Proposalof Rewinding Machine PDF

DIRE DAWA UNIVERSITY
INSTITUTE OF TECHNOLOGY
SCHOOL OF MECHANICAL AND INDUSTRIAL

ENGINEERING
TITLE: DESIGN AND PROTOTYPE MANUFACTURING OF SHEET METAL CUTTER AND
REWINDING MACHINE
NAME OF STUDENTS ID.NO
1.Kibitu Belay R/1129/08
2. Chaltu Senbeto R/0611/08
3. Olifan Abebe R/1248/08
SUBMITTED TO:
Date of submission: on january 2, 2021
|Page
[design and prototype manufactering of sheet metal and
rewinding machine] January 2, 2021
Contents
UNIT ONE .................................................................................................................................................... 1
Introduction .................................................................................................................................................. 1
1.1 Overview of the Thesis ....................................................................................................................... 1
1.2 Statement of the problem .................................................................................................................... 1
1.3 Objectives of the thesis ....................................................................................................................... 2
1.3.1 General Objective ........................................................................................................................ 2
1.3.2 Specific objective ......................................................................................................................... 2
1.4 significance of the thesis .................................................................................................................... 2
1.5 Scope of the Thesis ............................................................................................................................ 3
UNIT TWO ................................................................................................................................................... 4
2.1 Literature Review................................................................................................................................ 4
2.2 Justification of Literature Review ....................................................................................................... 9
CHAPTER THREE .................................................................................................................................... 10
3.1 Methodology ..................................................................................................................................... 10
3.1.1 Data Collection .......................................................................................................................... 10
3.1.2 Procedure for design of machine elements ................................................................................ 11
3.2. Materials Descriptions and Software’s that will be Used in the Project .......................................... 12
3.2.1. Materials and Equpment Descriptions ...................................................................................... 12
3.3 Material Selection and Detail Design Analysis of the Machine ....................................................... 12
3.3.1. Material Selection and Specification ........................................................................................ 12
3.3.2. Design Analysis of the Machine ............................................................................................... 14
CHAPTER FOUR....................................................................................................................................... 20
Cost Analysis .............................................................................................................................................. 20
4.1. Cost Analysis ................................................................................................................................... 20
i
List of figure
Figure 1:Hexagon-head bolt.[2] .................................................................................................................. 17
Figure 2: Screw thread.[2] .......................................................................................................................... 19
List of table
Table 1:material selection of the machine. ................................................................................................. 14

Table 2:specifications of the machine. ........................................................................................................ 14
Table 3:Material cost. ................................................................................................................................. 21
i|Page
UNIT ONE
Introduction
1.1 Overview of the Thesis

Sheet metal is simpily a metal in to thin and flat pieces. It is one of the fundamental forms used
in the metal working and can be cut and bent into a variefy of different shapes. Thicknesses can
vary significantly, although extremely thin thicknesses are considered foil or leaf and pieces
thiker than 7 mm are considered plate. Sheet metal is available in flat pieces or as a coiled strip.
The coils are formed by running a continuous sheet of metal through a roll slitter. Sheet metal
also has applications in car bodies, airplane wings, medical tabels, roofs for buldings
(Architectural) and many other things according to Raj Reddy in [2016] idea.
This project is study about the design and analysis of operated sheet metal cutting and rewinding
machine which shows capability to design more than one concept.other than that, it is important
to studies on failure identification and cutting force analysis which are the main topic for this
project. So, at the end of this project will be practicing on how to bulid and steps to follow to
complete the requirement for this project. The electric power operated cutting machine is
designed using various components. The components are electric motor ( driving the machine),
bearing ( support hollow shaft to rotate), hollow shaft (rolls) to transmit power, basic frame (used
to support entire load), mounting table for motor (support motor), cutter (used to cut sheet metal
at required dimension), Clamp mounting for cutter etc.
This thesis work primary helps to upgrade the design approach in extreme manner.The design
will improve the productivity of the industries and reduce the labor energy consumption and
much time consumption also it helps to reduce number of workers as well as to design the
machine with reasonable minimization of cost so as to eliminate the tedious hard work.
1.2 Statement of the problem

