABRASIVE PARTICLE FROM THE METAL

Grinding practice is a large and diverse area of manufacturing and tool making. It can
produce very fine finishes and very accurate dimensions; yet in mass production contexts it
can also rough out workpiece large volumes of metal quite rapidly. It is usually better suited
to the machining of very hard materials than is "regular" machining (that is, cutting larger
chips with cutting tools such as tool bits or milling cutters), and until recent decades it was
the only practical way to machine such materials as hardened steels. Compared to "regular"
machining, it is usually better suited to taking very shallow cuts, such as reducing a shaft’s
diameter by half a thousandth of an inch or 12.7 μm.
Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each grain of
abrasive functions as a microscopic single-point cutting edge (although of high negative rake
angle), and shears a tiny chip that is analogous to what would conventionally be called a "cut"
chip (turning, milling, drilling, tapping, etc.). However, among people who work in the
machining fields, the term cutting is often understood to refer to the macroscopic cutting
operations, and grinding is often mentally categorized as a "separate" process. This is why the
terms are usually used in separately in shop-floor practice.
Lapping and sanding are subsets of grinding.

19
 FIGURE- GRINDING OPERATION

Surface grinding uses a rotating abrasive wheel to remove material, creating a flat surface.
The tolerances that are normally achieved with grinding are ± 2 × 10−4 inches for grinding a
flat material, and ± 3 × 10−4 inches for a parallel surface (in metric units: 5 μm for flat
material and 8 μm for parallel surface). The surface grinder is composed of an abrasive
wheel, a work holding device known as a chuck, either electromagnetic or vacuum, and a
reciprocating table. Grinding is commonly used on cast iron and various types of steel. These
materials lend themselves to grinding because they can be held by the magnetic chuck
commonly used on grinding machines, and they do not melt into the wheel, clogging it and
preventing it from cutting. Materials that are less commonly ground are Aluminium, stainless
steel, brass & plastics. These all tend to clog the cutting wheel more than steel & cast iron,
but with special techniques it is possible to grind them.

SPRAY PAINT-
Aerosol paint can. Propellant in the top of the can pressures down on the paint propellant
mixture in the bottom. The paint mixture is pushed up through the dip tube when the valve is
opened.

20
 FIGURE-SPRAY PAINT

Spray paint (scientific name aerosol paint) is a type of paint that comes in a sealed
pressurized container and is released in a fine spray mist when depressing a valve button.
Spray paint leaves a smooth, evenly coated surface, unlike many rolled or brushed paints.
Standard sized cans are portable, inexpensive and easy to store. Aerosol primer can be
applied directly to bare metal and many plastics.

3.1.2 TOOLS

21
Mild Steel plate Steel plate cutter

22
Welding machine Lathe Machine

23
Drill machine Electric motor

24
 Iron angles

Steel file tool measuring tape

25
 Vices Cutting shearing pliers

3.2 WORKING

It is an equipment, which work on principle of conversion of solar energy into electrical

energy. A solar cell is used to develop 17 V & 1.16 amps current DC supply and 20W. This
electrical energy is stored in a battery which is of 12 volts DC supply which then supplies the
power to transformer

26
3.3 CAD MODEL-

Procedure

 The entire model has been designed with the help of designing software solid works.
 The stand of the frame is sketched and extruded up to a certain height and then taking
the reference of the stand the base of cooler box is sketched and extruded.
 The cooler box is then constructed on the base and curves are given with the help of
fillet feature, the fins are sketched and extruded.
 The battery is sketched at the back side of the frame.
 The other members are constructed for holding the solar panel.
 The solar panel is then sketched at an inclined plane and extruded.
 With the help of colour feature the colours are given to the entire model.
FIGURE- CAD MODEL OF THE ASSEMBLED PROJECT, DESIGNED ON SOLIDWORKS

CHAPTER – 4

EXPERIMENTATION

27
4.1 OBSERVATION

Based on the AC and DC supply we carried out some experimentation and got following
observations.
A. AC supply cooling at corner of chamber

28
 CHAPTER NO

MATERIAL SELECTION

The proper selection of material for the different part of a machine is

the main objective in the fabrication of machine. For a design engineer it is

must that he be familiar with the effect, which the manufacturing process and

heat treatment have on the properties of materials. The Choice of material for

engineering purposes depends upon the following factors:

6. Availability of the materials.

7. Suitability of materials for the working condition in service.

8. The cost of materials.

9. Physical and chemical properties of material.

10.Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the

ability of the material to resist mechanical forces and load. We shall now

discuss these properties as follows:

13.Strength : It is the ability of a material to resist the externally applied

forces

29
14.Stress: Without breaking or yielding. The internal resistance offered by a

part to an externally applied force is called stress.

15.Stiffness: It is the ability of material to resist deformation under stresses.

The modules of elasticity of the measure of stiffness.

