Major Project Report 1rv20mpd08

Major Project: Phase-II Report
on
"DEVELOPMENT OF ABRASIVE CUTTING
MACHINE TO CUT LARGER SPECIMENS”
18MPD41
Submitted by
BASAVARAJ GL
1RV20MPD08
Under the Guidance of

Dr. NATARAJ J R Mr. PRAKASH BALASUBRAMANIAN
ASSOCIATE PROFESSOR CHIEF EXECUTIVE OFFICER
DEPARTMENT OF MECHANICAL SASTHA SCIENTIFIC AGENCIES
ENGINEERING, PEENYA, 2ND STAGE
R V COLLEGE OF ENGINEERING BENGALURU- 560059
BENGALURU- 560059
Submitted in partial fulfillment for the award of degree

of
MASTER OF TECHNOLOGY
In
PRODUCT DESIGN AND MANUFACTURING

DEPARTMENT OF MECHANICAL ENGINEERING
2021-2022
ⅰ
RV COLLEGE OF ENGINEERING®
Bengaluru - 560059
(Autonomous Institution Affiliated to

Visvesvaraya Technological University, Belagavi)
CERTIFICATE
Certified that the major project work titled “DEVELOPMENT OF ABRASIVE CUTTING
MACHINE TO CUT LARGER SPECIMENS” was carried out by BASAVARAJ G L
(1RV20MPD08), who are the bonafede student of RV College of Engineering, Bangalore, in
partial fulfillment for the award of degree of Master of Technology in PRODUCT DESIGN
AND MANUFACTURING of Visvesvaraya Technological University, Belagavi during the year
2021-22. It is certified that all corrections indicate during the internal assessment have been
incorporated in the report deposited in the departmental library. The major project report has been
approved as it satisfies the academic requirements in respect of the work prescribed by the
institution for the said degree.
Dr. Nataraj J R Mr. Prakash Balasubramanian

Associate Professor CEO,
Dept of Mechanical Engineering Sastha Scientific Agencies
Peenya 2ND Stage, Bengaluru
Dr. Krishna M Dr. K N Subramanya

Prof. and Head Principle
Dept. of Mechanical Engineering R V College of Engineering
EXTERNAL VIVA
Name of the Examiner Signature with Date
1.
2.
ⅰ
RV COLLEGE OF ENGINEERING®,
(Autonomous Institution Affiliated to Visvesvaraya Technological University, Belagavi)
DEPARTMENT OF MECHANICAL ENGINEERING
Bangalore – 560059
DECLARATION
I, BASAVARAJ G L, student of third semester MTech in PRODUCT DESIGN AND

MANUFACTURING, DEPARTMENT OF MECHANICAL ENGINEERING, RV
College of Engineering®, Bengaluru declare that the Major project Phase-I with titled
“DEVELOPMENT OF ABRASIVE CUTTING MACHINE TO CUT LARGER
SPECIMENS”, has been carried out by me. It has been submitted in partial fulfillment for the
award of degree in Master of Technology in Product Design and Manufacturing of RV
College of Engineering®, Bengaluru, affiliated to Visvesvaraya Technological University,
Belagavi, during the academic year 2021-22. The matter embodied in this report has not been
submitted to any other university or institution for the award of any other degreeor diploma.
Date of Submission: 24/01/2022 Signature of the Student

Student Name: Basavaraj G L
USN: 1RV20MPD08
Department of Mechanical Engineering

RV College of Engineering®,
Bengaluru-560059
iii
ACKNOWLEDGMENT
The project is the result of the encouragement of many people who helped it by providing
feedback, direction and valuable support. It is with hearty gratitude that we acknowledge their
contribution to our project.
I would like to use this opportunity to show our deepest respect for the icon of our college
Dr. K N Subramanya, principal, R.V College of engineering, who has been an ocean of
inspiration to many students like us.
I also express our sincere gratitude to Dr. M Krishna, professor and head, department of
mechanical engineering, RVCE who has been the source of constant motivation.
I am extremely thankful to our guide Dr. Nataraj J.R, associate professor, department of
mechanical engineering, RVCE for his consistent guidance and encouragement throughout
the period of our project.
I am extremely thankful to our guide Mr. Prakash Balasubramanian, CEO, Sastha
Scientific Agencies, Peenya 2nd stage, Bengaluru for his consistent guidance and
encouragement throughout the period of our project. I wish to express my warm and sincere
thanks to the project evaluation committee members for their constant support in improving
the quality of the project.
I am also immensely grateful to all faculty and staff of the department who guided all
through the work to make it more presentable and fruitful. I also place on record, our sense
to gratitude one and all, who directly or indirectly, have let their hand in this venture.
BASAVARAJ G L
Product Design & Manufacturing