In Dire Dawa university there are different workshops like welding work shop, metal cutting and
generally mechanical workshops.Mostly this sheet metal as raw material it is use for different
applications so to produce them in desired size and shape there may be some distorted shape at
1|Page
their edges during machining and some times small size sheet metals may required in order to
achieve the specific task. Cutting of these sheet metal by hack saw or other hand cutting material
is required much more time and much energy. In order to reduce material wastage and manually
cut with hack saw or any other problems so to solve this problem the sheet metal cutter and
rewinding machine should be designed.
1.3 Objectives of the thesis
1.3.1 General Objective

The main objective of this project is designing manufacturing of sheet metal cutter and
rewinding machine.
1.3.2 Specific objective

The specific objective of this thesis is:
 To design and know the components of the machine i.e. rolling shaft, frame, cutter etc.
 To put the detail engineering design of cutter and rewinding machine will have done.
 To design the 3D assembly drawing of the machine with the help of AUTO CAD 2016
and CATIA V5R20.
 To know the properties of material.
 To make the prototype of the machine.
1.4 significance of the thesis

The significance of this thesis is:
 This thesis work primary helps to upgrade the design approach in extreme manner.
 The design will improve the productivity of the industries and reduce the labor energy
consumption.
 Much time consumption and number of workers will be reducing.
 To design the machine with reasonable minimization of cost so as to eliminate the tedious
hard work.
 To decrease floor area of the machine.
2
 To increase the advantages of the machine.
1.5 Scope of the Thesis

The detail engineering designs, selection of matrerial, to ensure a fully functional cutting,
rewinding and all associated cost handling system. This standard provides guidance for selection
and design practices to be adopted for cutter machines. Consequently, it is limited in terms of
precision but it is sufficient in the majority of cases. Many factors are not in to account in the
formulate but details are provided on their nature and their effect. The work in this project is
focusing more developing of cutting and rewinding machine, and it can help to solve the problem
of long hour job to slit the sheet
3
UNIT TWO
2.1 Literature Review
In this chapter, all the information that can be related for this project is reviewed. All
information about the machine that can be related with sheet metal cutter, and study about the
affective Engineering will be explored through many sources of journal and others.
Noraidah binti blar in [2012] has presented on [automatic rewinding machine for cable tape] [6].
Cutter infeed apparatus is for cutting installations for articles in tape or strip form or film-like
articles, circular cutters being fastened on upper and lower shafts and displaced with respect to
another for fixing the cutter in feed, and an electrical insulation between the upper and lower
shafts making it possible to detect the cutter contact during in feeding and there by make the
infeeding operation automatable. It is also possible to make the in feeding of the individual
cutters or cutter-box cutters such that it can be set depending on the difference in speed of the
upper and lower shafts. The apparatus can be used for cutting machines of all types in which
thin, uncoated or coated polymer films or metal foils can be cut.
Advantages of journal
 The apparatus can be used for cutting machines of all types in which thin, uncoated or
coated polymer films or metal foils can be cut.
 Have different feature, type, operating mechanism.
Limitation
 Does not cut and rewind strength materials.

 Have more complicated mechanisms.
Justification: - According to the explanation of each type of the rewinding tape machine, even
though they have different name, but the major function on rewinding the cable is almost the
same. According to the finding, there are two types of mechanism can be found in order to
produce the rewinding machine; cutting and spinning. Based on the original technique used to
discard sheet metal that is by cutting it manually, a machine of cutting and rewinding sheet metal
is possible to be produced. so by improving the literature wiil be design a machine of simple
construction, low cost (available material produced), easy to operate etc.
4
Roll Razor in [2015], has presented on [A paper slitter - rewinder] [9].
A paper slitter - rewinder is a converting machine used to reduce a large parent roll of paper
into rolls of smaller dimensions suitable for subsequent applications. The process has remained a
vital part of every paper processing industry around the world since it has direct impact on the
quality of the end paper product. Various slitting methods, winding techniques and tension
control mechanisms for the web have been developed and successfully implemented in order to
maximize the efficiency of the process and the edge quality of the cut paper the three main stages
of the machine are
 The unwinding stage,