16.Elasticity: It is the property of a material to regain its original shape after

deformation when the external forces are removed. This property is

desirable for material used in tools and machines. It may be noted that

steel is more elastic than rubber.

17.Plasticity: It is the property of a material, which retain the deformation

produced under load permanently. This property of material is necessary

for forging, in stamping images on coins and in ornamental work.

18.Ductility: It is the property of a material enabling it to be drawn into wire

with the application of a tensile force. A ductile material must be both

strong and plastic. The ductility is usually measured by the terms,

percentage elongation and percent reduction in area. The ductile materials

commonly used in engineering practice are mild steel, copper, aluminum,

nickel, zinc, tin and lead.

19.Brittleness: It is the property of material opposite to ductile. It is the

property of breaking of a material with little permanent distortion. Brittle

materials when subjected to tensile loads snap off without giving any

sensible elongation. Cast iron is a brittle material.

30
 20.Malleability: It is a special case of ductility, which permits material to be

rolled or hammered into thin sheets, a malleable material should be

plastic but it is not essential to be so strong. The malleable materials

commonly used in engineering practice are lead, soft steel, wrought iron,

copper and aluminum.

21.Toughness: It is the property of a material to resist the fracture due to

high impact loads like hammer blows. The toughness of the material

decreases when it is heated. It is measured by the amount of absorbed

after being stressed up to the point of fracture. This property is desirable

in parts subjected to shock an impact loads.

22.Resilience: It is the property of a material to absorb energy and to resist

rock and impact loads. It is measured by amount of energy absorbed per

unit volume within elastic limit. This property is essential for spring

material.

23.Creep: When a part is subjected to a constant stress at high temperature

for long period of time, it will undergo a slow and permanent deformation

called creep. This property is considered in designing internal combustion

engines, boilers and turbines.

24. Hardness: It is a very important property of the metals and has a wide

verity of meanings. It embraces many different properties such as resistance

to wear scratching, deformation and mach inability etc. It also means the

ability of the metal to cut another metal. The hardness is usually expressed in

31
 numbers, which are dependent on the method of making the test. The

hardness of a metal may be determined by the following test.

a) Brinell hardness test

b) Rockwell hardness test

c) Vickers hardness (also called diamond pyramid) test and

d) Share scaleroscope.

The science of the metal is a specialized and although it overflows in to realms

of knowledge it tends to shut away from the general reader. The knowledge of

materials and their properties is of great significance for a design engineer. The

machine elements should be made of such a material which has properties

suitable for the conditions of operations. In addition to this a design engineer

must be familiar with the manufacturing processes and the heat treatments have

on the properties of the materials. In designing the various part of the machine it

is necessary to know how the material will function in service. For this certain

characteristics or mechanical properties mostly used in mechanical engineering

practice are commonly determined from standard tensile tests. In engineering

practice, the machine parts are subjected to various forces, which may be due to

either one or more of the following.

1. Energy transmitted

2. Weight of machine

3. Frictional resistance

32
 4. Inertia of reciprocating parts

5. Change of temperature

6. Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that

are set up during operation. The material selected should with stand it. Another

criteria for selection of metal depend upon the type of load because a machine

part resist load more easily than a live load and live load more easily than a

shock load.

Selection of the material depends upon factor of safety, which in turn depends

upon the following factors.

1. Reliabilities of properties

2. Reliability of applied load

3. The certainty as to exact mode of failure

4. The extent of simplifying assumptions

5. The extent of localized

6. The extent of initial stresses set up during manufacturing

7. The extent loss of life if failure occurs

8. The extent of loss of property if failure occurs

Materials selected in m/c

Base plate, motor support, sleeve and shaft

33
Material used

Mild steel

Reasons:

8. Mild steel is readily available in market

9. It is economical to use

10.It is available in standard sizes

11.It has good mechanical properties i.e. it is easily machinable

12.It has moderate factor of safety, because factor of safety results in

unnecessary wastage of material and heavy selection. Low factor of

safety results in unnecessary risk of failure

13.It has high tensile strength

14.Low co-efficient of thermal expansion

RAW MATERIAL & STANDARD MATERIAL

MA
SR NO PART NAME QTY
T

1 FRAME MS 1

2 CHUCK STD 1

3 SHAFT EN8 2

4 PEDESTAL BEARING STD 4

5 HANDEL STD 1

34
6 SPRING SS 1
NUT BOLT WASHER M 8
7 MS
10 NOS
50
8 WELDING ROD -
NOS
9 COLOUR - 2 LIT

10 MISSILINOUS

35
4.2 CALCULATION

CHAPTER-05

MACHINE DESIGN

INTRODUCTION

The subject of MACHINE DESIGN deals with the art of designing machine of structure . A
machine is a combination of resistance bodies with successfully constrained relative motions
which is used for transforming other forms of energy into mechanical energy or transmitting
and modifying available design is to create new and better machines or structures and
improving the existing ones such that it will convert and control motions either with or without
transmitting power. It is the practical application of machinery to the design and construction
of machine and structure. In order to design simple component satisfactorily, a sound
knowledge of applied science is essential. In addition, strength and properties of materials
including some metrological are of prime importance. Knowledge of theory of machine and
other branch of applied mechanics is also required in order to know the velocity.
Acceleration and inertia force of the various links in motion, mechanics of machinery involve
the design.

