Multi-Function Machine Project Report

A PROJECT REPORT
ON
“FABRICATION BY USING MULTI FUNCTION

OPERATING MACHINE”
Submitted in partial fulfillment for requirement of the degree of

BACHELOR OF ENGINEERING
In
Mechanical Engineering Department
Prescribed by
Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur (M.S.)
Submitted By
AKANSH V. KADAO (304) PIYUSH M. NIKOSE (329)

DEVASHISH H. PAUL (313) PRANAY R. PATNE (333)
ISHAN S. BANGADKAR (316) VISHAL KUKDE (358)
Under the Guidance of

Prof. N. R. PATHARE
DEPARTMENT OF MECHANICAL ENGINEERING

PRIYADARSHINI COLLEGE OF ENGINEERING,
NAGPUR.
Session 2019 – 2020
PRIYADARSHINI COLLEGE OF ENGINEERING,
NAGPUR. (M.S.)
DEPARTMENT OF MECHANICAL ENGINEERING
Certificate
It is to certify that this is a bonafide record of Project Work entitled
“FABRICATION BY USING MULTI FUNCTION

OPERATING MACHINE”
Carried Out By
AKANSH V. KADAO (304) PIYUSH M. NIKOSE (329)

DEVASHISH H. PAUL (313) PRANAY R. PATNE (333)
ISHAN S. BANGADKAR (316) VISHAL KUKDE (358)
th
Of 8 Semester
B.E. MECHANICAL ENGINEERING

During the academic year of 2019 – 2020 in partial fulfillment
of the requirement for the award of the degree of
BACHELOR OF ENGINEERING
offered by
Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur (M.S.)
PROF. N. R. PATHARE PROF. S. P. LOKHANDE

(Project Guide) (Project Coordinator)
DR. K. S. ZAKIUDDIN DR. M. P. SINGH

(Head of the Dept.) (Principal)
Declaration
We hereby declare that the work of “FABRICATION BY USING MULTI FUNCTION
OPERATING MACHINE” presented in the project report have been carried out by us under
the guidance of Prof. N. R. Pathare. Associate Professor in Mechanical Engineering
Department, Priyadarshini College of Engineering, Nagpur.
The work is original and has not been submitted earlier as a whole or part for the
degree at this or any other institution. It contains no material which is previously published or
written by another person nor material which has been accepted for the award of any other
degree or diploma of the university or other institution of higher learning except where due
acknowledgement has been made in the text.
Place :- Nagpur
Date :-
AKANSH V. KADAO (304)
DEVASHISH H. PAUL (313)
ISHAN S. BANGADKAR (316)
PIYUSH M. NIKOSE (329)
PRANAY R. PATNE (333)
VISHAL KUKDE (358)

Acknowledgement
Before we get into thick of things, we would like to add few heartfelt words for the
people who were part of this project in numerous ways, people who gave their seemingly
endless support right from the stage of selection of the project topic. This word of
acknowledgement is to express our deep sense of gratitude to all those illuminaries and unseen
hands without whose support the completion of this detailed discourse would not have been
materialized.
We shall never be able to describe the spirit of cooperation with which we worked
together, nor shall ever be able to express our feelings towards our guide Prof. N. R. Pathare.
Who has provided us latest knowledge and techniques especially for our project work. The
pleasure of contemplating this project would never have been ours without the firm support
extended to us by him who gave us inspiration, determination, co-operation and guidance
towards the project.
We express our deep sense of gratitude and thanks to Mr. S. P. Lokhande our parents
for helping us and giving us the support at each and every time we required them.
We express our deep sense of gratitude to the head of Mechanical Engineering
Department Dr. K. S. Zakiuddin who gave the inspiration to pursue this project and providing
all facilities needed.
Finally, we thanks our principal Dr. M. P. Singh, for this encouragement and providing
all facilities needed.
AKANSH V. KADAO (304)
DEVASHISH H. PAUL (313)
ISHAN S. BANGADKAR (316)
PIYUSH M. NIKOSE (329)
PRANAY R. PATNE (333)
VISHAL KUKDE (358)

INDEX
Chapter No. Contents Page No.
1 INTRODUCTION
1.1 Introduction
1.2 Problem Statement
1.3 Problem Identification
1.4 Aims and Objectives of Study
2 LITERATURE REVIEW
3 PROJECT IDEA
4 WORKING PRINCIPLE
4.1 Component
4.1.1 Pedestal Bearing
4.1.2 Drilling
4.1.3 Bevel Gear
4.1.4 Drilling Tool
4.1.5 Electric Motor
4.1.6 Belt
4.1.7 Grinding Wheel
5 DESIGN OF COMPONENTS
5.1 Design of Shaft
5.2 Design of V-Belt
5.3 Design of Bevel Gear
6 FABRICATION OF MODEL
6.1 Hacksaw
6.2 Drilling
6.3 Cutting
6.4 Grinding
6.5 Buffing
7 FUTURE IMPLEMENTATION
8 ADVANTAGES & APPLICATION
9 CONCLUSION
10 REFERNCE
LIST OF FIGURE
Figure No. Name of Figure Page No.
3.1 Whitworth Mechanism
4.1 Pedestal Bearing
4.2 Drilling Machine
4.3 Electric Motor
4.4 Belt
4.5 Grinding Wheel
5.1 3D View
5.2 Design of Bearing Base
5.3 Design of Bearing
5.4 Design of Bevel Gear
5.5 Design of Buffing Wheel
5.6 Design of Cutter
5.7 Design of Grinding Wheel
5.8 Design of Motor
5.9 Design of Hacksaw
5.10 Design of Small Pulley
5.11 Design of Cutter Belt
6.1 Hacksaw
6.2 Drilling
6.3 Cutter
6.4 Grinding
ABSTRACT
This thesis deal with design development and fabrication of “MULTI PURPOSE
MECHANICAL MACHINE”. This machine is designed for the purpose of MULTI-
OPERATIONs i.e. DRILLING, CUTTING & SHAPING. This machine perform multipurpose
operation at same time with required speed & this machine is automatic which is controlled or
operated by motor which is run with the help of current. This machine is based on the
mechanism of whit worth return. This model of the multi OPERATIONAL machine is may be
used in industries and domestic OPERATION which can perform mechanical operation like
drilling, cutting & shaping of a thin metallic as well as wooden model or body.
The mentioned operations can however be replaced by similar type of operations.

Industries are basically meant for Production of useful goods and services at low production
time, low production cost, machinery cost and low inventory cost. In today’s era every task
have been made rapid and faster due to technology enhancement but this advancement also
requires huge investments and expenditure ,every industry wills to make high productivity rate
maintaining the quality and standard of the product at minimum average cost. We have
developed a model of a machine tool which would be capable of performing different operation
simultaneously, and it should be economically efficient. Our Objective behind development of
this model is to have conservation of electricity (power supply), reduction in cost associated
with power usage, increase in productivity, reduced floor space, reduce production time,
reduction of human resources etc.
CHAPTER :-1
INTRODUCTION
CHAPTER :-1
INTRODUCTION
1.1 INTRODUCTION
This deal with “MULTI-FUNCTION OPERATING MACHINE”. In today’s era every