 The slitting stage and
 The rewinding.
The unwinding stage: - consists of an unwind stand onto which the parent roll of paper is
loaded and secured. The stand holds the roll about its central axis and allows it to rotate. The
roll is held either by inserting two chucks each with mechanical griping elements on both ends
of the roll which expand to grab it, or by clamping the two exposed ends of a shaft which runs
along the whole length of the roll’s core on bearings on the back stand.
The Slitting Stage: - The slitting stage is where the actual separation of the web into multiple
smaller slits occurs. From the winding stage, the unwound continuous web of paper is passed
through a series of spreading rollers and through the slitter head. The slitter head is made up of
a series of either rotating knives or razors and it does the cutting of the web. The desired slit
widths are set manually or automatically depending on the type of machine being used by
varying the locations of the knives on the slitter head. Before the slitter head are rollers to
straighten the sheet to ensure good quality cuts.
The Rewinding Stage: -From the slitter head, the slits are rewound onto smaller cores on the
rewind stand to the desired footage or diameter. Various factors such as the type of material
being wound and the desired hardness of the final roll determine the type of winder to be used
under the given conditions. The rollers which are after the slitter head keep the slit sections
separate as they enter the winding and prevent the sheet from weaving back and forth between
adjacent rolls in the roll set.
 Used to design a machine that cuts paper sizes ranging from 189mm to 40mm.
5
 Used to design a machine that mainly operates on basic mechanical principles and
technology which do not require specialized training to reduce the cost of operation
and maintenance.
Limitation
 Used different loading cell mechanisms that leads to more power consumption.
 Has much more complicated mechanisms.
Justification: from here we take instead of paper sheet metal cutter and rewinding machine
with the same method but different design analysis, application. And also we use so simple and
easily understandable sheet metal cutter and rewinding machine.
Ahmed Ktari in [2011], has presented on [Modeling on three-roller bending] [1].In his paper he
has done Modeling and computation of the three-roller bending process of steel sheets. This
experiment consists of two-dimensional finite element model of this process was built under
the Abaqus /Explicit environment based on the solution of several key techniques, such as
contact boundary condition treatment, material property definition, meshing technique, and so
on.
 Uses two-dimensional finite element model

 This process was built under the Abaqus /Explicit environment based on the solution
of several key techniques, such as contact boundary condition treatment, material
property definition, meshing technique, and so on.
Limitation
 He has done Modeling rather than experiment and practical.

 Limited to specific materials i.e. steel sheet only.
Jong GyeShin in [2001], has presented on [Mechanics-Based Determination of the Center Roller]
[3].In their paper he has done the experiment on Mechanics-Based Determination of the
6
Center Roller Displacement in three-Roll Bending for Smoothly Curved Rectangular Plates.
The objective of this paper is to develop a logical procedure to determine the center roller
displacement, in the three-roll bending process, which is required in the fabrication of curved
rectangular plates with a desired curvature.
 Determine the Center Roller Displacement in three-Roll Bending.

 Develop a logical procedure for fabrication of curved rectangular plates with a desired
curvature.
Limitation
 He determines the Center Roller Displacement in three-Roll Bending. But he didn’t

consider more than three roller.
M K Chudasama in [2012], has presented on [Analytical Model for Prediction of Force] [5]. In
their paper he has done the experiment on Analytical Model for Prediction of Force during 3-
RollerMulti-pass Conica Bending. In this paper, the total deflection of the top roller required
is divided in steps to get the multi pass bending.
 used multi pass bending mechanism.

 used for Conical Bending.
 Done experiment on Analytical Model for Prediction of Force.
Limitation
 More complicated model analysis.