Department of Mechanical Engineering
RV College of Engineering®,
Bengaluru-59
iv
TABLE OF CONTENT
CERTIFICATE ............................................................................................................................. I
DECLARATION ........................................................................................................................ III
ACKNOWLEDGMENT ............................................................................................................ Ⅳ
TABLE OF CONTENTS .............................................................................................................V
LIST OF FIGURES .................................................................................................................... VI
LIST OF TABLES .................................................................................................................... Ⅶ
CHAPTER 1
INTRODUCTION
1.1 Background ....................................................................................................................................... 1
1.2 Literature survey.............................................................................................................................. 2
1.3 objectives of project ........................................................................................................................ 4
1.4 Problem definition.......................................................................................................................... 4
CHAPTER 2
THEORY AND CONCEPTS

2.1 Abrasive cutting ............................................................................................................................... 5
2.2 Abrasive machining process… ...................................................................................................... 5
2.2.1 Basic principal of abrasive cutting ............................................................................................. 4
2.2.2 Types of Abrasive Machining Processes .................................................................................... 5
2.3 Vibration .......................................................................................................................................... 5
2.3.1 Types of vibration ......................................................................................................................... 5

v
2.3.2 What is vibration Analysis ........................................................................................................... 7
2.3.2 Vibration analysis methodology ................................................................................................... 7
2.4 Servo motor .................................................................................................................................... 8
2.4.1 Types of Servo Motor .................................................................................................................... 8
2.4.1.1 DC Servo Motor ..........................................................................................................................8
2.4.1.2 AC Servo Motor ......................................................................................................................... 8
2.4.1.3 Positional Rotation Servo Motor… .......................................................................................... 9
2.4.1.4 Continuous Rotation Servo Motor… ......................................................................................10
2.4.1.5 Linear Servo Motor… ............................................................................................................. 10
2.5 Induction motor .............................................................................................................................10
2.5.1 What is an Induction Motor… ................................................................................................. 11
2.5.2 Working Principle of Induction Motor .................................................................................... 11
2.5.3 Types of Induction Motors… .................................................................................................... 11
CHAPTER 3
PROJECT METHODOLOGY
3.1 Problem definition ......................................................................................................................... 12
3.2 Project methodology...................................................................................................................... 12
3.3 flow Chart Of Project Methodology ............................................................................................ 13
vi
CHAPTER 4
DESIGN OF ABRASIVE CUTTING MACHINE
4.1 Conceptual mechanical design .................................................................................................... 14
4.2 Parameters consider and its calculation ...................................................................................... 17
4.3 Bevel gear design calculation ........................................................................................................ 19
CHAPTER 5
CONCLUSION
5.1 Conclusion ......................................................................................................................... 20
REFERENCES ............................................................................................................................21
vii
LIST OF FIGURES
PAGE
FIG
DESCRIPTION NO.
NO.
1.1 Abrasive Cutting Machine 1
2.2.1 Basic principle of abrasive cutting 5
2.4.1 Dc servo motor 8
2.4.2 Ac servo motor 9
2.4.3 Positional rotation servo motor 9
2.4.4 Continuous rotation servo motor 10
2.4.5 Linear servo motor 10
2.5.1 Induction motor 10
3.3 Flow Chart of Project Methodology 13

Different Views of Abrasive Cutting Machine
4.1.1 14
4.1.2 Bill Of Material of Abrasive Cutting Machine 15
4.1.3 Abrasive Cutting Machine Operated by Belt and Pulley 16
4.1.4 Abrasive Cutting Machine Operated by Bevel Gear 16
Ⅵ
LIST OF TABLES
TABLE DESCRIPTION PAGE