task have been made rapid and faster due to technology enhancement but this advancement also
demands huge investments and expenditure, every industry desires to make high productivity
rate maintaining the quality and standard of the product at low average cost. So in this
mechanism we have a proposed a machine which can perform operations like drilling, grinding,
cutting, punching and some other lathe operations at different working centres simultaneously
which implies that industrialist have not to pay for machine performing above tasks individually
for operating operation simultaneously. In present condition many electrically operated power
machines of different companies with different specifications are available for the use in shop
floor.
These machines are so precise that they can cut metal with minimum time made up of
different materials but they have one and major disadvantage that those are able to perform
single operation of machining at a time. For industries to achieve the mass production, it is
necessary to perform multiple operations with high rate. So it is impossible to depend upon
conventional single machines and need the improvement in technology and design of such
machines. Multi-function operation machine tool helps us to get high speed cutting rate and to
achieve mass production for maximum profit in related companies. As this machine overcomes
all the limitations and drawbacks of conventional machines, it is also helpful for small scale
industries due to its simple working and operating conditions along with its compatibility,
efficiency and affordable price. Moreover, the above mentioned operations can be replaced by
similar type of operations. This machine is may be used in industries and domestic operation
and low production cost. This project work subject is one in which actually we are learning
theoretical concepts in practical view. In an industry a considerable portion of investment is
being made for machinery installation.
Industries are basically meant for Production of useful goods and services at low
production cost, machinery cost and low inventory cost. Today in this world every task have
been made quicker and fast due to technology advancement but this advancement also demands
huge investments and expenditure, every industry desires to make high productivity rate
maintaining the quality and standard of the product at low average cost In an industry a
considerable portion of investment is being made for machinery installation. So in this paper we
have a proposed a machine which can perform operations like drilling, sawing, shaping, some
lathe operations at different working centers simultaneously which implies that industrialist
have not to pay for machine performing above tasks individually for operating operation
simultaneously.
Economics of manufacturing: According to some economists, manufacturing is a wealth-
producing sector of an economy, whereas a service sector tends to be wealth-consuming.
Emerging technologies have provided some new growth in advanced manufacturing
employment opportunities in the Manufacturing Belt in the United States. Manufacturing
provides important material support for national infrastructure and for national defense.
1.2 PROBLEM STATEMENT
To design and development of MULTI PURPOSE MECHANICAL MACHINE, a structured

which is designed for the purpose of MULTI-OPERATIONs i.e. DRILLING, CUTTING &
SHAPING.
1.3 PROBLEM IDENTIFICATION
This machine perform multipurpose operation at same time with required speed & this machine
is automatic which is controlled or operated by motor which is run with the help of current. This
machine is based on the mechanism of whit worth return.
This model of the MULTI OPERATIONAL machine is may be used in industries and domestic
OPERATION which can perform mechanical operation like drilling, cutting & shaping of a thin
metallic as well as wooden model or body.
1.4 AIM AND OBJECTIVE OF WORK

The aim of our project is the” Design and development of MULTI-FUNCTION OPERATING
MACHINE TOOL”, a structure, which is used for performing Simultaneous operations like,
1. Drilling
2. Cutting
3. Grinding
4. Punching
OBJECTIVES OF THE STUDY
 The objective of this experiment is to investigate the performance of a whitworth quick
turn motion and to verify that the motion does have a quick return stroke and a slow
cutting or forward stroke.
 To reduce size of model.
 To perform all three operations simultaneously on same machine.
 Multi operations are performed at one time.
 We can perform multipurpose operations on thin metallic as well as wooden model.
 Operation of any complicated components can be done with this machine

CHAPTER :-2
LITERATURE REVIEW
CHAPTER :-2
LITERATURE REVIEW
Before starting our work we have undergone through many research papers which indicates that
for a production based industries machine installation is a tricky task as many factor being
associated with it such as power consumption (electricity bill per machine), maintenance cost,
no of units produced per machine i.e. capacity of machine, time consumption and many more….
Some research papers which have led us to approach to the idea of a machine which may give
solution to all these factors are as follows:
Heinrich Arnold1 November 2001 : Rather long re- investment cycles of about 15 years have
created the notion that innovation in the machine tool industry happens incrementally. But
looking at its recent history, the integration of digital contro ls technology and computers into
machine tools have hit the industry in three waves of technology shocks. Most companies
underestimated the impact of this new technology. This article gives an overview of the history
of the machine tool industry since numerical controls were invented and introduced and
analyzes the disruptive character of this new technology on the market. About 100 interviews
were conducted with decision- makers and industry experts who witnessed the development of
the industry over the last forty years. The study establishes a connection between radical
technological change, industry structure, and competitive environment. It reveals a number of
important occurrences and interrelations that have so far gone unnoticed.
Dr. Toshimichi Moriwaki (2006): Recent trends in the machine tool technologies are surveyed
from the view points of high speed and high performance machine tools, combined
multifunctional machine tools, ultra precision machine tools and advanced and intelligent
control technologies.
Frankfurt-am Main, 10 January 2011. : The crisis is over, but selling machinery remains a
tough business. Machine tools nowadays have to be veritable “jack of all trades”, able to handle
all kinds of materials, to manage without any process materials as far as possible, and be capable
of adapting to new job profiles with maximized flexibility. Two highly respected experts on
machining and forming from Dortmund and Chemnitz report on what’s in store for machine tool
manufacturers and users.
Multi-purpose machines are the declarations of independence. The trend towards the kind of
multi-purpose machining centers that are able to cost efficiently handle a broad portfolio of
products with small batch sizes accelerated significantly during the crisis. “With a multi-purpose
machine, you’re less dependent on particular products and sectors”, explains Biermann.
CHAPTER: 3
PROJECT IDEA
CHAPTER: 3
PROJECT IDEA
WHITWORTH’S QUICK RETURN MECHANISM
OBJECTIVE
The objective of this experiment is to investigate the performance of a whit worth quick return
motion and to verify that the motion does have a quick return stroke and a slow cutting or
forward stroke.
THEORY
Definition of mechanism
Mechanism is a simplified model, usually in the form of a line diagram, which is used to
reproduce exactly the motion occurring in a machine. The purpose if this reproduction is to
enable the nature of the motion to be investigated without the encumbrance of the various solid
bodies which forms the machine elements.
WHITWORTH QUICK RETURN MECHANISM
Fig. 3.1 Whitworth Mechanism

The above diagram shows the mechanism as used on the apparatus. Link 1 on the top diagram is
extended to point A. Attach to point A is another link with pivot. The other end of this link
terminated in a slider. In a machine tool where this mechanism is used the cutting tool is attached
to this slider.
The link POA rotates about a O. The mechanism is driven by crank PC which rotates about C
with constant velocity. The slider at P slides along POA as the crank is turned. Its path is shown
by the dashed circle, centered on C and through
P. Clearly when P is at P1 the slider S is at the outer extremely of its travel. When P is at P2 the
slider S is at the inner extremely of its travel.
Now as PC rotates with constant velocity the time taken to go from P1 to P2 is less than that
taken to go from P2 to P1. However during both those time intervals the slider as moving the
same distance. Therefore the speed of S is different during the different parts of cycle. During
the shorter time intervals P1 to P2 the slider as has the greater speed and during the interval P2 to
P1 it has slower speed. Thus P1 to P2 is quick return and P2 to P1.
When applied to metal cutting machine the other advantage is variable power distribution during
the cycle. When S is on the return stroke the slider at P is nearer O and simple moment shows
that the torque applied is low. Hence, the return stroke uses less power as P=T.W. During the
cutting stroke the slider at P is at greater radius from O and thus more power is available to
perform useful work in the cutting metal.
Thus the overall performance is to provide high power forward cutting stroke with a low
powe r and higher speed quick return in preparation for the next cut.
CHAPTER :- 4
WORKING PRINCIPLE
CHAPTER :- 4
WORKING PRINCIPLE
Here the bevel gear arrangement is used for carrying out the operations. Bevel gear is used to
perpendicular (90) power transmission. One of the bevel gear is connected with the motor and
another one with the drill chuck hence when the motor is rotated the drill chuck also rotates. The
motor pulley shaft is connected to a cam arrangement on the other side. Cam arrangement
converts rotary motion into reciprocating motion and the reciprocating motion is used for the
slotting and shaping operation.
The slotting toll and shaping tool are guided by a horizontal guide bush. The up down table is
mounted on a hydraulic bottle jack piston rod hence when the bottle jack handle is pumped the
table height can be adjusted according to the requirement when the after the process is
completed the pressure should be released through pressure relief valve to make the table come
down. A vice is mounted on the table to hold the work piece.
List of materials factors determining the choice of materials