CONCEPT IN M.D.P.

Consideration in Machine Design

When a machine is to be designed the following points to be considered: -

i) Types of load and stresses caused by the load.

ii) Motion of the parts and kinematics of machine. This deals with the
iii) Type of motion i.e. reciprocating . Rotary and oscillatory.

36
 iii) Selection of material & factors like strength, durability, weight, corrosion resistant,
weld ability, machine ability are considered.
iv) Form and size of the components.
v) Frictional resistances and ease of lubrication.
vi) Convenience and economy in operation.
vii) Use of standard parts.
viii) Facilities available for manufacturing.
ix) Cost of making the machine.
x) Number of machine or product to be manufactured.

GENERAL PROCEDURE IN MACHINE DESIGN

The general steps to be followed in designing the machine are as followed.

i) Preparation of a statement of the problem indicating the purpose of

the machine.

ii) Selection of groups of mechanism for the desire motion.

iii) Calculation of the force and energy on each machine member.
iv) Selection of material.
v) Determining the size of component drawing and sending for
manufacture.

vi) Preparation of component drawing and sending for manufacture.

vii) Manufacturing and assembling the machine.
viii) Testing of the machine and for functioning.

GENERAL PROCEDURE IN MACHINE DESIGN

The general steps to be followed in designing the machine are as followed.

ix) Preparation of a statement of the problem indicating the purpose of

the machine.

x) Selection of groups of mechanism for the desire motion.

xi) Calculation of the force and energy on each machine member.
xii) Selection of material.
xiii) Determining the size of component drawing and sending for

37
 Manufacture.

xiv) Preparation of component drawing and sending for manufacture.

xv) Manufacturing and assembling the machine.
xvi) Testing of the machine and for functioning.

EN 10083 C45 steel carbon steel

C45 steel sheet Physico-chemical testing items for products of the plant include
tensile test ,hardness test ,impact test ,flattening test ,and chemical composition
analysis ,etc .C20,C45 steel pipes are manufactured by cold drawn process.

C45 is a medium carbon steel is used when greater strength and hardness is
desired than in the "as rolled" condition. Extreme size accuracy, straightness
and concentricity combine to minimize wear in high speed applications. Turned,
ground and polished.

Soft Annealing
Heat to 680-710oC, cool slowly in furnace. This will produce a maximum
Brinell hardness of 207.

Normalizing
Normalizing temperature: 840-880oC/air.

Hardening
Harden from a temperature of 820-860oC followed by water or oil quenching.

Tempering
Tempering temperature: 550-660oC/air.

38
C45 steel plate, EN 10083 C45 steel plate, under EN 10083 standard, we can
regard C45 steel plate as high carbon steel.

C45 steel plate is one mainly of high carbon steel,EN 10083 C45 steel plate is
for quenching and tempering. Technical delivery conditions for non alloy
steels,these steels are for general engineering purposes

Comparision of steel grades

JIS G 4051 S 45 C
DIN 17200 C 45
C45
NFA 33-101 AF65-C 45
EN 10083-2 UNI 7846 C 45

Number:1.0503 BS 970 070 M 46

UNE 36011 C 45 k
SAE J 403-AISI 1042/1045

Chemical Composition of EN C45 steel

Grade C(%)min Si(%)min- Mn(%)min P(%)max S(%)max Cr(%)mi

-max max -max n-max

C45 0.42- 0.15-0.35 0.50-0.80 0.025 0.025 0.20-

39
 0.50 0.40

Mechanical Properties of EN C45 steel

Grade Condition Yield Tensile Elon- Hardness Quenchi Benda- Nominal

Strength Strength ng Thickness,t
gation HRC bility
R°(Mpa) Rm Tempera 1.95mm≤t≤10.0
A5(%)
ture mm
(Mpa)
Rolled Annea
(℃)
led

Rolled 460 750 18 58 820 Min.reco- 2.0 1.0×t

mmended
Annealed 330 540 30 55 860 ×t
Bending
C45 Water- 2270
radius
quenched
1980
(≤90°)
Oil
quenched

Properties of   steel   C45 (1.0503) Properties of   steel   C45 (1.0503)

40
Weldability: Due to the medium-high carbon content it can be welded with
some precautions. 
 Hardenability: It has a low hardenability in water or oil; fit for surface
hardening that gives this steel grade a high hardness of the hardened shell.

