Professional Documents
Culture Documents
PROJECT REPORT
ON
Submitted to
B.E. (MECHANICAL)
Under guidance of
PROF. A. M. RATHOD.
CERTIFICATE
Has presented and submitted the Project work entitled “DESIGN AND
MANUFACTURE SPECIAL PURPOSE MACHINE FOR BRAKE WHEEL
CYLINDER”. In the partial fulfilment for the award of degree of Bachelor in
Mechanical Engineering at SHIVAJI UNIVERSITY, KOLHAPUR. This is the record
of their work carried out during the academic year 2016-2017.
DATE: / / 2017
PLACE: ICHALKARANJI
PROF.DR.P.V.KADOLE
(PRINCIPAL)
We would like to express our sincere Gratitude to our H.O.D. PROF.DR.V.R.NAIK for
his valuable role in making this project successful.
Lastly, we would like to express my sincere thanks to all my colleagues and friends who
have assuredly helped to us a lot and without their availability collecting this matter would
have been facile.
Manufacturing plays vital role in any industry for producing the product. With stiff
competition & challenges in the present day market, manufacturers are compelled to be more
responsive to the customer’s demand regarding not only quality, but scheduled delivery.
Enhancing productivity is a key concern for almost all of the mass manufacturing industries
In this project we are going to design and fabricate SPM for BAJAJ RE component
for drilling, surfacing, tapping grooving etc. operations.
In this the design of SPM tool post, fixture, rotary turret, clamping arrangement and
hydraulic power pack is required. The main objective of this project is to design and
manufacture a SPM for increase in production rate and minimisation of worker requirement
at optimum cost. This also eliminate bottleneck of machine line.
The production rate is very low due to time required for loading, clamping and
manual drilling operation and de-clamping operation. The man-power required is more and
skilled. If machine design and may workable it will boost the company’s production rate at
lesser labour requirement rate.
1. INTRODUCTION
As SPM is self-contained machine having inbuilt units like a gear box, a bed,
hydraulic drives pneumatic systems of combination of all at a time. SPM is a machine which
is component or work piece oriented.
For the design and manufacturing of the SPM the components and the related
machining processes are taken into considerations and the specific customer requirements are
considered, from all above considerations takes place in the design of an SPM. SPM is
considered as the development of the basic machine tools available.
In this project the following studies are carried out Time saved by component
handling (loading and unloading), using hydraulic clamping, Increase in productivity both
qualitative and quantitative, Less human intervention, indirectly reduction in operator fatigue,
Increase the profit of company. Special purpose machine is part of multi-tasking machine.
This is new approach to increase the productivity of organization. If we compare between
ordinary machine and special purpose machine in terms of time, costs, number of steps
involved, etc. The multi-tasking machine is preferred choice. The most noteworthy aspect
when using multi-spindle machines is the cycle time, due to parallel machining the total
operating time is dramatically decreased.
Special purpose machine (SPM) is combining the two machines which used for
drilling and riveting operation separately. This machine concept provided most compact,
economical and simple in operation by a single person. The machine consist of single phase
induction motor transmit power to drive mechanism by pulleys through V-belt and a
hydraulic cylinder which drive the process unit.
1.2. APPLICATIONS
Productivity has now become everyday watchword. It is crucial to the well fair of the
industrial firm as well as for the country. High productivity refer to doing the work in shortest
possible time with least expenditure on inputs without sacrificing quality and with minimum
rejection.
Modern SPM’s,
1.3. ADVANTAGES
1. Cycle time is less for SPM as compared to GPM.
2. High or mass production rates thus increasing profit level.
3. High accuracy and performance.
4. Very less human intervention required, thus unskilled and low operator skill is
required.
5. Efficient and very less use of shop floor area.
6. Reduction in operator’s fatigue, hence more efficient work output.
7. Efficient payback period.
1 DRILLING 9 9.5
2 SPOT FACING 19 2
MIN – 3.5
5 INTERNAL TURNING 12.5
MAX. - 9
6 TAPPING 10 9.5
8 DRILL 6 1
9 DRILL 6 11
11 TAPPING 7 8.5
TABLE NO. 1:- OPERATION DETAILS
In the conventional manner only one job can be worked at a time for either of the above
operations, but with increase in productivity demands a special purpose device or attachments
is need which will increase productivity by,
The special purpose Multitasking machine is an ideal solution to the above problem
which is used to perform eleven operations at a time. In the multitasking machine eleven
operations are carried out simultaneously.