NO. NO.
1 Bevel Gear Design Calculation 19
Ⅶ
DEVELOPMENT OF ABRASIVE CUTTING MACHINE
CHAPTER 1
INTRODUCTION
1.1 Background
A cut-off is one of the most commonly used machinery in the manufacturing process, and almost
every workshop has one. It is easy to use, maintainable and cost effective. Several types of cutting
machines are available for production cutting of tube and bar, such as cold saws, band saws, lasers,
shears, waterjets, and abrasive cutting machines. While each has its advantages and disadvantages,
abrasive cutting fills a niche with its ability to accommodate special applications, such as difficult-
to-cut stock; tube that must be cut cleanly without serious distortion, especially very thin-walled
tube; short cut lengths; and applications that require scrap minimization. Sectioning is the primary
step in metallographic sample preparation. Area of interest has to be sectioned from parent material
using suitable cutter with appropriate cut of wheel intended forth application. Smooth finish and
burn free sample is ideal for metallographic examination. The existing machines can cut up to
120mm so we want to fabricate the machine which can cut up to 200mm without any vibration,
abrasive cutting is generally used for metal specimens sample preparation, it starts with "cutting"
and good "cutting" means a good start. Selecting the right cut-off wheel ensures freedom from
burn and distortion and is the best way to save time and consumables. Correct cutting produces
specimens which are in perfect condition for the next preparation steps proper sectioning is
required to minimize damage, which may alter the micro structure and produce false
metallographic characterization. Proper cutting requires the correct selection of abrasive type,
bonding and size, as well as proper cutting speed, load and coolant.
Figure 1.1: ABRASIVE CUTTING MACHINE
Dept of Mechanical Engineering, RVCE Page 1

1.2 LITERATURE SURVEY
1. S.J. OJOLO et al. [1] It Was Discovered from The Tests That Depending On The Length Of Cut
And Material Being Cut, The High Speed Abrasive Cutting Machine Was More Efficient, In
TermsOf Cutting Time, Than The Power Hacksaw. The Implemented Examinations Lead To The
Conclusion That Cut-Off Wheels With Prevailing Cubical Grit Show The Longest Life-Time.
ThisOriginates from the Higher Grit Strength and the Grit’s Better Adhesion in the Bonding Agent.
With Low Cutting Stress Concerning Force And Temperature, Cut- Off Wheels Made Of
Prevailing Splinter-Shaped Grit Also Showed Clear Advantages. When The Stress Increases The
Bonding Agent Fails Relatively Fast. If The Advantages Of Shape-Assorted Grit Compounds,
Which Are Very Expensive At The Moment, Are To Be Used, It Is Necessary To Optimize The
Entire DesignOf Such Cut-Off Wheels. Besides The Often-Mentioned Influence Of The Bonding
Agent The Best Type Of Wear For Cut-Off Wheels In Combination With Economic
Considerations Has To Be Determined. From The Present Point Of View A Cut-Off Wheel With
Shape Defined Grits Can Only Be Implied Profitably Where Special UndConstant Cutting
Conditions Exist. The ExpansionOf The New Test Assembly At The Institute Of Machine Tools
And Production Processes Of The Chemnitz University Of Technology, Where The Operator’s
And Machine’s Influences Can Be Kept Constant, Created The Prerequisite For Continuing
Research. The Measurement Of Wear AndCutting Sharpness Allows Objective Benchmark Of
Cut- Off Wheels. Furthermore, The Scientific Work for Invest Ligating The Wear Mechanism In
Cutting Under Conditions Of Abrasive Cut-OffCan Be Continued.
2. C. Jegan1 et al. [2] When, The Heavy Load Is Performed On The Cutting Blade The Motor Is
Affected And The Motor Cannot Be Reused. So, Why Armature Motors Are Replaced By The
Winding Motors. Winding Motors Can Be Reused. When, The Heavy Load Given By The
Cutting Tool The Motor Will Not Get Affected. Winding Motors Are Stable To Run When
Heavy Load Is Given Also.
3. Mohammad Waleed et al. [3] This Project Emphasizes The Development Of Low-Pressure
AWJM, Making It Less Expensive Regarding Running Costs. In Addition, It Also Acts As A
Testing Ground For AWJC Tests At Reduced Pressure.