41
Why Mild steel C-45 is selected in our project.

1. Easily available in all sections.

2. Welding ability
3. Machinability
4. Cuttingablity
5. Cheapest in all other metals.

Material = C 45 (mild steel)

Take fos 2

σt = σb = 540/fos = 270 N/mm 2

σs = 0.5 σt

= 0.5 x 270

= 135 N/mm2

DESIGN OF MOTOR:-

42
Power of motor = 373 N- m /s

Rpm of motor = 1390 rpm

CALCULATION FO FINAL SPEED & TORQUE

Power of motor= P = 373 watt.

P = 2π N T

60

Where,

N→ Rpm of motor = 3400 rpm

T →Torque transmitted

373 = 2π x 1390 x T

60

T = 2.56 N-m

T = 2560 N-mm

43
 Now, pulley of 75 and 75 diameter is mounted.

So, ratio : 1:1

T2 = N-mm

N2 = 1390 rpm

Design of V- belt:

NUMBER OF V-BELTS

44
We know that the power transmitted per belt

P = (T1-T2) x V

As we know maximum torque on shaft = Tmax = T = 2480 N-mm

Where ,

T1 = Tension in tight side

T2 = Tension in slack side

O1,O2 = center distance between two shaft

From fig.

Sin  = R1 - R2

O1O2

Sin  = 50 - 50

305

Sin  = 0

=0

TO FIND 
 = (180 –2 ) X 3.14/180

 = (180 –2*0 ) X 3.14/180

 =3.142 rad

we know that,

T1/T2 = e Cosec β

T1/T2 = e0.25 x 3.142 cosec 20

45
T1 = 8.36T2

We have,

T = ( T1 – T2 ) X R

2480 = (2.36T2 – T2 ) X 50

T2 = 2480/68= 36.47N

T1 = 2.36 X 36.47

T1 =72.94 N

So tension in tight side = T1= 72.94 N

V = DN/60

= 3.142 x 0.75 x 1390/60

54.58 m/sec. 54585 mm/sec

P = (72.94 –36.47) x 7.06

P = 372.60 W (N-m/s)

Number of V-Belts:-

Total Power transmitted

N=

Power transmitted per belt

= ( 0.5 hp power = 373 waats )

46
 = 0.99

Say 1 belt

So 1 belt is sufficient for transmission of power

CALCULATION OF LENGTH OF BELT:-

We know that radius of pulley on shaft

r1 = d1/2 = 75 /2 = 37.5mm

Radius of pulley on motor shaft

r2 = d2/2 = 75/2 = 37.5 mm

Center distance between two pulley = 260mm

We know length of belt

L = П (r2+r1) + 2 x X + (r2-r1)2/x

= П (37.5 + 37.5) + (2 x260) + (37.5 – 37.5)2/260

=755.61 mm

L = 762 mm = 30 inch

47
Now, T3 is the maximum torque among all shafts, so we will check shaft for failure here.

T=π/16 x135xd3

d3=11760 x 16/ 3.142 x 135

d=3√4436=16.43=17 mm

but we are using- 20 mm shaft so design is safe.

For 20mm Shaft diameter we take standard breaking no. P204

48
P=pedestal bearing

2=spherical ball or deep groove ball bearing

=04=5 * 4 = 20mm

Bore diameter of bearing.

Design of bolt:- tension

Bolt is to be fastened tightly also it will take load due to rotation. Stress for C-45 steel ft
=420 kg/cm2 . Std nominal diameter of bolt is 9.31 mm. From table in design data book,
diameter corresponding to M10 bolt is 8 mm
Let us check the strength :-
Also initial tension in the bolt when belt is fully tightened.
P = 981 N is the value of force
P = 981 N
Also, P = Π /4 dc2x ft
981 x 4
ft = ------------------------------ 3924/201 = 19.51 N / mm2
3.14 x ( 8)2

49
 the calculated ft is less than the maximum ft hence our design is safe

Let the total weight (P) of our machine including solar panels be 40 kg, now this 40 kg
weight is kept on four angle,

P = 40/4 = 10 kg.

P = 10 x 9.8 = 100 N.
B 20mm b= 17 mm
L = 190 mm.

M = WL/4 = 100 × 190/4

= 4750 N-mm
3mm

ᶟ
Section of modulus = Z= B /6 - b⁴/(6 x B)
20 mm

Z= 20ᶟ/6-17⁴/6×20 = 1333.3-696.4

Z= 638 mmᶟ

Bending stress = M/Z = 4750/638 = 7.4 N/mm²

As induced bending stress is less then allowable bending stress i.e. 270 N/mm2 design is safe.

Design of transverse fillet welded joint.

50
Hence, selecting weld rod size = 3.2mm

Area of Weld = 0.707 x Weld Size x L

h=25 mm
= 0.707 x 3.2 x 25
= 56.56 mm2
Force exerted = ---N
Stress induced = Force Exerted / Area of Weld
21 = F / 56.56
b= 5 mm
F= 1187.76 N = 121.07 kg
Maximum Allowable Stress for Welded Joints = 21 N/mm2

CHAPTER NO

COST ESTIMATION

51
 Cost estimation may be defined as the process of forecasting the expenses that
must be incurred to manufacture a product. These expenses take into a consideration all
expenditure involved in a design and manufacturing with all related services facilities such
as pattern making, tool, making as well as a portion of the general administrative and selling
costs.