 Just the analysis used for conical bending only.
Dr. C. C. Handaet. Al in [1979], has presented on[manually and power operated sheet bending
machine] [10].This paper gives a review and Discussed about the productivity analysis of
7
manually and power operated sheet bending machine considering time required to complete
one pipe, total expenditure required to manufacture one pipe, number of operators and labors
required during both operations, etc. Limitations of the manually operated sheet bending
process over power operated sheet bending machine is also discussed.
 Discussed limitations of the manually operated sheet bending process over power
operated sheet bending machine.
 Considers time required to complete one pipe, total expenditure required to manufacture
one pipe, number of operators and labors required during both operations, etc.
Limitation
 Limited to pipe bending analysis.
Justifications: It used to help expenditure calculation, number of operator estimation etc. And
we justify as sheet metal rewinding rather than pipe bending.
P.G. Mehar in [2005], has presented on [Improving the Productivity of Sheet Bending Operation
in Pipe Manufacturing Industry] [7]. In his M. Tech Thesis studied the manually operated
and power operated sheet bending machine. Experimentations were conducted on sheet in order
to measure actual no. of passes, time required to complete bending process etc. Also,
productivity of sheet bending process is analyzed in depth. Design of various components of
power operated sheet bending machine considering various theories of failure in elastic region
and values for bending force, power required, spring back radius etc. for different diameters,
thicknesses and width of sheet metal has been determined.
 Used experimentations in order to measure actual no. of passes, time required to

complete bending process etc.
 Used manually operated and power operated sheet bending machine.
8
 His design considers various theories of failure in elastic region and values for bending
force, power required, spring back radius etc.
Limitation
 The results are mostly depend upon the thickness of the sheet, not on material and
loading conditions.
 Thickness of sheet used practically varies from 0.8mm to 1.5 mm only for sheet metal
bending.
 Only considers bending operation.
 Does not consider cost of machines etc.
Justifications: From this journal we gain different mechanisms, analysis methods, desired
component to be design and cause of failure about bending operation. In addition to the above
advantages we modify the sheet thickness to be bend, cost of machines and the result changing
according to the material and according to the loading condition, thickness of the sheet and
finally we used to translate in to rewinding machine by integrating with cutting operations.
2.2 Justification of Literature Review

From the above all literature reviews by taking some idea such as mechanism, structure, feature
etc., that used to develop (support) the project and by adding other idea to modifiy and to build
cost effective, environment friendly, simple structure etc. of sheet metal cutter and rewinding
machine. Different designers are done their own ideas and modification from the conventional
huge machine of the sheet metal cutter and rewinding machine individually. After reading these
written documents will be getting important ideas. For example, M. B. Bassett, and W. Johnson
are done Analysis Process manual, maintenance manual, machine capacity chart and technical
specification of rolling machine.so, instead of manual we make it motorized the rolling
principle is as it is. Having same idea, by making some important modifications to the project
like decreasing the floor space and cost of the machine. Not only this but the machine works two
functions i.e. cutting and rewinding process. This is the best function of the machine.
So, this project is more simplified, cost effective and dual functional b/c of the above reasons.
9
CHAPTER THREE
3.1 Methodology
3.1.1 Data Collection

In this thesis work, different methods and methodologies that are the main inputs for our
thesis are used. These are: In the beginning of the thesis work we observe a problem related to
the sheet metal cutting process in our university workshops like consuming energy, time and
difficulties to cut such sheets. Then we agreed with one solution i.e. to design cutter machine
with rewinding as further function. After this agreement we read different journals and project
related to our machine. But we didn’t get such machine. Only we found the cutter machine &
rewinding (bending) machine in different separate machines projects. So, we combine these
ideas to reach this machine
In this project by using both primary and secondary data sources to get information.
Among the primary sources:
 Interview(better manufacturig PLC which found in Holeta)

 Visual Observation(Holeta marketing center)
 Observation the manual etc.
Steps we used:
A.Data Collection
Data’s were collected from:
 Documentation
 Internet
 Tables
 Books
10
B. Data Analysis
In this project simple analysis will used to calculate all the unknown data’s using different
formulas based on the definitions and specifications of design analysis.
3.1.2 Procedure for design of machine elements

Generally, the procedure to follow during realizing the project looks like as follows:
1. Problem identification and planning
 Planning
2. Literature study
 Make review on other model and focusing on how to make it simple and relevance
to the project title.
3. Conceptual design
 Sketching several types of design based on concept that being choose and select the
best concept.
4. Design analysis and materials Selection
Design analysis
 Geometrical analysis with 2D drawing;

 Assemble all the part to the design materials Selection
 Selected the true material based on model design and criteria.
 Light, and easy to manufacture.
 Assemble all the part to the design.
 Finally modelling the prototype of the machine.
Generally, thesis done by the following methodology the final task of this design is prototype
manufacture of the machine based on available materials by considering the scale.
11
3.2. Materials Descriptions and Software’s that will be Used in the Project
3.2.1. Materials and Equpment Descriptions