We also had different alternatives which we could have opted such as fully automatic
machine, semi-automatic machine or CNC machine. But we choose to produce an in house
special purpose machine for manual operation which would be far more economical for small
scale industries for increasing production output.
4. LITERATURE REVIEW
SUMMARY
By referring all above research paper we got general guideline about design and
manufacturing of special purpose machine. We also got information about increasing the
productivity of production line.
5. JOB DESCRIPTION
A wheel cylinder is a component in a drum brake system. It is located in each wheel and
is usually positioned at the top of the wheel, above the shoes. Its function is to exert force
onto the shoes so as to bring them into contact with the drum and stop the vehicle with
friction. The wheel cylinders are usually connected to the shoes with small bird-beak shaped
rods.
It is very similar to slave cylinder and functions in much the same way, internally
consisting of only a simple plunger. On older vehicles these may begin to leak and hinder the
performance of the brakes, but are normally inexpensive and relatively easy to replace.
The purpose of this project is development of a Special Purpose Machine for mass
production of Drum Brake Wheel Cylinder. The SPM designed and manufactured will be
able to perform total of 11 operations simultaneously which in turn reduce the cycle time and
will increase the rate of production.
We have done the Time Study for current manufacturing method. According to our study
it takes on an average of 15 seconds for clamping the job and about 5 seconds for changing
the tools after each operation. The main purpose is to reduce the time required for production
of one job by a factor of four. Also this will reduce the fatigue of the worker.
7.1. BENEFITS:-
1. Increased rate of production.
2. Minimized worker requirement.
3. Eliminated bottlenecking of machining line.
We have recorded the total time required for production of one job. The time analysis
with considering different allowances is listed below.
Since there are total of 11 operations are to be performed after clamping of the job.
Total time required for one job = (Time for changing tool x 11) +
(Time for operation x 11) +
= (3 x 11) + (3 x11) + 5 + 3
= 74 sec
= 1 min (approximately).
Conventionally, the job is done on a quick change drilling machine. Working over this
machine is very cumbersome since it involves manually changing the tools after every
operation.
This results in a large cycle time and consequently a smaller rate of production. Also
changing tools of drilling machine is very risky due to the uncertainties present in the
switching of motors. The conventional method being very slow is not able to fulfil the
demands of the production. A worker with conventional method can produce 250 jobs per
shift (8 hours) i.e. 32 jobs per hour.
So as to increase the production rate the company is in need of a special machine that
will increase the production rate from 32 jobs per hour to 250 jobs per hour (that will increase
the production rate by seven time). To achieve such a drastic increase in the production rate
either the special purpose machine must be able to perform different operations
simultaneously on a single job or it must be able to perform different operations on different
jobs successively but simultaneously. Since the product being too small in size it will be
inconvenient to perform different operations simultaneously on the single job hence choosing
the later method is right.
The concept of the special purpose machine for this particular job, consist of a
rotating turret at the centre and the fixed tools at various stations around. The turret at the
centre will hold the fixtures for fixing the job. The tools fixed around the central turret will be
in sequence such that the jobs fixed on the central turret will undergo subsequent operations
as the reach the next tool after the rotation of the central turret. The jobs will be fixed in a
way that the surface on which the operation is to be performed will always face towards the
tool, this is possible because the operation that currently performed on QUICK CHANGE
MACHINE are to be performed on the same surface and hence the critical task of rotating the
job will be eliminated.
Also the tools fixed will be arranged at the precise locations such that the surface on
which the operation is to be performed comes next to the tool and will make the required
angle at which the operation is to be performed. The locations of the tools will be decided on
the basis of the sequence of the operations and according to the angular rotation of the turret.
Since the total 11 operations are to be done on the same face (some of them at
different angles to the face) the fixture is designed accordingly. The CATIA model of
the fixture is shown in the figure. The various design related consideration about
every component of the fixture plate are listed below.