The various factors which determine the choice of material are discussed below.
Properties
The material selected must possess the necessary properties for the proposed application. The
various requirements to be satisfied that Can be weight, surface finish, rigidity, ability to
withstand environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
The various physical properties concerned are melting point, thermal Conductivity, specific
heat, coefficient of thermal expansion, specific gravity, electrical conductivity, magnetic
purposes etc. The various Mechanical properties Concerned are strength in
tensile, Compressive shear, bending, torsional and buckling load, fatigue resistance, impact
resistance, elastic limit, endurance limit, and modulus of elasticity, hardness, wear resistance
and sliding properties.
The various properties concerned from the manufacturing point of view are,
a. Cast ability
b. Weld ability
c. Forge ability
d. Surface properties
e. Shrinkage
f. Deep drawing etc.
Manufacturing case
Sometimes the demand for lowest possible manufacturing cost or surface qualities obtainable by
the application of suitable coating substances may demand the use of special materials.
Quality Required
This generally affects the manufacturing process and ultimately the material. For example, it
would never be desirable to go casting of a less number of components which can be fabricated
much more economically by welding or hand forging the steel.
Availability of Material
Some materials may be scarce or in short supply it then becomes obligatory for the designer to
use some other material which though may not be a perfect substitute for the material designed.
The delivery of materials and the delivery date of product should also be kept in mind.
Space consideration
Sometimes high strength materials have to be selected because the forces involved are high and
space limitations are there.
Cost
As in any other problem, in selection of material the cost of material plays an important part and
should not be ignored. Sometimes factors like scrap utilization, appearance and non-
maintenance of the designed part are involved in the selection of proper materials.
Merits
a. Easy to operate.
b. Reduces time and increases production rate.
c. Low maintenance.
d. Easy to implement
Applications
a. Used in small scale industries to reduce machine cost.
b. In such places where frequent change in operation are required.
Advantages
 Multi machine are performed at one time.

 Our machine is used Return stroke (whit worth) mechanism.
 The return stroke of shaper machine is utilized as cutting operation.
 All operation is performed by only one motor.
 Size is compact therefore it requires less space.
 Time saving.
 Less man power is required.
 Low manufacturing & maintenance cost.
4.1COMPONENT OF MACHINE
1) Ecentric Frame
2) Pedalstal Bearing
3) 2 Single Solid Shaft
4) 1 C-Channel Hollow Shaft
5) Wooden Cutter Blade 7 Inch
6) Metal Cutter Blade 7 Inch
7) Buffing Wheel 7 Inch
8) Grinding Wheel 7 Inch
9) Hacksaw Blade Assembly With Cranck And Pivoted Pin
10) Bench Vice 0 Or 0.05 Size
11) Bevel Gear Pair
12) Drilling Prob With Drinlling Bit
13) B Type Pully 3.6 inch
14) Motor 0.5 Hp 2800 Rpm Ac
15) Belt
16) Other Components
The following components are the major components of the multi process machine.
4.1.1 PEDESTAL BEARING
Fig. 4.1 Pedestal Bearing
A pillow block usually refers to a housing with an included anti-friction bearing. A pillow block
refers to any mounted bearing wherein the mounted shaft is in a parallel plane to the mounting
surface, and perpendicular to the center line of the mounting holes, as contrasted with various
types of flange blocks or flange units. A pillow block may contain a bearing with one of several
types of rolling elements, including ball, cylindrical roller, spherical roller, tapered roller, or
metallic or synthetic bushing. The type of rolling element defines the type of pillow block. These
differ from "plummer blocks" which are bearing housings supplied without any bearings and are
usually meant for higher load ratings and a separately installed bearing.
4.1.2 DRILLING
A drill is a tool fitted with a cutting tool attachment, usually a drill bit used for drilling holes in
various materials or fastening various materials together with the use of fasteners. The
attachment is gripped by a chuck at one end of the drill and rotated while pressed against the
target material. The tip of the cutting tool does the work of cutting into the target material.
Drills are commonly used in woodworking, metalworking and construction.
Specially designed drills are also used in medicine, space missions and other applications. Drills
are available with a wide variety of performance characteristics, such as power and capacity.
Fig. 4.2 Drilling Machine
4.1.3 BEVEL GEAR

A bevel gear is a type of mechanical gear. These gears where the axes of the two shafts intersect
and the tooth bearing faces of the gears themselves are conically shaped. Bevel gears are most
often mounted on shafts that are 90 degrees apart, but can be designed to work at other angles as
well. The pitch surface of bevel gears is a cone. Sliding bearings, usually called bushes bushings
journal bearings sleeve bearings rifle bearings or plain bearings. rolling- element bearings such
as ball bearings and roller bearings.
Jewel bearings, in which the load is carried by rolling the axle slightly off- center. fluid bearings,
in which the load is carried by a gas or liquid magnetic bearings, in which the load is carried by
a magnetic field. Flexure bearings, in which the motion is supported by a load element which
bends. Bearings vary greatly over the forces and speeds that they can support. Forces can be
radial, axial (thrust bearings) or moments perpendicular to the main axis.
Bearings very typically involve some degree of relative movement between surfaces, and
different types have limits as to the maximum relative surface speeds they can handle, and this
can be specified as a speed in ft/s or m/s. The moving parts there is considerable overlap between
capabilities, but plain bearings can generally handle the lowest speeds while rolling element
bearings are faster, hydrostatic bearings faster still, followed by gas bearings and finally magnetic
bearings which have no known upper speed limit.
4.1.4 DRILLING TOOL

Drilling tool is a cylindrical end-cutting tool used to originate or enlarge circular holes in solid
material. Usually, drills are rotated by a drilling machine and fed into stationary work, but on
other types of machines a stationary drill may be fed into rotating work or drill and work may
rotate in opposite directions. To form the two cutting edges and to permit the admission of a
coolant and the ejection of chips, two longitudinal or helical grooves or flutes are provided. The
point or tip, of a drill is usually conical in shape, and it has cutting edges where the flutes end.
The angle formed by the tapering sides of the point determines how large a chip is taken off with
each rotation of the drill. The degree of twist of the helical flutes also affects the drill’s cutting
and chip-removal properties. For general purpose twist drills the helix angle is about 32°. The
angle formed by the two sides of the tapering point is 118° for standard drills, while for drilling
tough metals, a flatter point with a 135° angle is recommended.
The peripheral portion of the drill body not cut away by the flutes is called the la nd, and to
reduce friction and prevent the land from rubbing against the sides of the hole, most of the land
is cut away, leaving a narrow ridge called the margin that follows the edge of the side of the
flute that forms the cutting edge. The fluted part, or body, of a drill is either hardened high-
carbon steel or high-speed steel; other drills have inserts of cemented carbide to form cutting
edges or are made from sintered-carbide rods. The shanks of twist drills are either straight or
tapered and when not integral with the body are made from low-carbon steel and welded to the
body.
4.1.5 ELECTRIC MOTOR
Fig. 4.3 Electric Motor
An electric motor is an electrical machine that converts electrical energy into mechanical

energy. Most electric motors operate through the interaction between the motor's magnetic
field and electric current in a wire winding to generate force in the form of torque applied on the
motor's shaft. Electric motors can be powered by direct current (DC) sources, such as from
batteries, motor vehicles or rectifiers, or by alternating current (AC) sources, such as a power
grid, inverters or electrical generators. An electric generator is mechanically identical to an
electric motor, but operates with a reversed flow of power, converting mechanical energy into
electrical energy.
Electric motors may be classified by considerations such as power source type, internal
construction, application and type of motion output. In addition to AC versus DC types, motors
may be brushed or brushless, may be of various phase (see single-phase, two-phase, or three-
phase), and may be either air-cooled or liquid-cooled. General-purpose motors with standard
dimensions and characteristics provide convenient mechanical power for industrial use. The
largest electric motors are used for ship propulsion, pipeline compression and pumped-
storage applications with ratings reaching 100 megawatts.
4.1.6 BELT
Fig. 4.4 Belt
A belt is a loop of flexible material used to link two or more rotating shafts mechanically, most
often parallel. Belts may be used as a source of motion, to transmit power efficiently or to track
relative movement. Belts are looped over pulleys and may have a twist between the pulleys, and
the shafts need not be parallel.
In a two pulley system, the belt can either drive the pulleys normally in one direction (the same
if on parallel shafts), or the belt may be crossed, so that the direction of the driven shaft is
reversed (the opposite direction to the driver if on parallel shafts). As a source of motion,
a conveyor belt is one application where the belt is adapted to carry a load continuously between
two points. The belt drive can also be used to change the speed of rotation, either up or down, by
using different sized pulleys.
4.1.7 GRINDING WHEEL
Fig. 4.5 Grinding Wheel
A grinding wheel is a wheel composed of an abrasive compound and used for various grinding