 Caliper –to measure the diameter of the shaft
 Ruler- to measure the length and other dimension
 Marker and chalk -to mark point
 Glass- to protect eyes
 Electrodes- for welding and
 Different machines like drilling cutter etc. for our operation.
All most all the machining operations of machine shop going to used while constructing the
model of the machine. These are drilling, cutting, grinding, work bench bending, joining,
welding,painting and etc. In general, the major production processes like; surface finishing,
temporary and permanently fastening or joining, bench works and so on will be used.
3.3 Material Selection and Detail Design Analysis of the Machine
3.3.1. Material Selection and Specification

Metal cutters are product of hardened material to avoid frequent injury and to resist wear. The
fabric used for this machine are soft-cast steel, cast iron, die steel, steel, high speed steel,
nickelchrome steel, bronze, plastic material etc. cutters are made from a variety of materials,
some of which can be hardened to resist wear. It is sometimes necessary to use nonferrous metals
like phosphor bronze to reduce wear of the mating parts, or nylons or fiber to prevent damage
to the work-piece. The selection of a proper material, for engineering purposes, is one of the
most difficult problems for the designer. The best material is one, which serves the desired
objective at the minimum cost.
The following factors should be considered while selecting the material:
Availability of the materials

Suitability of the materials for the working conditions in service, and
The cost of the materials
12
The important properties, which determine the utility of the material, are physical, chemical and
mechanical properties. Each material is choosing for each application due to its particular
properties or characteristics.
The most important properties include:
Density: - the mass per unit volume of a material – this weight density: the weight per unit
volume of a material.
Strength: - the maximum force per unit area that a material can support without failure.
Stiffness: - the ability of a material to resist deformation.
Specifications for the Design Thesis
During the collection of data, by collecting the relevant data from the beneficiaries. Then
selecting the material to be cut or rewind is mild steel. Mild steel is a type of steel alloy which is
the most common high-volume steel in production. It is now the most common form of steel
because of its price is relatively low while it provides material properties that are acceptable
for many applications. It contains small amount of carbon making it malleable and ductile. Mild
steel has a relatively low tensile strength, but it is cheap and easy to form. It is quite soft
and malleable so can be bent and forged into different shapes with minimal heat treatment.
Unlike other grades of carbon steel, which tend to be brittle, mild steel is very hard, yet
malleable, making it the perfect choice for construction materials and many other every day
products. It can be easy to shape and machine because it is flexible and hardened by a heat
treatment process called carburizing. It is a suitable material for producing a variety of products
in the consumer industry. Due to these reasons most metal industries, workshops and garages
used mild steel for many applications. Now from this evidence by selecting mild/plain/ steel to
be cut by machine.
Material Selection of the Machine
13
Table 1:material selection of the machine.
s/no component Material selection

1 Electric motor drive 3phase,2850/3410 rpm
2 Belt drive Leather
3 pulley Cast iron
4 Shaft (hollow, journal) C45 Plain carbon steel
5 bearing Ball (bronze)
6 c-channel frame Cast iron
7 Bolt and nut A307-83a stainless steel
8 cutter Cast iron(30Ni4Cr1)
9 Sheet metal mild steel
Specifications of the Machine and Assumptions

Table 2:specifications of the machine.
length 3570mm
Width 1240 mm
Height 1250mm
3.3.2. Design Analysis of the Machine
3.3.2.1. Motor
Motor selection consideration
Due to the power output from the motor, there is rotational motion of the pulley. The pulley
drives the belts that are used to transmit power from one shaft to another by means of pulley
which rotates at the same speed or different speed. It is very important to obtain all the listed
information before making selection.
14
 Source of input power

 Types of driven equipment
 Power to be transmitted
 Speed and size of driven shaft
 Drive center distance and drive arrangement
 Means of center distance arrangement, if any
 Available lubrication type
 Spare limitations
 Adverse environmental conditions
3.3.2.2 Design of Belt Driving Mechanism