1. Base plate – This is the rectangular plate on which the central turret as well as all the
11 tool posts will be mounted. This plate should have enough strength to bear the load of the
turret as well as the tool posts. As we consider the ergonomics the plate should be at enough
height that the fixture plate mounted on the turret will reach to height of stomach of the
human operator who is going to mount and unmounts the job in the fixture. The dimensions
of the base plate are given below. This base plate will rest on a foundation of 35cm in
height. A tray will be attached on the upper edges of the foundation to collect the burr
formed during the operation.
2. Fixture plate - This is the circular plate which will hold all the 12 fixtures on its
circumference. The diameter if the fixture plate is 550mm and it is made of cast iron. The
fixture plate will mount on the indexing plate of the turret. We have imported the 12 station
turret BTP-125-12-R-415 from PRAGATI AUTOMATION PVT. LIMITED BANGLORE.
The dimensions of the turret indexing plate are given below in the drawing. Our fixture plate
with 12 fixtures on its circumference will mount on this indexing plate of the turret and the
plate is fixed with 6 bolts of diameter 20mm. Fixture plate should be light in weight so as to
reduce the torque required to rotate it. The diameter of the fixture plate is 550mm.
3. Fixture – The fixture designed for holding the job is shown in the drawing below. This
fixture is mounted on the circumference of the fixture plate. This is fixed to the fixture plate
with 3 vertical bolts at the base. The diameter of the bolts is 10mm. Use of three bolts in a
single plane ensures that the fixture won’t move in any direction as the thrust force applies
during the operation. The drafting of the fixture designed is shown below.
8.4. ERGONOMICS
This factor as compared to GMP has prime importance in designed SPM.
The word Ergonomics has its origin in two Greek words Ergo means Work and
Nomos meaning laws. It can be defined as – “The applications of human biological
sciences along with engineering sciences to achieve optimum mutual adjustment of
men and his work, the benefits being measured in terms of human efficiency and
well-being.”
1. The various disciplines that are going to have influence of human factor are
a) Engineering: Design of work system suitable for worker.
b) Physiology: Study of man and is working environment.
c) Anatomy: Study of body dimensions and relations for work design.
d) Psychology: Study of adaptive behaviour and skill of people.
e) Industrial hygiene: Occupational hazards and workers health.
8.8. BEARINGS
Viscosity is one of the important design parameter which influences the value of film
thickness, load capacity, friction torque etc. For a given oil thicker oil forms a larger film
thickness and improves load capacities but increase the heat generation.
The oil which is used should have a high Viscosity Index (VI) of 90 min. i.e. mineral
oil with minimum VI of 90-95 is used.
The above SPM will accommodate all design consideration. Hence above SPM will
beneficial to greater extend.
9. CALCULATION
2
1.25 × D × K × ns ×( 0.056+1.5 S)
Power at Spindle Ps = 5
10
1.25 × 92 × 1.5× 817.77 ×(0.056+1.5 ×0.2)
=
105
= 0.44214 KW
= 442.14 W
Efficiency of transmission E ¿ 90 %.
Ps
Power at Motor Pm =
E
442.14
=
0.9
= 493.26 W.
975× Pm (KW )
Torque T =
ns
975× 0.49326
=
817.77
= 0.58571 Kgf.m
= 5.746 Nm.
2. FOR SECOND OPERATION:
Machining Data Required:
Cutting Speed Cs= 23 m/min.
Feed per revolution S= 0.2 mm/rev.
Material Factor K=1.5
Drill diameter= D mm.
C s ×320
Speed n =
(D)
23 × 320
=
(19)
= 387.368 rpm.
n
Spindle Speed for Spot facing ns =
3
387.368
=
3
= 129.123 rpm
1.25 × D 2 × K × ns ×(0.056+1.5 S)
Power at Spindle Ps ¿
105
1.25 ×16 2 × 1.5× 129.123 ×(0.056+1.5 ×0.2)
¿
105
= 0.31114 KW
= 311.14W
Efficiency of transmission E = 90%.
Ps
Power at Motor Pm ¿
E
311.14
¿
0.9
= 345.71 W.
Thus we have selected 0.75 HP Motor.
975× Pm (KW )
Torque T ¿
ns
975× 0.34571
¿
129.123
= 2.605 Kgf.m.
= 25.6 Nm.
3. FOR THIRD AND TENTH OPERATION:
Machining Data Required:
Cutting Speed Cs= 23 m/min.