(abrasive cutting) and abrasive machining operations. Such wheels are used in grinding
machines. The wheels are generally made from a composite material consisting of coarse-
particle aggregate pressed and bonded together by a cementing matrix (called the bond in
grinding wheel terminology) 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. Today most grinding wheels
are artificial composites made with artificial aggregates, but the history of grinding wheels
began with natural composite stones, such as those used for millstones.
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 produced on rotation.
CHAPTER: 5
DESIGN OF COMPONENTS
CHAPTER: 5
DESIGN OF MODEL
Fig. 5.1 :- 3D VIEW

Fig. 5.2 :- Design of Bearing Base
Fig. 5.3 :- Design of Bearing

Fig. 5.4 :- Design of Bevel Gear
Fig. 5.5 :- Design of Buffing Wheel

Fig. 5.6 :- Design of Cutter
Fig. 5.7 :- Design of Grinding Wheel

Fig. 5.8 :- Design of Motor
Fig. 5.9 :- Design of Hacksaw

Fig. 5.10 :- Design of Small Pulley
Fig. 5.11 :- Design of Cutter Belt

Project
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Last Saved Friday, February 14, 2020
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Contents
 Units
 Model (A4)
o Geometry
 Parts
o Coordinate Systems
o Connections
o Mesh
o Static Structural (A5)
 Analysis Settings
 Loads
 Solution (A6)
 Solution Information
 Equivalent Stress
 Material Data
o Cast Iron
Units
TABLE 1
Unit System Metric (mm, kg, N, s, mV, mA) Degrees rad/s Celsius
Angle Degrees
Rotational
rad/s
Velocity
Temperature Celsius
Model (A4)
Geometry
TABLE 2
Model (A4) > Geometry
Object Name Geometry
State Fully Defined
Definition
C:\Users\Dell\AppData\Local\Temp\WB_DESKTOP-
Source
7EQS0NP_Dell_2980_3\unsaved_project_files\dp0\SYS\DM\SYS.agdb
Type DesignModeler
Length Unit Meters
Element Control Program Controlled
Display Style Body Color
Bounding Box
Length X 1724. mm
Length Y 3178. mm
Length Z 919.4 mm
Properties
Volume 1.4724e+007 mm³
Mass 106.53 kg
Scale Factor Value 1.
Statistics
Bodies 3
Active Bodies 3
Nodes 23048
Elements 8958
Mesh Metric None
Basic Geometry Options
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Material Properties No
Advanced Geometry Options
Use Associativity Yes
Coordinate Systems No
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On
No
Update
Attach File Via Temp
Yes
File
Temporary Directory C:\Users\Dell\AppData\Local\Temp
Analysis Type 3-D
Decompose Disjoint
Yes
Geometry
Enclosure and
Yes
Symmetry Processing
TABLE 3
Model (A4) > Geometry > Parts
Object Name frame2 frame2 frame2
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Stiffness Behavior Flexible
Coordinate System Default Coordinate System
Reference
By Environment
Temperature
Material
Assignment Gray Cast Iron Structural Steel
Nonlinear Effects Yes
Thermal Strain Effects Yes
Bounding Box
Length X 1724. mm 30. mm
Length Y 2678. mm 500. mm
Length Z 919.4 mm 50. mm
Properties
Volume 1.3924e+007 mm³ 4.e+005 mm³
Mass 100.25 kg 3.14 kg
Centroid X 37.314 mm 801.37 mm 722.63 mm
Centroid Y 714.59 mm 2428. mm
Centroid Z 394.19 mm 76.563 mm
Moment of Inertia Ip1 6.2043e+007 kg·mm² 66146 kg·mm²
Moment of Inertia Ip2 2.3736e+007 kg·mm² 877.5 kg·mm²
Moment of Inertia Ip3 7.0922e+007 kg·mm² 65564 kg·mm²
Statistics
Nodes 21712 668
Elements 8798 80
Mesh Metric None
Coordinate Systems
TABLE 4
Model (A4) > Coordinate Systems > Coordinate System
Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System
0.
ID
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]
Connections
TABLE 5
Model (A4) > Connections
Object Name Connections
State Fully Defined
Auto Detection
Generate Automatic Connection On
Yes
Refresh
Transparency
Enabled Yes
Mesh
TABLE 6
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Physics Preference Mechanical
Relevance 0
Sizing
Use Advanced Size Function Off
Relevance Center Medium
Element Size Default
Initial Size Seed Active Assembly
Smoothing Medium
Transition Fast
Span Angle Center Coarse
Minimum Edge Length 2.0 mm
Inflation
Use Automatic Inflation None
Inflation Option Smooth Transition
Transition Ratio 0.272
Maximum Layers 5
Growth Rate 1.2
Inflation Algorithm Pre
View Advanced Options No
Patch Conforming Options
Triangle Surface Mesher Program Controlled
Patch Independent Options
Topology Checking No
Advanced
Number of CPUs for Parallel Part
Program Controlled
Meshing
Shape Checking Standard Mechanical
Element Midside Nodes Program Controlled
Straight Sided Elements No
Number of Retries Default (4)
Extra Retries For Assembly Yes
Rigid Body Behavior Dimensionally Reduced
Mesh Morphing Disabled
Defeaturing
Pinch Tolerance Please Define
Generate Pinch on Refresh No
Automatic Mesh Based Defeaturing On
Defeaturing Tolerance Default
Statistics
Nodes 23048
Elements 8958
Mesh Metric None
Static Structural (A5)
TABLE 7
Model (A4) > Analysis
Static Structural
Object Name
(A5)
State Not Solved
Definition
Physics Type Structural
Analysis Type Static Structural
Solver Target Mechanical APDL
Options
Environment
22. °C
Temperature
Generate Input Only No
TABLE 8
Model (A4) > Static Structural (A5) > Analysis Settings
Object Name Analysis Settings
State Fully Defined
Step Controls
Number Of Steps 1.
Current Step Number 1.
Step End Time 1. s
Auto Time Stepping Program Controlled
Solver Controls
Solver Type Program Controlled
Weak Springs Program Controlled
Solver Pivot
Program Controlled
Checking
Large Deflection Off
Inertia Relief Off
Restart Controls
Generate Restart
Program Controlled
Points
Retain Files After
No
Full Solve
Nonlinear Controls
Newton-Raphson
Program Controlled
Option
Force Convergence Program Controlled
Moment Convergence Program Controlled
Displacement
Program Controlled
Convergence
Rotation
Program Controlled
Convergence
Line Search Program Controlled
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact
No
Miscellaneous
General
No
Miscellaneous
Store Results At All Time Points
Analysis Data Management
Solver Files Directory
7EQS0NP_Dell_2980_3\unsaved_project_files\dp0\SYS\MECH\
Future Analysis None
Scratch Solver Files
Directory
Save MAPDL db No
Delete Unneeded
Yes
Files
Nonlinear Solution No
Solver Units Active System
Solver Unit System nmm
TABLE 9
Model (A4) > Static Structural (A5) > Loads
Fixed Fixed Support
Object Name Force Force 2
Support 2
State Fully Defined
Scope
Scoping Method Geometry Selection
Geometry 3 Faces 2 Faces 2 Edges
Definition
Type Fixed Support Force
Suppressed No
Define By Components
Coordinate
Global Coordinate System
System
X Component 0. N (ramped)
Y Component 0. N (ramped)
Z Component 200. N (ramped)
FIGURE 1
Model (A4) > Static Structural (A5) > Force
FIGURE 2
Model (A4) > Static Structural (A5) > Force 2
Solution (A6)
TABLE 10
Model (A4) > Static Structural (A5) > Solution
Object Name Solution (A6)
State Solve Failed
Adaptive Mesh Refinement
Max Refinement Loops 1.
Refinement Depth 2.
Information
Status Solve Required
Post Processing
Calculate Beam Section
No
Results
TABLE 11
Model (A4) > Static Structural (A5) > Solution (A6) > Solution Information
Solution
Object Name
Information
State Solve Failed
Solution Information
Solution Output Solver Output
Newton-Raphson Residuals 0
Update Interval 2.5 s
Display Points All
FE Connection Visibility
Activate Visibility Yes
Display All FE Connectors
Draw Connections Attached
All Nodes
To
Line Color Connection Type
Visible on Results No
Line Thickness Single
Display Type Lines
TABLE 12
Model (A4) > Static Structural (A5) > Solution (A6) > Results
Object Name Equivalent Stress
State Solve Failed
Scope
Geometry All Bodies
Definition
Type Equivalent (von-Mises) Stress
By Time
Display Time Last
Calculate Time History Yes
Identifier
Suppressed No
Integration Point Results
Display Option Averaged
Average Across
No
Bodies
Results
Minimum
Maximum
Minimum Occurs On
Maximum Occurs On
Information
Time
Load Step 0
Substep 0
Iteration Number
Material Data
Gray Cast Iron
TABLE 13
Gray Cast Iron > Constants
Density 7.2e-006 kg mm^-3
Coefficient of Thermal
1.1e-005 C^-1
Expansion
Specific Heat 4.47e+005 mJ kg^-1 C^-1
Thermal Conductivity 5.2e-002 W mm^-1 C^-1
Resistivity 9.6e-005 ohm mm
TABLE 14
Gray Cast Iron > Compressive Ultimate Strength
Compressive Ultimate Strength MPa
820
TABLE 15
Gray Cast Iron > Compressive Yield Strength
Compressive Yield Strength MPa
0
TABLE 16
Gray Cast Iron > Tensile Yield Strength
Tensile Yield Strength MPa
0
TABLE 17
Gray Cast Iron > Tensile Ultimate Strength
Tensile Ultimate Strength MPa
240
TABLE 18
Gray Cast Iron > Isotropic Secant Coefficient of Thermal Expansion
Reference Temperature C
22
TABLE 19
Gray Cast Iron > Isotropic Elasticity
Temperature Young's Modulus
Poisson's Ratio Bulk Modulus MPa Shear Modulus MPa
C MPa
1.1e+005 0.28 83333 42969
TABLE 20
Gray Cast Iron > Isotropic Relative Permeability
Relative Permeability
10000
Structural Steel
TABLE 21
Structural Steel > Constants
1.2e-005 C^-1
Expansion
TABLE 22
Structural Steel > Compressive Ultimate Strength
0
TABLE 23
Structural Steel > Compressive Yield Strength
250
TABLE 24
Structural Steel > Tensile Yield Strength
250
TABLE 25
Structural Steel > Tensile Ultimate Strength
460
TABLE 26
Structural Steel > Isotropic Secant Coefficient of Thermal Expansion
22
TABLE 27
Structural Steel > Alternating Stress Mean Stress
Alternating Stress
Cycles Mean Stress MPa
MPa
3999 10 0
2827 20 0
1896 50 0
1413 100 0
1069 200 0
441 2000 0
262 10000 0
214 20000 0
138 1.e+005 0
114 2.e+005 0
86.2 1.e+006 0
TABLE 28
Structural Steel > Strain-Life Parameters
Strength Strength Ductility Ductility Cyclic Strength Cyclic Strain
Coefficient MPa Exponent Coefficient Exponent Coefficient MPa Hardening Exponent
920 -0.106 0.213 -0.47 1000 0.2
TABLE 29
Structural Steel > Isotropic Elasticity
C MPa
2.e+005 0.3 1.6667e+005 76923
TABLE 30
Structural Steel > Isotropic Relative Permeability
10000
Project
Save Project Before
No
Solution
Contents
 Units
 Model (A4)
o Geometry
 shaft2
o Mesh
 Loads
 Solution (A6)
 Material Data
o Gray Cast Iron
Units
TABLE 1
Angle Degrees
Rotational
rad/s
Velocity
Temperature Celsius
Model (A4)
Geometry
TABLE 2
State Fully Defined
Definition
Source
Type DesignModeler
Length Unit Meters
Bounding Box
Length X 1002. mm
Length Y 50. mm
Length Z 50. mm
Properties
Mass 14.165 kg
Statistics
Bodies 1
Active Bodies 1
Nodes 2478
Elements 462
Mesh Metric None
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On
No
Update
Yes
File
Analysis Type 3-D
Decompose Disjoint
Yes
Geometry
Enclosure and
Yes
Symmetry Processing
TABLE 3
Object Name shaft2
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Reference Temperature By Environment
Material
Assignment Gray Cast Iron
Bounding Box
Length X 1002. mm
Length Y 50. mm
Length Z 50. mm
Properties
Mass 14.165 kg
Centroid X 1.9904e-014 mm
Centroid Y 3.7946e-016 mm
Centroid Z -5.3931e-004 mm
Moment of Inertia Ip1 4382.4 kg·mm²
Moment of Inertia Ip2 1.1814e+006 kg·mm²
Statistics
Nodes 2478
Elements 462
Mesh Metric None
Coordinate Systems
TABLE 4
Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System
0.
ID
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]
Mesh
TABLE 5
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Relevance 0
Sizing
Smoothing Medium
Transition Fast
Inflation
Maximum Layers 5
Growth Rate 1.2
Advanced
Program Controlled
Meshing
Defeaturing
Statistics
Nodes 2478
Elements 462
Mesh Metric None