Design of Belt and Pulley
Belt
The belts are used to transmit power from one shaft to another by means of pulleys which
rotate at the same speed or at different speeds. The amount of power transmitted depends
upon the velocity of the belt, the tension under which the belt is placed on the pulleys, the arc
of contact between the belt and the smaller pulley and the conditions under which the belt is
used.
Material selection for belt; The material used for belts must be strong, flexible, and durable. It
must have a high coefficient Of friction. Because of this the selected material for design is
leather belt.
Pulley
The pulleys are used to transmit power from one shaft to another by means of flat belts, V-belts
or ropes. Since the velocity ratio is the inverse ratio of the diameters of driving and driven
pulleys, therefore the pulley diameters should be carefully selected in order to have a
desiredvelocity ratio. The pulleys must be in perfect alignment in order to allow the belt to travel
in a line normal to the pulley axes.
15
Material selection for pulley; The pulleys may be made of cast iron, cast steel or pressed steel,
wood and paper. The cast materials should have good friction and wear characteristics. The
pulleys made of pressed steel are lighter than cast pulleys, but in many cases they have lower
friction and may produce excessive wear. Due to this we select malleable cast iron having a
tensile stress of 413.6Mpa and a density of 7300kg/m3 to achieve this goal.
Design of Shaft
Shaft is a rotating member of machine element (usually circular) which transmits power from
one point to another point. It is one of the most common and basic machine elements which
are used in a variety of ways in mechanical equipment. It is used with power transmission
elements like gears, pulleys, flywheels, cranks, etc. These shafts are designed to transmit
produced torque and to support the rotating elements like gears and pulleys. These elements
produce bending moment in addition to torque. A shaft must be strong enough to sustain static
and dynamic loading.
Design and Selection of Bearing
A bearing is a machine element which supports another moving machine element (known as
journal shaft). It permits a relative motion between the contact surfaces of the members, while
carrying the load. In our design bearings are used at the cutter shaft or on frame used to support
the rotating shaft by preventing wear. The selected type of bearing is radial ball bearing. A
number of balls are used and these are held at proper distances by retainers so that they do not
touch each other. The retainers are thin strips and usually in two parts which are assembled
after the balls have been properly spaced.
Material selection for bearing
Since the rolling elements and the races are subjected to high local stresses of varying
magnitude with each revolution of the bearing, therefore the material of the rolling element
(i.e. steel) should be of high quality. The balls are generally made of high carbon chromium
steel. The material of both the balls and races are heat treated to give extra hardness and
16
toughness. by selecting roller bearing for the design. The contact between the bearing surfaces is
rolling by the following merits.
Accuracy of shaft alignment.

Reliability of service.
Low cost of maintenance, as no lubrication is required while it is in service.
Small overall dimension.
Ability to with stand momentary shock loads.
Clean lines.
Easy to mount and erect.
Design of Bolt and Nut
In this machine we need 32 bolts and nuts to fasten the parts in place. So, by selecting bolt which
has equal stress. It offers more corrosion resistance and strength at elevated temperatures.
Material selection A307-83a stainless steel.
Geometric layout:
Figure 1:Hexagon-head bolt.[2]
Design of Cutter
Material Selection
17
To prepare any machine part, the type of material should be properly selected, considering
design, safety. The selection of material for engineering application is given by the following
factors;
1) Availability of materials
2) Suitability of the material for the required components.
3) Suitability of the material for the required components.
The cutter is basically made up of mild Carbide stainless steel. The reasons for the selection
are mild carbide steel is readily available in market. It is economical to use and is available in
standard sizes. It has good mechanical properties i.e. it is easily machinable. 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. It has high hardness.
Low coefficient of thermal expansion. Material for the cutter 30Ni4Cr
Design of Power Screw
A power screw is a device used in machinery to change angular motion into linear motion, and,
usually, to transmit power. Familiar applications include the lead screws of lathes, and the
screws for vises, presses, and jacks. The screw clamp is used to hold the work piece firmly
during rewinding operation First to select the type of thread that is suited for operation since
there are different types of threads.
18
Figure 2: Screw thread.[2]
By selecting a square thread type screw because it is efficiency of transmitting the torque is
relatively high and they are mostly used for clamping purpose Material selection: due to low
cost, availability, wear resistance, high fatigue resistance material for this reason select SAE
1020 steel.
Design analysis of frame
A structure is called a frame if at least one of its individual members is a multi-force member.
A multi-force member is defined as one with three or more force acting on it, or one with two
or more forces and one or more coupling acting on it. Frames are structures which are designed
to support applied loads and are usually fixed in position.
19
CHAPTER FOUR
Cost Analysis
4.1. Cost Analysis