Feed per revolution S= 0.06 mm/rev.
Material Factor K=1.5, Drill diameter= D mm.
C s ×320
Spindle Speed ns ¿
( D)
23 × 320
¿
(2.5)
= 2944 rpm.
1.25 × D 2 × K × ns ×(0.056+1.5 S)
Power at Spindle Ps ¿
10 5
1.25 × 2.52 × 1.5× 2944 ×(0.056+1.5 × 0.06)
¿
10 5
= 0.05037 KW
= 50.37 W
975× Pm (KW )
Torque T =
ns
975× 0.05596
=
2944
= 0.01853 Kgf.m.
= 0.18183 Nm.
1.25 × D 2 × K × ns ×( 0.056+1.5 S)
Power at Spindle Ps =
10 5
1.25 × 62 × 1.5× 1226.67 ×( 0.056+1.5 ×0.2)
=
105
= 0.29476 KW
= 294.76 W
Ps
Power at Motor Pm =
E
294.76
=
0.9
= 327.52W.
Thus we have selected Half HP Motor
975× Pm ( KW )
Torque T ¿
ns
975× 0.32752
¿
1226.67
= 260.324 Kgf.m.
= 2.553 KNm.
C s ×320
Spindle Speed ns ¿
( D)
23 × 320
¿
(7)
= 1051.428 rpm
1.25 × D 2 × K × ns ×( 0.056+1.5 S)
Power at Spindle Ps =
10 5
1.25 × 72 × 1.5× 1051.428 ×( 0.056+1.5 ×0.18)
=
105
= 0.31491 KW
= 314.91 W
Ps
Power at Motor Pm =
E
314.91
=
0.9
= 314.91/0.9
= 349.90 W.
Thus we have selected Half HP Motor
975× Pm (KW )
Torque T =
ns
975× 349.90
=
1051.428
= 0.324 Kgf.m
= 0.3.13 Nm.
Ps
Power at Motor Pm=
E
504.15
=
0.9
= 560.17 W
Thus we have selected 1 HP Motor
975× Pm (KW )
Torque T =
ns
975× Pm (KW )
=
ns
= 0.7036 Kgf.m
= 6.9024 Nm
2
0.433× D× p × ns × K
Power at Spindle Ps ¿ 4
10
0.433× 7 ×12 × 1108.891 ×1.5
¿
10 4
= 504.15 W
Ps
Power at Motor Pm ¿
E
504.15
¿
0.9
= 560.17 W
Thus we have selected 1 HP Motor
975× Pm (KW )
Torque T=
ns
975× 0.56017
=
1108.891
= 0.4925 Kgf.m
= 4.831 Nm
Kh = 1.73
Power at spindle, Ps = U × K h × K r ×Q
= 24 ×1.73 × 1.13× 9.2
= 431.61W
975× Pm (KW )
Torque at Spindle, T =
ns
975× 0.47960
=
1177.6
= 0.3971 Kgf.m
= 3.8954 Nm
9.2. CALCULATIONS FOR THRUST FORCES
1. First operation
T h=1.16 kD(100 S)0.85
T h=1.16 ×1.5 ×9 (100× 0.2)0.85
Th = 199.83 kg.f
2. Second operation
T h=1.16 kD(100 S)0.85
T h=1.16× 1.5 ×10(100 × 0.2)0.85
Th = 222.04 kg.f
3. Third operation
T h=1.16 kD(100 S)0.85
T h=1.16× 1.5 ×2.5(100 × 0.06) 0.85
Th = 19.94kg.f
4. Forth operation
T h=1.16 kD(100 S)0.85
T h=¿ 1.16 ×1.5 × 9(100 ×0.2)0.85
Th = 199.83 kg.f
5. Fifth operation
6120 × N
Pz ¿
v
6120 × 431.64 × 10−3
=
23
¿ 114.683 kg.f
6. Seventh operation
T h=1.16 kD(100 S)0.85
T h=1.16 ×1.5 ×6 (100 ×0.18)0.85
Th = 121.80 kg.f
7. Eight operation
T h=1.16 kD(100 S)0.85
T h=1.16 ×1.5 ×6 (100 ×0.18)0.85
Th = 121.80 kg.f
8. Ninth operation
0.85
T h=1.16 kD(100 S)
0.85
T h=1.16× 1.5 ×6(100× 0.18)
Th = 121.80 kg.f
9. Tenth operation
T h=1.16 kD(100 S)0.85
0.85
T h=1.16 ×1.5 ×2.5( 100× 0.06)
Th = 19.94kg.f
Since all the three type of motors we used are normal Torque, Synchronous motors the
correction factor according service for all the three types of motors is 1.2 ( operational hours
10to 12 per day)
Since Design Power for all the three types of motor is below 1000 watts (1 KW).