TABLE 6
Static Structural
Object Name
(A5)
State Solved
Definition
Options
Environment 22. °C
Temperature
TABLE 7
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Solver Controls
Solver Pivot
Program Controlled
Checking
Inertia Relief Off
Restart Controls
Generate Restart
Program Controlled
Points
Retain Files After
No
Full Solve
Nonlinear Controls
Newton-Raphson
Program Controlled
Option
Displacement
Program Controlled
Convergence
Rotation
Program Controlled
Convergence
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact
No
Miscellaneous
General
No
Miscellaneous
Directory
Save MAPDL db No
Delete Unneeded Yes
Files
TABLE 8
Fixed Fixed Support
Object Name Force
Support 2
State Fully Defined
Scope
Geometry 1 Face 1 Edge
Definition
Suppressed No
Coordinate
System
FIGURE 1
Solution (A6)
TABLE 9
Solution
Object Name
(A6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
No
Results
TABLE 10
Solution
Object Name
Information
State Solved
Display Points All
All Nodes
To
Display Type Lines
TABLE 11
State Solved
Scope
Geometry All Bodies
Definition
By Time
Display Time Last
Identifier
Suppressed No
Average Across
No
Bodies
Results
Minimum 5.149e-003 MPa
Maximum 2.1454 MPa
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
FIGURE 2
Model (A4) > Static Structural (A5) > Solution (A6) > Equivalent Stress
TABLE 12
Time
Minimum [MPa] Maximum [MPa]
[s]
1. 5.149e-003 2.1454
Material Data
Gray Cast Iron
TABLE 13
1.1e-005 C^-1
Expansion
TABLE 14
820
TABLE 15
0
TABLE 16
0
TABLE 17
240
TABLE 18
22
TABLE 19
C MPa
1.1e+005 0.28 83333 42969
TABLE 20
10000
Project
Save Project Before
No
Solution
Contents
 Units
 Model (A4)
o Geometry
 shaft2
o Mesh
 Loads
 Solution (A6)
 Material Data
o Gray Cast Iron
Units
TABLE 1
Angle Degrees
Rotational
rad/s
Velocity
Temperature Celsius
Model (A4)
Geometry
TABLE 2
State Fully Defined
Definition
Source
Type DesignModeler
Length Unit Meters
Bounding Box
Length X 1002. mm
Length Y 50. mm
Length Z 50. mm
Properties
Mass 14.164 kg
Statistics
Bodies 1
Active Bodies 1
Nodes 2420
Elements 451
Mesh Metric None
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On
No
Update
Yes
File
Analysis Type 3-D
Decompose Disjoint
Yes
Geometry
Enclosure and
Yes
Symmetry Processing
TABLE 3
Object Name shaft2
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 1002. mm
Length Y 50. mm
Length Z 50. mm
Properties
Mass 14.164 kg
Centroid X 1.0673e-014 mm
Centroid Z 5.3931e-004 mm
Moment of Inertia Ip1 4382.4 kg·mm²
Statistics
Nodes 2420
Elements 451
Mesh Metric None
Coordinate Systems
TABLE 4
Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System
0.
ID
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]
Mesh
TABLE 5
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Relevance 0
Sizing
Smoothing Medium
Transition Fast
Inflation
Maximum Layers 5
Growth Rate 1.2
Advanced
Program Controlled
Meshing
Defeaturing
Statistics
Nodes 2420
Elements 451
Mesh Metric None