In order to calculate the cost analysis of materials first knowing the density of materials,
volume materials, mass of materials and the cost of materials in birr per kilogram of materials.
The system which systematically records all the expenditure to determine the cost of
manufacture product is called costing. The total cost on this project is depending up on three
main elements;
 Material cost
 Labor cost
 Expense cost
Material cost
To estimate the cost by taking the density of material will be use i.e.
ρ Steel = 7850 kg/m3, price per kg = 0.5$/kg
ρ Bronze = 8730 kg/m3, price per kg = 0.451$/kg,
ρ Cast iron =7250 kg/m3, price=0.3$/kg and 1$=37 Ethiopian birr
These are material types used in the design.
Then to find volume of each material by using known formula for, volume (v)
v =M/ ρ
And volume for circular material like shaft, cutter, V = πD2/4
For rectangular object like frame =L*W*H
20
Table 3:Material cost.
UNIT TOTAL
Part name Material DESCRIPTION QTY
COST AMOUNT(ETB)
3 phase
Electric
induction 4Hp, 3000rpm 1 9000 9000
motor
motor
bearing Bronze Φ 110mm 14 150 2100
Hollow
PCS Φ100 and 35 7 300 2100
shaft
Mild
cutter stainless 3 150 300
steel
Bolt and
Mild steel Φ10 30 90 2700
nut
18
C-channel Cast iron 50*20 300 5400
pieces
V-belt Leather B115-17*2925 3 350 1050
roller PCS Φ50 11 200 2200
key Mild steel Φ12 8 40 320
Handle Al alloy Φ15 2 30 60
pulley Cast iron Φ 75, Φ200 14 200 2800
Solid
PCS Φ90 14 90 1260
journal
Power SAE1020
Φ25 2 150 300
screw steel
Frame Cast iron 300*12*2300 2 250 500
Total 30,090ETB
21
1) Material cost; The total cost of material is ETB 30,090.

2) Labor cost; On lathe machine and milling machine operations total welding and cutting
operation. Approximately take ETB 20,000.
3) Direct expense cost; There is Direct other expenses and Overhead expenses having
estimated with ETB 3000.
Schedule prepared to accomplish the project
Topic to be covered Time required(weekly)

Introduction of sheet metal cutter and First Week (26/04/2013-3/05/2013)
rewinding machine
Literature review of the project Second week(4/05/2013-11/05/2013)
Methodolgy of the project Third week (12/05/2013-19/05/2013)
Material Selection and Detail Design Fourth week and fifth week(20/05/2013-
Analysis of the Machine 30/05/2013)
Results and Discussion Fifth week(1/06/2013-4/06/2013)
Cost Analysis and Manufacturing Process Sixth week(5/06/2013-8/06/2013)
prototype for the project Seventh week(9/06/2013-20/06/2013)
22
Reference
[1] Ahmed Ktari et. al, (Manuscript Received July 9, 2010; Revised December 13, 2010;
Accepted September 18, 2011). Journal of Mechanical Science and Technology 26 (1) (2012)
123 128, “Modeling and computation of the three-roller bending process of steel sheets”.
[2] Budynas-Nisbett, “Shirley’s Mechanical Engineering Design”, Eighth Edition
[3] Jong Gye Shin et. al, International Journal Volume 15. No.12, pp. 1655-1663, 2001.
“Mechanics-Based Determination of the Centre Roller Displacement in Three-Roll Bending
for Smoothly Curved Rectangular Plates”, KSME.
[4] M. B. Bassett, and W. Johnson, ASME Papers No. 78wa/Prod 6, 1979. ,” J. strain Analysis,
vol. 1, no. 5,pp. 398, 1996. [15] N. E. “The bending of plate using a three roll pyramid type
plate bending machine Hanson, and O. Jannerup, “Modeling of elastic plastic bending of beams
using a roller bending machine”.
[5] M. K Chudasama1 et. al, ISSN 2278-0149S, VOL.1, NO.3, October 2012, “Analytical Model
for Prediction of Force During 3-Roller Multi pass Conical Bending And Its Experimental
Verification, international journal of mechanical engineering and robotics research”.
[6] Noraidah Binti Blar, Sesi Pengajian: 2012/13 Semester 2, “Development of an Automatic
Rewinding Machine for Cable Tape Considering Affective Analysis”.
[7] P. G. Mehar, Y.C.C.E., Nagpur, June 2005. “Improving the Productivity of Sheet Bending
Operation in Pipe Manufacturing Industry”, M.Tech. Thesis, Department of Production
Engineering.
[8] Raj Reddy, (Special Issue on ICRIET-2016) 7(2): 360-365(2016) “Fabrication of
pneumatic sheet metal Cutter .International Journal on Emerging Technologies”.
[9] Roll Razor, Accessed 5 October 2015, “Slitter Rewinder Machines - Paper, Laminates,
Film, Foils, Labels”, [Online] Available at: http://rollrazor.com/about/slitter-rewind.
23
[10] Tool Engineering and Design G.R.NAPAL P. G. Mehar, ET ALE Dr. A, V, Vanalkar,
Dr. C. C. Handa, Issue 2, Mar-Apr 2012, pp.111-114 “Productivity Analysis of Manually
Operated and Power Operated Sheet Bending Machine: A Comparative Study”, International
Journal of Engineering Research and Applications, Vol. 2.
24