PURPOSE OF COST ESTIMATING:

1. To determine the selling price of a product for a quotation or contract so as to ensure

a reasonable profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the product.
4. To determine standards of production performance that may be used to control the
cost.
BASICALLY THE BUDGET ESTIMATION IS OF TWO TYRES:

1. material cost
2. Machining cost
MATERIAL COST ESTIMATION:

Material cost estimation gives the total amount required to collect the raw material which has
to be processed or fabricated to desired size and functioning of the components.

These materials are divided into two categories.

1. Material for fabrication:

In this the material in obtained in raw condition and is manufactured or processed to finished
size for proper functioning of the component.

1. Standard purchased parts:

This includes the parts which was readily available in the market like allen screws etc. A list
is forecast by the estimation stating the quality, size and standard parts, the weigh of raw
material and cost per kg. For the fabricated parts.

MACHINING COST ESTIMATION:

This cost estimation is an attempt to forecast the total expenses that may include to
manufacture apart from material cost. Cost estimation of manufactured parts can be

52
considered as judgment on and after careful consideration which includes labour, material
and factory services required to produce the required part.

PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is

1. After designing a project a bill of material is prepared which is divided into two
categories.
a. Fabricated components
b. Standard purchased components
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchased taken and added up.
LABOUR COST:

It is the cost of remuneration (wages, salaries, commission, bonus etc.) of the employees of a
concern or enterprise.

Labour cost is classifies as:

a. Direct labour cost

b. Indirect labour cost
Direct labour cost:

The direct labour cost is the cost of labour that can be identified directly with the
manufacture of the product and allocated to cost centers or cost units. The direct labour is one
who counters the direct material into saleable product; the wages etc. of such employees
constitute direct labour cost. Direct labour cost may be apportioned to the unit cost of job or
either on the basis of time spend by a worker on the job or as a price for some physical
measurement of product.

Indirect labour cost:

It is that labour cost which can not be allocated but which can be apportioned to or absorbed
by cost centers or cost units. This is the cost of labour that doesn’t alters the construction,
confirmation, composition or condition of direct material but is necessary for the progressive
movement and handling of product to the point of dispatch e.g. maintenance, men, helpers,
machine setters, supervisors and foremen etc.

53
The total labour cost is calculated on the basis of wages paid to the labour for 8 hours per
day.

Cost estimation is done as under

Cost of project = (A) material cost + (B) Machining cost + (C) lab our
cost
(A) Material cost is calculated as under :-
i) Raw material cost

ii) Finished product cost

i) Raw material cost:-

It includes the material in the form of the Material supplied by the “ Steel authority of India
limited” and ‘Indian aluminum co.,’ as the round bars, angles, square rods , plates along with
the strip material form. We have to search for the suitable available material as per the
requirement of designed safe values. We have searched the material as follows:-

Hence the cost of the raw material is as follows:-

54
 RAW MATERIAL & STANDARD MATERIAL

SR NO PART NAME MAT QTY COST

1 CHASSI C-CHANNEL MS 50 KG 3000

2 PETROL ENGINE STD 1 NOS 9000

3 SHAFT DIA 20 MM MS 10 KG 700

4 CHAIN SS 1 SET 900

5 SPROCKET SS 2 NOS 1600

6 SHEET METAL MS 5 SQM 1600

7 WHEEL STD 3 NOS 1800

8 BEARING CI 4 NOS 1600

9 PLY WOOD WOOD 1 SQM 300

10 NUT BOLT WASHER M 10 MS 20 NOS 275

11 FUEL TANK STD 1 NOS 600

12 ACCELERATOR STD 1 NOS 350

13 MS PLATE C-45 5 KG 400

11 MS ANGLE C-45 10 KG 600

12 WIRE CU 4M 150

13 MISCELLINOUS - - 1000

TOTAL

B) DIRECT LABOUR COST:-

SR. NO. OPERATION HOURS RATE / AMOUNT

LABOUR
55
 1.
Turning 10 150 1500

3.
Drilling 7 100 700

4.
Welding 16 175 2800

5.
Grinding 3 60 180

6.
Tapping 3 40 120

7.
Cutting 8 40 320

8.
Gas cutting 8 50 400

9.
Assembly 2 100 200

10.
Painting 2 100 200

TOTAL 6720/-

INDIRECT COST

Transportation cost = 500/-

Coolent & lubricant = 100/-

Drawing cost = 500/-

56
Project report cost = 2000/-

TOTAL INDIRECT COST = 2100/-

TOTAL COST

Raw Material Cost + STD Parts Cost + Direct Labour Cost +Indirect Cost

Total cost of project = + 6720 +2100

Total cost of project = /-

CHAPTER NO
MANUFACTURING

The process of conversion of raw material in to finished products using the three resources as
Man, machine and finished sub-components.
Manufacturing is the term by which we transform resource inputs to create Useful goods and
services as outputs. Manufacturing can also be said as an intentional act of producing
something useful . The Transformation process is
Shown below-