TABLE 6
Static Structural
Object Name
(A5)
State Solved
Definition
Options
Environment 22. °C
Temperature
TABLE 7
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Solver Controls
Solver Pivot
Program Controlled
Checking
Inertia Relief Off
Restart Controls
Generate Restart
Program Controlled
Points
Retain Files After
No
Full Solve
Nonlinear Controls
Newton-Raphson
Program Controlled
Option
Displacement
Program Controlled
Convergence
Rotation
Program Controlled
Convergence
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact
No
Miscellaneous
General
No
Miscellaneous
Directory
Save MAPDL db No
Delete Unneeded Yes
Files
TABLE 8
Fixed Fixed Support
Object Name Force Force 2 Force 3
Support 2
State Fully Defined
Scope
Definition
Suppressed No
Coordinate
System
FIGURE 1
FIGURE 2
FIGURE 3
Solution (A6)
TABLE 9
Solution
Object Name
(A6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
No
Results
TABLE 10
Solution
Object Name
Information
State Solved
Display Points All
All Nodes
To
Display Type Lines
TABLE 11
State Solved
Scope
Geometry All Bodies
Definition
By Time
Display Time Last
Identifier
Suppressed No
Average Across
No
Bodies
Results
Maximum 4.8574 MPa
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
FIGURE 4
TABLE 12
Time
[s]
1. 3.6978e-003 4.8574
Material Data
Gray Cast Iron
TABLE 13
1.1e-005 C^-1
Expansion
TABLE 14
820
TABLE 15
0
TABLE 16
0
TABLE 17
240
TABLE 18
22
TABLE 19
C MPa
1.1e+005 0.28 83333 42969
TABLE 20
10000
Project
Save Project Before
No
Solution
Contents
 Units
 Model (A4)
o Geometry
 shft
o Mesh
 Loads
 Solution (A6)
 Material Data
o Gray Cast Iron
Units
TABLE 1
Angle Degrees
Rotational
rad/s
Velocity
Temperature Celsius
Model (A4)
Geometry
TABLE 2
State Fully Defined
Definition
Source
Type DesignModeler
Length Unit Meters
Bounding Box
Length X 1622. mm
Length Y 50. mm
Length Z 350. mm
Properties
Mass 28.987 kg
Statistics
Bodies 1
Active Bodies 1
Nodes 1665
Elements 265
Mesh Metric None
Parameters Yes
Parameter Key DS
Attributes No
Named Selections No
Reader Mode Saves
No
Updated File
Use Instances Yes
Smart CAD Update No
Compare Parts On
No
Update
Yes
File
Analysis Type 3-D
Decompose Disjoint
Yes
Geometry
Enclosure and
Yes
Symmetry Processing
TABLE 3
Object Name shft
State Meshed
Graphics Properties
Visible Yes
Transparency 1
Definition
Suppressed No
Material
Bounding Box
Length X 1622. mm
Length Y 50. mm
Length Z 350. mm
Properties
Mass 28.987 kg
Centroid X 384.49 mm
Centroid Z 82.462 mm
Statistics
Nodes 1665
Elements 265
Mesh Metric None
Coordinate Systems
TABLE 4
Global Coordinate
Object Name
System
State Fully Defined
Definition
Type Cartesian
Coordinate System
0.
ID
Origin
Origin X 0. mm
Origin Y 0. mm
Origin Z 0. mm
Directional Vectors
X Axis Data [ 1. 0. 0. ]
Y Axis Data [ 0. 1. 0. ]
Z Axis Data [ 0. 0. 1. ]
Mesh
TABLE 5
Model (A4) > Mesh
Object Name Mesh
State Solved
Display
Defaults
Relevance 0
Sizing
Smoothing Medium
Transition Fast
Inflation
Maximum Layers 5
Growth Rate 1.2
Advanced
Program Controlled
Meshing
Defeaturing
Statistics
Nodes 1665
Elements 265
Mesh Metric None

TABLE 6
Static Structural
Object Name
(A5)
State Solved
Definition
Options
Environment 22. °C
Temperature
TABLE 7
State Fully Defined
Step Controls
Number Of Steps 1.
Step End Time 1. s
Solver Controls
Solver Pivot
Program Controlled
Checking
Inertia Relief Off
Restart Controls
Generate Restart
Program Controlled
Points
Retain Files After
No
Full Solve
Nonlinear Controls
Newton-Raphson
Program Controlled
Option
Displacement
Program Controlled
Convergence
Rotation
Program Controlled
Convergence
Stabilization Off
Output Controls
Stress Yes
Strain Yes
Nodal Forces No
Contact
No
Miscellaneous
General
No
Miscellaneous
Directory
Save MAPDL db No
Delete Unneeded Yes
Files
TABLE 8
Fixed Fixed Support
Object Name Force
Support 2
State Fully Defined
Scope
Definition
Suppressed No
Coordinate
System
Z Component -300. N (ramped)
FIGURE 1
Solution (A6)
TABLE 9
Solution
Object Name
(A6)
State Solved
Refinement Depth 2.
Information
Status Done
Post Processing
No
Results
TABLE 10
Solution
Object Name
Information
State Solved
Display Points All
All Nodes
To
Display Type Lines
TABLE 11
State Solved
Scope
Geometry All Bodies
Definition
By Time
Display Time Last
Identifier
Suppressed No
Average Across
No
Bodies
Results
Maximum 5.6196 MPa
Information
Time 1. s
Load Step 1
Substep 1
Iteration Number 1
FIGURE 2
TABLE 12
Time
[s]
1. 3.2349e-002 5.6196
Material Data
Gray Cast Iron
TABLE 13
1.1e-005 C^-1
Expansion
TABLE 14
820
TABLE 15
0
TABLE 16
0
TABLE 17
240
TABLE 18
22
TABLE 19
C MPa
1.1e+005 0.28 83333 42969
TABLE 20
10000
CALCULATION:-
5.1 DESIGN OF SHAFT :- (Solid Shaft)
Material :- Gray C. I.
Length of Shaft = 1002 mm
Diameter of Shaft = 50 mm
Force (F) = 200 N. , M = 14.18 kg.
1) Design Torque (Td) :-

60 P × K l
Td =
2 πN
K l=1.75 (Given) on D. D. B. Page no. 112
60× 200 ×1.75

Td = (N = 100 rpm)
2 π × 100
Td = 33.42 N-mm
2) Maximum Stress (Tmax)
60× 103 √
Tmax = ¿¿
π D3
60× 103 ( 2 2
3 √
Tmax = ( 14.16 ) + ( 33.42 ) )
π (50)
Tmax = 1.47 N/mm2
5.2 DESIGN OF V- BELT

Motor rpm = 2800 rpm (N1)
Material = rubber
Diameter of Pully = 91.44 mm (small)
Diameter of large Pully = 330.2 mm
1) Design of Power (Pd)

Pd = PA × K 1
Pd = ?
P out 2 πNT
Pd = , Pout =
nbelt 60
2 π × 2800× 33.42
Pout = (T = 33.42 from design of shaft)
60
= 9799.25 w
Pout =9.79 kw
9.79 ×103 n
PR = ( v−belt =90 % ¿ given
0.9
PR = 10.87 ×103 w
Now,
Pd = 10.87 ×103 ×1.10 ( K 2=load factor , K 1 =1.10line shaft ¿
Pd = 11.95 kw
2) Select Section of Belt :-
Pd = 11.95 kw
According to Table on Data Book
W = 17 mm, t = 11 mm
D = 135 mm or 225 mm (safe)
Dmin = 5.3 inch, K2 = 4.34
V1 = No slip
π D 1 N 1=π D2 N 2
π × 91.44 × 2800=π ×330.2× N 2
N 2=775.38 rpm
3) Vp = Peripheral Speed :-
VP = π D 1 N 1=π ×91.44 × 2800
VP = 804.34 m/min3 safe according to D.D.B. T-xv-10
4) Center Distance (C) :-

C = D1 + D2 = 91.44 + 330.2
C = 421.64 mm
5) Coefficient of Friction :-
μ=μ 1=μ2=0.3
6) Angle of Lap (Q)