Hence all the dimensions of standard Z cross section V belt are as follows-
The pitch length of V-belt can be calculated from the following Equation= L
2
π ( D+ d) ( D−d )
L= 2C + +
2 4c
Where,
L = Pitch Length in mm
2. Spot Facing
π ( D+ d) ( D−d )2
L= 2C + +
2 4c
π (200+60) ( 200−60 )2
L= 2 x 250+ +
2 4 x 250
L = 928mm
π ( D+ d) ( D−d )2
L= 2C + +
2 4c
π (60+56) ( 60−56 )2
L= 2 x 250+ +
2 4 x 250
L = 682.22mm
4. Drilling 6mm
2
π ( D+ d) ( D−d )
L= 2C + +
2 4c
2
π (71+60) (71−60 )
L= 2 x 250+ +
2 4 x 250
L = 705.89 mm
5. Drilling 7 mm
π ( D+ d) ( D−d )2
L= 2C + +
2 4c
π (80+60) ( 80−60 )2
L= 2 x 250+ +
2 4 x 250
L = 720.31mm
2
π ( D+ d) ( D−d )
L= 2C + +
2 4c
π (71+60) (71−60 )2
L= 2 x 250+ +
2 4 x 250
L = 705.89 mm
2
π ( D+ d) ( D−d )
L= 2C + +
2 4c
π (140+60) ( 140−60 )2
L= 2 x 250+ +
2 4 x 250
L = 820.55 mm
8. Tap M7x1 – 6H
π ( D+ d) ( D−d )2
L= 2C + +
2 4c
π (140+60) ( 140−60 )2
L= 2 x 250+ +
2 4 x 250
L = 820.55 mm
f = 7-9 mm, (Distance of the edge of the pulley to first groove centre)
The hydraulic cylinder that we have used in our project is designed to give the required thrust
force for the operation and conforming to the standards.
The circuit used in the hydraulic pack is called rapid feed and rapid return circuit. This circuit
consists of the following elements-
1. 4/3 direction control valve – (double solenoid)
2. 4/2 direction control valve - (single solenoid)
3. Flow control valve- (knob operated)
4. Pressure relief valve.
The hydraulic power pack that we have manufactured at Steel Tech Yadrav, has the
capacity to simultaneously supply to three hydraulic actuators having 40mm bore size
diameter and 150mm of stroke length. According to standards the volume of the power pack
should be at least 5 times greater than the pump discharge per minute. Here in this hydraulic
power pack 3 gear pump providing a discharge of 7lt/min are used in a set since one power
pack supplies oil to 3 hydraulic actuators.
PLCs are similar to computers but have certain features which are specific to their use
as controllers. As the machine starts PLC sends the signal to operate the valves and rapid feed
mechanism is brought in the operation in this case solenoid 1 and 3 are operated in orders to
give the tool maximum possible speed till it reaches the job. Once the tool reaches the job the
limit switch mounted at the back of slider is operated which in turn sends signal to the PLC to
operate slow feed mechanism. The tool is then fed at the required feed rate which is set
practically for each actuator. For slow feeding only solenoid 1 is operated. Once the operation
is done again another limit switch mounted at the rear is operated which again sends signal to
the PLC to activate rapid return mechanism. As the PLC receives the signal from second limit
switch it operates solenoid 2 and 3 to carry out the quick return of the tool. Another limit
switch is mounted at the back of the slider which is operated when the slider is returned back
to its initial position. As this switch is operated the PLC sends signal to operate pressure relief
valve which in turn stops the actuator.