Input conventional process out put

Element Transformation Useful product

Material Machines Products
Data Interpretation Knowledge
Energy Skill Services
Variable cost Fixed cost Revenue

57
It s the phase after the design. Hence referring to the those values we will plan
The various processes using the following machines:-

i) Universal lathe
ii) Milling machine
iii) Grinding machine
iv) Power saw
v) Drill machine
vi) Electric arc welding machine

 MANUFACTURING PROCESS :

The following are the various manufacturing process used in mechanical

engineering.

1) Primary Shaping Process :

The process used for the preliminary shaping of the machine component is
known as primary shaping process.

2) Machine Process :

The process used for giving final shape to the machine component, according
to planned dimensions is known as machining process. The common operation
drilling, boring etc.

3) Surface Finishing Process :

The process used to provide a good shape surface finish for the machine
components are known as surface finishing processes. The common operation used
for the process are polishing, buffing, lapping etc.
4) Joining Process :

The process used for joining machine components are known as joining
process. The common operation used for this process are soldering, brazing, welding
etc.

58
5) Process Affecting Change In Properties :

These are intended to import specific properties to material e.g. heat treatment,
hot working, cold rolling etc.

59
 FABRICATION

MACHINING OF PARTS

GENERAL WORKSHOP TECHNOLOGY:

The components of project models have been machined to the required dimensions on the center

lathe machine.

The raw material stocks are either cut to size on power hacksaw machine or by hand hack saw on the

worktable.

The drilling of notes have been carried out on pillar drill machine prior to scribing the center lines &

cross lines & marking out the inch marks at the drill centers.

1) Hack Saw Cutting:-

The speed is 350RPM & the feed is automatic, maintain a cutting margin of about 3 to 5 mm. Extra

for large sections & 1 to 2 mm extra for light sections. This is an Auto operation.

2) Lathe Machine:-

a) Facing & turning speed - 650 to 850 rpm.

b) Boring, Reaming, Thread - 70 rpm.

c) Lapping, Honing & Polishing Speed – 1000 rpm.

Cutting Tools:-

i) Tungsten carbide Tipped tools either side or crank types.

ii) Parting tools or V threading tools.

iii) High speed steel tools (H.S.S.) as above.

60
 3) Drill Machine :

i) Parallel shank in H.S.S. – Reading

ii) Taper shank in H.S.S. – available

4) Coolants & Cutting Oils :

i) Proprietary Brand : - For machining M.S., L.C.S.

Hindustan petroleum Oil H.S.C. Alloy Steels & Stainless Steels.

Mixed in water in 1:10 ratio

ii) Kerosene:- For machining of all grades of

L.M. – 1 to L.M.-6 Aluminium

(L.M. = Light Metal)

iii) No cutting Oil or coolant :- For machining in dry state of brass copper

Cast iron, raw material.

5) Threading :-

Light duty threading is done with the help of H.S.S. Tap set (Inside Threading) & H.S.S. Round Dies

(outside threading) by hand tap & die wrenches.

6) Drilling of Holes :-

Please note that similar the hole x dia. The higher the speed. Larger the hole dia., lower the speed.

Micro drilling speeds are above 1000 rpm.

7) Reaming of Holes :-

Drilled or bored holes are finished to close tolerance by parallel or taper shank reamers readily

available in the market.

8) Heat Treatment of Alloy Steel :

Hardening & Tempering of alloy steels are being carried out by out side specialists & not being done

in the sponsors workshop.

61
 9) Grinding :

Grinding of cylinder bores, after heat treatment is carried out with the help of Tools Post Grinder.

10) Lapping:-

Out side surface are finished by removes of high spots to a extra fine & smooth finish by tapping

operation. Laps are made in the workshop.

11) Polishing :-

Polishing is the inside & outside surface of the machined parts is required to with stand ere & teat &

also for smooth vibration free operation, polishing parts are available in the market & generally

designed as valve grinding & polishing compounds.

12) Lubricants :-

I) High grade Machine : Used for all heavy duty rotary & Reciprocating parts.

Oil No.HP-30 to 3 in 1

Proprietary brand singer oil

II) Kerosene or Keo : Used for light duty rotating & Reciprocating part.

Car pin oil

III) Alvinia Wheel Bearing : Used for all open type of Ball Bearings.

Grease No.20

Special grease is duly impregiated in the Z series sealed Ball Bearings by the bearing manufacturers.

13) Measuring Instruments :

During Machining operations the dimensions are measured accurately by using :- Hand

Verniers , Micrometers, Merrier Depth Gauges, Thread Gauges. Radius Gauges, Go/No-

Go Plug Gauges, Snap Gauges, Inside & Outside Calipers.