D 2−D 1
Q=π ±
C
D 2−D 1 330.2−91.44
Q 1=π− =π−
C 421.64
Q 1=¿ 2.57 radian
D 2−D 1 330.2−91.44
Q 2=π + =π +
C 421.64
Q 2=¿ 3.70 radian
7) Belt Tension
F 1 μθ /sin ⁡( α2 )
=e
F2
F 1 μ θ /sin ⁡( α2 )
1 1
=e (α =380 given)
F2
F 1 0.3 ×2.57 / sin⁡( 382 )

=e
F2
F1
=10.67 ------ Small
F2
F 1 μ θ /sin ⁡( α2 )
2 2
=e
F2
F 1 0.3 ×3.70 /sin ⁡( 382 )

=e
F2
F1
=30.24 ------ Bigger
F2
Smaller Pulley governs the design
F 1 μ θ /sin ⁡( α2 )
1 1
=e
F2
F1
=10.67
F2
8) Power Ratting :-
F 1 μ θ / sin ⁡( α2 )
1 1
=e −1
F2
Power Rating = ( F w −F c ¿ α
F1 μ θ /sin ⁡( )
1 1
2
=e
F2
F w =w 2=172=289 (T × V −8 ¿ m D . D .O .)
V1 2
F c =K c ( )
5
408.34 2
F c =4.43( )
5
F c =31.81 N
Power Rating = 289 – 31.81 ( 10.67

10.67 ) ×(
804.34
60 )
Table up = m/sec.
( 804.34
60 )=
13.40 m
sec
.
= 289 – 31.81 ( 10.67

10.67 )
×31.40
= 3123.35 w
Power Ratting = 3.12 kw.
9) No. of Belt :-
Design Power 11.95
No. of Belt = =
Power Rating 3.12
No. of Belt = 3.83
N ≅4
10) Length of Belt

2
L = π ( D1−D2 )
× ( D1 + D2 ) +2 C+
2 4C
2
π ( 330.2−91.44 )
L = × ( 91.44 +330.2 )+(2 × 421.64)+
2 4 × 421.64
L = 1539.39 mm
L = 1.5m
All dimension are safe
5.3 DESIGN OF BEVEL GEAR

PR = 15 KN
Item Pinion Gear
Teeth 20 60
Material Steel C.I.
Basis Strength 210 MPa. 105 MPa
Thickness 250 BHN 180 BHN
Speed 120 rpm 1400 rpm
Teeth Profile 20 FD 20 FD
CHAPTER: 6
FABRICATION OF MODEL
CHAPTER: 6
FABRICATION OF MODEL
Operations perform by machine:-
1. HACKSAW
2. CUTTER
3. GRINDING
4. BUFFING
5. DRILLING
6.1 HACKSAW
Fig. 6.1 Hacksaw
A hacksaw is a fine-toothed saw, originally and mainly made for cutting metal. The

equivalent saw for cutting wood is usually called bow saw. Most hacksaws are hand saws with a
C-shaped walking frame that holds a blade under tension. Such hacksaws have a handle, usually
a pistol grip, with pins for attaching a narrow disposable blade. The frames may also be
adjustable to accommodate blades of different sizes. A screw or other mechanism is used to put
the thin blade under tension. On hacksaws, as with most frame saws, the blade can be mounted
with the teeth facing toward or away from the handle, resulting in cutting action on either the
push or pull stroke. In normal use, cutting vertically downwards with work held in a bench vice,
hacksaw blades are set to be facing forwards.
The pitch of the teeth can be from fourteen to thirty-two teeth per inch (TPI) for a hand
blade, with as few as three TPI for a large power hacksaw blade. The blade chosen is based on
the thickness of the material being cut, with a minimum of three teeth in the material. As
hacksaw teeth are so small, they are set in a "wave" set. As for other saws they are set from side
to side to provide a kerf or clearance when sawing, but the set of a hacksaw changes gradually
from tooth to tooth in a smooth curve, rather than alternate teeth set left and right.
Hacksaw blades are normally quite brittle, so care needs to be taken to prevent brittle

fracture of the blade. Early blades were of carbon steel, now termed 'low alloy' blades, and were
relatively soft and flexible. They avoided breakage, but also wore out rapidly. Except where cost
is a particular concern, this type is now obsolete. 'Low alloy' blades are still the only type
available for the Junior hacksaw, which limits the usefulness of this otherwise popular saw.
For several decades now, hacksaw blades have used high speed steel for their teeth, giving
greatly improved cutting and tooth life. These blades were first available in the 'All-hard' form
which cut accurately but were extremely brittle. This limited their practical use to benchwork on
a workpiece that was firmly clamped in a vice. A softer form of high speed steel blade was also
available, which wore well and resisted breakage, but was less stiff and so less accurate for
precise sawing. Since the 1980s, bi-metal blades have been used to give the advantages of both
forms, without risk of breakage. A strip of high speed steel along the tooth edge is electron beam
welded to a softer spine. As the price of these has dropped to be comparable with the older
blades, their use is now almost universal.
6.2DRILLING
Fig. 6.2 Drilling
Drilling is the operation of producing circular hole in the work-piece by using a rotating cutter
called DRILL.
 The machine used for drilling is called drilling machine.

 The drilling operation can also be accomplished in lathe, in which the drill is held in tailstock and
the work is held by the chuck.
 The most common drill used is twist drill.
Drilling Machine
 It is the simplest and accurate machine used in production shop.

 The work piece is held stationary i.e. champed in position and the drill rotates to make a hole.
Components of Drilling Machine
1. Spindle
The spindle holds the drill or cutting tools and revolves in a fixed position in a sleeve.
2. Sleeve
The sleeve or quill assembly does not revolve but may slide in its bearing in a direction parallel
to its axis. When the sleeve carrying the spindle with a cutting tool is lowered, the cutting tool is
fed into the work and when its moved upward, the cutting tool is withdrawn from the work.
Feed pressure applied to the sleeve by hand or power causes the revolving drill to cut its way into
the work a fraction of an mm per revolution.
3. Column
The column is cylindrical in shape and built rugged and solid. The column supports the head
and the sleeve or quill assembly.
4. Head
The head of the drilling machine is composed of the sleeve, a sp indle, an electric motor and
feed mechanism. The head is bolted to the column.
5. Worktable
The worktable is supported on an arm mounted to the column. The worktable can be adjusted
vertically to accommodate different heights of work or it can be swung completely out of the
way. It may be tilted up to 90 degree in either direction, to allow long pieces to be end or angle
drilled.
6. Base
The base of the drilling machine supports the entire machine and when bolted to the floor,
provides for vibration- free operation and best machining accuracy. The top of the base is
similar to the worktable and may be equipped with t- slot for mounting work too large for the table.
7. Hand feed
The hand feed drilling machine are the simplest and most common type of drilling machine in use
today. These are light duty machine that are operated by the operator, using a feed handled, so
that the operator is able to “feel” the action of the cutting tool as it cuts through the work piece.
These drilling machines can be bench or floor mounted.
8. Power feed
The power feed drilling machine are usually larger and heavier than the hand feed ones they are
equipped with the ability to feed the cutting tool in to the work automatically duty work or the
work that uses large drills that require power feed larger work pieces are usually clamped
directly to the table or base using t- bolts and clamps by a small work places are held in a vice.
A depth- stop mechanism is located on the head, near the spindle, to aid in drilling to a precise
depth.
6.3CUTTER
A hacksaw is a fine tooth saw with a blade held under tension in a frame, used for cutting
materials such as metal or plastics, hand held hacksaws consist of a metal arch with a handle,
usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other
mechanism is used to put the thin blade under tension. The blade can be mounted with a teeth
facing toward or away from the handle, resulting in cutting action on either the push or pull
stroke. On the push stroke, the arch will flex slightly, decreasing the tension on the blade.
Blades are available in standardized lengths, usually 10 or 12 inches for a standard hand
hacksaw. “junior” hacksaws are half the size. Powered hacksaw may use large blade in a range
of sizes, or small machines may use the same hand blades.
Fig. 6.3 Cutter

Specification of hacksaw
Size of hacksaw blade:-
Thickness = 1.27-2.54mm Width = 25.40-50.80mm Length = 304.80-609.60mm
Work piece material Cutting speed in m/s