11.WORKING OF SPM
At first the operator on the machine will press the button which unclamps the
machined job at tool station one and will mount the job to be machined. Once the job is
mounted again the same button is pressed. This will fix the job with hydraulic clamp and
reduce its degree of freedom to zero. As the job is clamped the fixture plate rotates and the
job at 1st tool station will move to the next (2nd) tool station and second to the 3rd and so on.
Then at the 2nd tool station the drilling operation is carried out where the continuous
duty ¾ HP motor provides the torque required through a V-belt drive transmission. The
diameter of the tool used is 9mm and hole formed is the inlet port hole to the cylinder. The
tool is fed at a feed rate of 0.2mm/rev. The feeding is powered by the hydraulic cylinder
whose pressure and flow is regulated by pressure and flow regulators respectively. The speed
of approach of tool, feed rate of machining and speed of retract are controlled by limit
switches which are automatically operated at different positions of the tool spindle as shown
in the CATIA design. As a particular limit switch operates it sends the signal to the PLC and
then the corresponding programme runs.
Every time the last tool retracts to its original position, the operator presses the start
button to initiate next cycle which begins with rotation of fixture plate and ends with
retraction of the last tool. At the third tool station spot facing operation is carried out on the
face of the port hole. This operation is generally carried out to provide seating for washer.
The depth of cut for spot facing is 2mm and the operation is powered by a continuous duty ¾
HP motor through a V-belt transmission system. At the next tool station (4 th) a through drill of
diameter 2.5mm is operated at the centre of the port hole. Since the power required for this
operation is less (as observed in the calculations) it is run by ½ HP motor. On the next tool
station a flat drill is operated in the port hole in order to increase the depth of the port whole
to 10.5mm and to remove the cone left due to the tip of the twist drill. The next tool station
(5th) carries out the operation of internal grooving at the inner end of the port hole. It
penetrates the job up to a depth of 12.5mm. The geometry of tool forms a cone inside the port
hole. The maximum diameter of the cone (at the depth of 12.5mm) is 9mm and the minimum
diameter (at a depth of 10.5mm) is 3.5mm. The slant length of the cone makes an angle of 45
degree with the axis of tool.
On the next tool station M10 x 1 - 6H tap is operated. In order to get the precise feed
rate the lead screw mechanism is used for feeding the tap. The pitch of the lead screw is same
as that of the threading required ie.1mm. From the next tool station (7 th) the operations for
bleeder hole are carried out. First of all on the 7 th tool station centre drill of diameter 6mm is
operated up to a depth of 8.5mm. Then on the next tool station 7mm drill is used to chamfer
the outer edge of the hole it is fed up to 2mm depth from the edge of the hole. Next tool
increases the depth of the bleeder hole to 11mm. As the fixture plate rotates to move the job
to 11th tool station a 2.5mm trough hole is drilled in the bleeder hole. At the last tool station
M7 x 1- 6H tap is operated in the bleeder hole. This tap is also fed through the lead screw
mechanism up to a depth of 8.5mm.
12.MACHINE ASSEMBLY
Rs.20 Lakh
1 Project cost
(approximately)
3 Power-pack 03 1,20,000
4 Structure - 14,00,000
5 PLC - 50,000
Total - 20,40,000
15.1. Since 11 operations are done simultaneously the fatigue of the worker is reduced and
hence the enthusiasm of the worker is maintained throughout the shift.
15.2. Due to the significant reduction in cycle time for one job the production rate is
drastically increased and hence the profit is increased.
15.3. Due to atomisation of the operations the accuracy is maintained and hence the rate of
rejection of jobs is reduced.
15.4. Compact is size and hence less space is occupied than earlier machine.
Other operations such as reaming, tapping, boring can be done on the same head.
The new idea is that we can operate various tool as per our need by switching to
manual mode on the SPM.
Use of manual mode in the SPM opens doors to various permutations of operations
with different sequences.
17. CONCLUSION
In Global economic era the importance of mass production and the rate of production
of machine is increasing tremendously. Thus it was decided to design and manufacture of
special purpose machine (SPM).
While designing the SPM the special design consideration like ergonomics lubrication
and control panel design are to be made, along with this the environment factors also taken
into account.
REFERENCES
2. Ali Riza Motorcu, Abdulkadir Gullu - Statistical process control in machining, a case
study for machine tool capability and process capability. Materials and Design 27
(2006) 364–372