14) Fabrication: -

62
Various steel sections are aluminium sections are employed in the fabrication work such as angles,

clits, gussets, fillets flats & the round bars. These sections are cut to required size marked for drilled

holes & then fastened together with the help of rivets & bolts, Nuts & Screws.

Welding, Brazing & Soft Soldering of fabricated joints are obtained from outside parties & not in the

consoler’s workshop.

i) Electric Arc Welding : For heavy duty parts.

ii) Gas Welding : For light duty parts.

iii) Gas Brazing : For Brass & copper parts.

iv) Soft Tin soldering : For light duty parts in M.S. Brass & copper.

63
COMPONENT :- FRAME

MATERIAL :- M.S. ANGLE

QUANTITY :- 1

SR. NO DESCRIPTION OF MACHINE CUTTING MEASUREMENT TIME

OPERATION USED

1 Cutting the angle Gas cutting Gas cutter Steel rule 15min.
in to length as per machine
dwg
2 Cutting the angle Gas cutting Gas cutter Steel rule 15min.
in to number of machine
piece as per dwg
3 Filing operation
can be performed
Bench vice Try square 15 min.
on cutting side and File
bring it in
perpendicular C.S.
4 Weld the angles to Electric arc ------- Try square 20 min
the required size as welding
per the drawing machine
5 Drilling the frame Radial drill Twist drill Vernier 10 min.
at required points machine calliper
as per the drawing.

64
65
COMPONENT : BEVEL

MATERIAL : BRIGHT STEEL

QUANTITY : 2

SR. TOOL /
OPERATION M/C USED TIME
NO GAUGE

1 A mild steel blank of 62 ф is cut Power saw Steel rule 20 min

for 42 mm width

2 It is faced and turned for 60 mm Universal lathe Facing tool and 15 min
and 40mm width vernier calliper

3 It is bored for 20 mm Diameter --do-- Twist drill of 10 min

size12 ф

4 It is provided with 5x5 key way Slotting machine Vernier calliper 15 min

5 It is installed on the indexing head Universal milling Form mill-cuter 90 min

and hole is selected to cut 40 teeth m/c

6 It is drilled and tapped for M14 Radial drill Twist drill of 13 30 min
machine and tap ф and tap of M14
die

7 The gear is kept in the furnace and Furnace Tounge 30 min

held it there for 750mm C for 15
min and suddenly quenched in the
oil bath to make it hard

NAME OF THE PART – SHAFT

MATERIAL – BRIGHT STEEL

QUANTITY – 2

66
 SR.NO. DETAIL M/C. TOOL ACCES MEA.INST.
OPER. USED USED

1. Marking on - - - Scale
shaft

2. Cutting as per Power Hock saw Jig & Scale

dwg hack saw blade fixtures

3. Facing both Lathe Single point Chuck Vernier

side of shaft machine cutting tool caliper

4. Turning as per - - - -
dwg size

5. Key way on Milling Milling - Vernier

end of shaft m/c. cutter caliper

6. Filling on both Flat file Vice -

end

3 CARE & MAINTENANCE OF MACHINE

Maintenance Is An Important At The Point Of Fabrication Work. If There IslessUse

Of Care More Accidents Will Occur And Efficiency Of Machine Will I.E. Reduced Due To
Loss Of Power.

67
Following Care Should Be Taken While Doing The Work.
1. First Set The Proper Sequence Of Assembly. Before Starting The Machine We Must
Check The Fitting Of Nut, Bolts Of Whole Machine To Avoid Maximum Vibration.
2. Gearing, Oiling Of Bearing & Rotating Part Should Be Done Weekly.
3. Tension In The Belt Should Be Checked Monthly.
4. The Insulation Of Wire Electric Motor Should Be Checked Periodically.

Use Current Method Of Performing The Operation.

68
 CHAPTER NO 5

MANUFACTURING

The process of conversion of raw material in to finished products using tJhe three resources as Man,
machine and finished sub-components. Manufacturing is the term by which we transform resource
inputs to create Useful goods and services as outputs. Manufacturing can also be said as an
intentional act of producing something useful . The transformation process is Shown below-

Input conventional process out put

Element Transformation Useful product

Material Machines Products

Data Interpretation Knowledge

Energy Skill Services

Variable cost Fixed cost Revenue

It s the phase after the design. Hence referring to the those values we will plan