Proposalof Rewinding Machine PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Proposalof Rewinding Machine PDF

Uploaded by

Copyright:

Available Formats

DIRE DAWA UNIVERSITY

SCHOOL OF MECHANICAL AND INDUSTRIAL

NAME OF STUDENTS ID.NO

1.Kibitu Belay R/1129/08

2. Chaltu Senbeto R/0611/08

3. Olifan Abebe R/1248/08

Date of submission: on january 2, 2021

Table 1:material selection of the machine. ................................................................................................. 14

1.1 Overview of the Thesis

1.2 Statement of the problem

1.3 Objectives of the thesis

1.3.1 General Objective

1.3.2 Specific objective

1.4 significance of the thesis

 To increase the advantages of the machine.

1.5 Scope of the Thesis

2.1 Literature Review

 Does not cut and rewind strength materials.

Roll Razor in [2015], has presented on [A paper slitter - rewinder] [9].

 The unwinding stage,

 Uses two-dimensional finite element model

 He has done Modeling rather than experiment and practical.

 Determine the Center Roller Displacement in three-Roll Bending.

 He determines the Center Roller Displacement in three-Roll Bending. But he didn’t

 used multi pass bending mechanism.

 More complicated model analysis.

 Limited to pipe bending analysis.

 Used experimentations in order to measure actual no. of passes, time required to

2.2 Justification of Literature Review

3.1.1 Data Collection

Among the primary sources:

 Interview(better manufacturig PLC which found in Holeta)

Data’s were collected from:

3.1.2 Procedure for design of machine elements

4. Design analysis and materials Selection

 Geometrical analysis with 2D drawing;

3.2.1. Materials and Equpment Descriptions

3.3 Material Selection and Detail Design Analysis of the Machine

3.3.1. Material Selection and Specification

The following factors should be considered while selecting the material:

Availability of the materials

The most important properties include:

Stiffness: - the ability of a material to resist deformation.

Specifications for the Design Thesis

Material Selection of the Machine

Table 1:material selection of the machine.

s/no component Material selection

Specifications of the Machine and Assumptions

3.3.2. Design Analysis of the Machine

 Source of input power

3.3.2.2 Design of Belt Driving Mechanism

Design and Selection of Bearing

Material selection for bearing

Accuracy of shaft alignment.

Design of Bolt and Nut

Figure 1:Hexagon-head bolt.[2]

2) Suitability of the material for the required components.

3) Suitability of the material for the required components.

Design of Power Screw

Figure 2: Screw thread.[2]

Design analysis of frame

4.1. Cost Analysis

ρ Steel = 7850 kg/m3, price per kg = 0.5$/kg

For rectangular object like frame =LWH