Mild steel 0.75
Cast iron 0.50

Brass/ aluminum 1.5
Bronze 1.25
Thin section(pipes & tubes) 1.5
6.4 GRINDING
Fig. 6.4 Grinding
Grinding practice is a large and diverse area of manufacturing and toolmaking. It can

produce very fine finishes and very accurate dimensions; yet in mass production contexts it can
also rough out 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 separately in shop-floor practice.
6.5 BUFFING
Buffing are finishing processes for smoothing a workpiece's surface using an abrasive

and a work wheel or a leather strop. Technically polishing refers to processes that use an
abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to the work
wheel. Polishing is a more aggressive process while buffing is less harsh, which leads to a
smoother, brighter finish. A common misconception is that a polished surface has a mirror bright
finish, however most mirror bright finishes are actually buffed.
Polishing is often used to enhance the appearance of an item, prevent contamination of

instruments, remove oxidation, create a reflective surface, or prevent corrosion in pipes.
In metallography and metallurgy, polishing is used to create a flat, defect-free surface for
examination of a metal's microstructure under a microscope. Silicon-based polishing pads or a
diamond solution can be used in the polishing process. Polishing stainless steel can also increase
the sanitary benefits of it.
The removal of oxidization (tarnish) from metal objects is accomplished using a metal
polish or tarnish remover; this is also called polishing. To prevent further unwanted oxidization,
polished metal surfaces may be coated with wax, oil, or lacquer. This is of particular concern for
copper alloy products such as brass and bronze.
CHAPTER:- 7
FUTURE IMPLIMENTATION
CHAPTER:- 7
FUTURE IMPLIMENTATION
 To implement this project we have to apply the lever arrangement to engage or disengage
the driven shaft from driver shaft.
CHAPTER:- 8
ADVANTAGES & APPLICATION
CHAPTER:- 8
ADVANTAGES & DISADVANTAGES
 Multi operations are performed at one time.
 All operation is performed by only one motor.
 The return stroke of shaper machine is utilized as cutting operation.
 Time saving.
 Less man power is required.
 Size is compact therefore it requires less space.
 Low manufacturing & maintenance cost.
APPLICATION
 A drilling machine is a tool used for drilling holes in various types of wood, plastic and
metal. The bench drill is bolted down for safe drilling of such materials.
 A grinding machine, often shortened to grinder, is any of various power tools or

machine tools used for grinding, which is a type of machining using an abrasive wheel
as the cutting tool. Each grain of abrasive on the wheel's surface cuts a small chip from
the work piece via shear deformation.
 A shaper is a type of machine tool that uses linear relative motion between the work
piece and a single-point cutting tool to machine a linear tool path. Its cut is analogous to
that of a lathe, except that it is (archetypally) linear instead of helical.
 A cutting tool or cutter is any tool that is used to remove material from the work piece
by means of shear deformation. Cutting may be accomplished by single-point or
multipoint tools.
CHAPTER:- 9
CONCLUSION
CHAPTER:- 9
CONCLUSION
After completing the major project on “MULTI PURPOSE MECHANICAL

MACHINE” we are much happy and would like to thank our teacher guides and the
lectures of the concerned department who have guided us.
While making this project we have been also to learn a lot and understand the various
aspects of “MULTI PURPOSE MECHANICAL MACHINE” we can use our
knowledge, which we get during our study.
The research his carried out by us made an impressing task in the field of industrial and
automated workshops. It is very usefully for the workers to work in the industrial workshop
are in the service station. This project research has also reduced the cost involved in the
concern. Project has been designed to perform the entire requirement task which has also
been provided.
CHAPTER:- 10
REFRENCE
CHAPTER:- 10
REFRENCE
BOOK REFERENCE
 Heinrich Arnold1”The recent history of the machine tool industry and the effects of
technological change “University of Munich, Institute for Innovation Research and
Technology Management, November 2001.
 Dr. Toshimichi Moriwaki “Trends in Recent Machine Tool Technologies” Professor
Department f Mechanical Engineering Kobe University, NTN Technical Review
No.74(2006).
 Frankfurt am Main “Multi-purpose machines ensure enhanced “, 1 January 11.
 T. Moriwaki “Multi-functional machine tool”, Department of Industrial and Systems
Engineering, Setsunan University, Neyagawa, Japan CIRP Annals –Manufacturing
Technology DOI:10.1016/j.cirp.2008.09.004.
 “Selecting and Planning the Process of Manufacture: Dr. Pulak M. Pandey.
http://paniit.iitd.ac.in/~pmpandey
 B. H. Amstead, P. Ostwald, M.L.Begaman, Manufacturing Processes,(8 Edition)
 Moltrecht, Karl Hans: Machine Shop Practice, 2nd ed. New York: Industrial Press,
1981, Volume 1, p. 403.
 El – Hoffy : Advance Machining Process, McGraw Hill Companies, 0.007- 1466940,
2005.
The websites:-
 www.technogystudent.com
 www.terry-eng27.blogspot.in
 www.wikipedia.org
 www.ask.refrence.com
 www.dictionary.refrence.com
 www.community.machinedesign.com
 www.google.com
 www.sciencedirect.com

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A PROJECT REPORT

“FABRICATION BY USING MULTI FUNCTION

Submitted in partial fulfillment for requirement of the degree of

AKANSH V. KADAO (304) PIYUSH M. NIKOSE (329)

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

It is to certify that this is a bonafide record of Project Work entitled

“FABRICATION BY USING MULTI FUNCTION

AKANSH V. KADAO (304) PIYUSH M. NIKOSE (329)

B.E. MECHANICAL ENGINEERING

Rashtrasant Tukadoji Maharaj Nagpur University, Nagpur (M.S.)

PROF. N. R. PATHARE PROF. S. P. LOKHANDE

DR. K. S. ZAKIUDDIN DR. M. P. SINGH

We hereby declare that the work of “FABRICATION BY USING MULTI FUNCTION

the guidance of Prof. N. R. Pathare. Associate Professor in Mechanical Engineering

Department, Priyadarshini College of Engineering, Nagpur.

acknowledgement has been made in the text.

AKANSH V. KADAO (304)

DEVASHISH H. PAUL (313)

ISHAN S. BANGADKAR (316)

PIYUSH M. NIKOSE (329)

PRANAY R. PATNE (333)

VISHAL KUKDE (358)

AKANSH V. KADAO (304)

DEVASHISH H. PAUL (313)

ISHAN S. BANGADKAR (316)

PIYUSH M. NIKOSE (329)

PRANAY R. PATNE (333)

VISHAL KUKDE (358)

The mentioned operations can however be replaced by similar type of operations.

This deal with “MULTI-FUNCTION OPERATING MACHINE”. In today’s era every

1.2 PROBLEM STATEMENT

To design and development of MULTI PURPOSE MECHANICAL MACHINE, a structured

1.3 PROBLEM IDENTIFICATION

1.4 AIM AND OBJECTIVE OF WORK

 To reduce size of model.

 To perform all three operations simultaneously on same machine.

 Multi operations are performed at one time.

 We can perform multipurpose operations on thin metallic as well as wooden model.

 Operation of any complicated components can be done with this machine

WHITWORTH’S QUICK RETURN MECHANISM

WHITWORTH QUICK RETURN MECHANISM

Fig. 3.1 Whitworth Mechanism

List of materials factors determining the choice of materials

 Multi machine are performed at one time.

4.1.1 PEDESTAL BEARING

Fig. 4.1 Pedestal Bearing

Fig. 4.2 Drilling Machine

4.1.3 BEVEL GEAR

4.1.4 DRILLING TOOL

Fig. 4.3 Electric Motor

An electric motor is an electrical machine that converts electrical energy into mechanical

Fig. 4.4 Belt

Fig. 4.5 Grinding Wheel

A grinding wheel is a wheel composed of an abrasive compound and used for various grinding

Fig. 5.1 :- 3D VIEW

Fig. 5.3 :- Design of Bearing

Fig. 5.5 :- Design of Buffing Wheel

Fig. 5.7 :- Design of Grinding Wheel

Fig. 5.9 :- Design of Hacksaw

Fig. 5.11 :- Design of Cutter Belt

Static Structural (A5)