The various processes using the following machines:-

i) Universal lathe

ii) Milling machine

iii) Grinding machine

iv) Power saw

69
v) Drill machine

vi) Electric arc welding machine

70
COMPONENT : hot end side Tube

MATERIAL : brass

MATERIAL SPECIFICATION : 16ф od 2 mm thick x 225 mmlength

Part no: 01 Material specification: Brass

Part Name: Tube Raw material size: tube of 300 mm

length

od 16, 2 mm
thickness

Discription
SR. of
TOOLS Time in minutes
NO OPERATIO
N

jigs and M/c Cutting Measuring Setting M/c Total Time

fixture tools tools instrumen Time Time
t

1 Cutting for Bench Hecksa Tape 12 5 17

length 225 vice w
mm

1 Clamp 4 jaw - - Vernier 10 10

stock on chuck
lathe

2 Holding Magnetic 10 10
job on bench
center

3 Facing Tool post Single Vernier 15 10 25

point
cutting
tool

4 Threading Singlep Vernier 15 10 25

oint
cutting
tool

5 Checking

Table no. 1: list of manufacturing process for brass tube

71
COMPONENT : body

MATERIAL : mild steel

MATERIAL SPECIFICATION : 15ф id 2 mm thick x 37 mmlength

Part no: 02 Material specification: mild steel C-

45

Part Name: Tube Raw material size: 15ф id 2 mm

thick x 37

Mmlength

Discription
SR. of
TOOLS Time in minutes
NO OPERATIO
N

jigs and M/c Cutting Measuring Setting M/c Total

fixture tools tools instrumen Time Time Time
t

1 Holding Vertical Vernier 5 5

job drill
machine

1 Drilling Vice - Drill Vernier 10 10

2 Holding Vernier 10 10
job on
center

3 Welding Coupling Weldin - Vernier 5 10 15

g
electric
arc

4 Grinding Benchvic Hand Grindin - 15 10 25

e grinder g
wheel

5 Checking

72
Table no. 2: list of manufacturing process for body

73
COMPONENT : Spinner

MATERIAL : Nylon

MATERIAL SPECIFICATION :

Part no: 03 Material specification: Nylon

Part Name: Spinner Raw material size: 40 diam, 80 mm

lenght

Discription
SR. of
TOOLS Time in minutes
NO OPERATIO
N

jigs and M/c Cutting Measuring Setting M/c Total

fixture tools tools instrumen Time Time Time
t

1 Holding 4 jaw Hand 5 5

job chuck key
lathe

2 Holding Vernier 10 10
job on
center

3 Drilling - Tail Drill bit - 5 10 15

stock 4 mm

4 Boring - Tail Drill bit - 15 10 25

stock 6 mm

5 Turning - Lathe - 10 10

6 Step
turning 14
mm length
25 mm dia

7 Step
turing 36
mm length
18 mm

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8 Tangential Bench Hecksa Vernier 10 15 25
cuts 1 mm vice w
3 numbers

9 Checking

Table no. 3: list of manufacturing process for spinner

CHAPTER – 6

ADVANTAGES, DISADVANTAGES AND APPLICATION

6.1 ADVANTAGES

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 1. Light weight and compact for very small heat loads.

2. No CFC gases or refrigerant are used for cooling.

3. No moving parts, eliminating vibration, noise, and problems of wear.

4. Reversing the direction of current transforms the cooling unit into a heater.

5. Operates in any orientation.

6. Not affected by gravity or vibration.

7. Very low cost device for cooling in small appliances.

8. Precision temperature control capability.

9. It can be used in drought affected areas.
10. Solar operation makes it more economical and environment friendly.

6.2 DISADVANTAGES

1. Limited to very small refrigeration loads due to size compaction.

2. Not suitable for higher refrigeration use due to poor efficiency.

3. Thermo-electric modules become very heavy and bulky as the refrigeration capacity
increases.

4. The technology is normally used only to cool small surfaces (for example a processor
in a computer) since there have been complications when making the system bigger.

6.3 APPLICATIONS

1. Electronics — miniature cooling units for incoming stages of highly sensitive

receivers and amplifiers; coolers for high power generators, laser emitters and
systems, CCD cameras, parametric amplifiers, vacuum and solid-state photo detectors
and CPU coolers.
2. , mechanical diggers, trucks; coolers for motorcycle helmets.

CHAPTER – 7

CONCLUSION AND FUTURE SCOPE

76
7.1 CONCLUSION

After conducting experiments on the project we have found that the temperature difference
with respect to time, which is important in determining the performance of the refrigerator,
comes
a lot of potential to create energy saving and effective solutions for the industry and
commercially as well.

7.2 FUTURE SCOPE

There are some points that could be researched in future:

CHAPTER - 8

REFERENCE

[1] International Journal of Engineering (IJE), Volume (5): Issue (1): 2011, Riffat SB.
Xiaolima Thermo-electric: A Review of Present and Potential Applications. Applied
Thermal Engg. 2003: 23: 913-35.

77
 Bhandari V.B., “Design Of Machine Elements”, Tata Magraw Hill Publishing
Company Ltd., New Delhi. 8Th Reprint 19
 New Nashikworkshop,Alephata .
 Design of Machine Element ( Niraliprakashan )
 Production Technology ( Niraliprakashan )
 http://www.wiki.pedia .co.in/

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