4. Derzija Begic-Hajdarevica et al. [4] The Aim Of This Study Was Examined The Effects Of
Abrasive Water Jet Variables Such As Traverse Speed, Abrasive Mass Flow And Material
Thickness On Surface Roughness In Abrasive Water Jet Cutting Of Aluminum. The Varied
SurfaceRoughness Across The Depth Of Cut Was Also Examined.
5. Norbert Asamer et al [8]At various stages during the hot rolling process, the different rolled
products – blooms, billets, bars, respectivelysections, but also slabs or plates – need to be cut. While
the cross sections of these products are being reduced during each rolling pass, the lengths are being
increased accordingly. Thus, it becomes necessary to cut the products to shorter lengths suitable
forthe next steps of production by state-of-the-art designed dry abrasive cut-off machines.
1.3 Main objectives of project
1. To Design an Abrasive Cutting Machine Which Is Adjustable To Cut Larger Materials.

2. To Procure Materials and Construct/fabricate Abrasive Cutting Machine.
3. To perform Vibration analysis Of Abrasive Cutting Machine.
4. To Perform Analysis by Calculating Vibrations and Measurement of Torque Vs Cutting Force.
and Comparison with Old version of Machine.
1.4 Problem Definition

The existing abrasive cutting machine can cut up to 100mm and it is side handle operated and the t
slot can move only in one direction so now we want to make abrasive cutting machine which can
cut up to 150mm and operated by using bevel gear and the t slot can move in x and y direction by
using servo motor.

CHAPTER 2
THEORY AND CONCEPT
2.1 Abrasive Cutting
Operations such as shearing produce severe cold work, which can alter the microstructure of a sample.
Abrasive cutting (sectioning) offers the best solution to eliminate these undesirable features; the
resultant surface is smooth, and the sectioning task is quickly accomplished. Low-speed cut-off
wheels are utilized in cases where the heat created by standard abrasive cutters must be avoided.
Ample coolant and proper speed control are essential in all sectioning operations. Abrasive Cut-Off
Wheels consist of abrasive grains (such as Aluminum Oxide or Silicon Carbide), bonded together
with rubber or other materials in the form of a thin wheel. Rubber bonded wheels are most extensively
used for wet operation and resin bonds for dry cutting. When sectioning a piece of metal, the abrasive
grains on the cutoff wheel become dull, therefore, the bond must be destroyed at the correct rate so
that new grains are always at the edge and are still held firmly by the bonding material. The rate at
which the bond breaks down is affected by several different factors, including:
1) The hardness of the bond.
2) The hardness and workability of the metal sample.
3) The size and speed of the wheel.
4) The power of the driving motor.
5) The type and amount of coolant and its method of application.
6) The amount of pressure by which the wheel is applied to the sample.
7) The amount of vibration in the machine.
2.2 Abrasive machining process

Abrasive machining involves material removal by the action of hard, abrasive particles. The use of
abrasives to shape parts is probably the oldest material removal process. They are important because
Introduction They can be used on all types of materials ranging from soft metals to hardened steels
and hard non-metallic materials such as ceramics and silicon. Extremely fine surface finishes (0.025
µm). For certain abrasive processes, dimensions can be held to extremely close tolerances.
2.2.1 Basic principal of abrasive cutting

Abrasive cutting is the sectioning of material, using a relatively thin rotating disc composed of
abrasive particles supported by a suitable media. Ideally, each abrasive particle should function as an
individual cutting tool. In a machine tool, as shown in Figure, the angle at which the tool contacts the
work is fixed so that near ideal conditions are readily achieved. Abrasive wheels, however, are
necessarily composed of randomly oriented abrasive particles which contact the work at various

Angles. Ideal cutting is, therefore, not achieved by every abrasive particle; the more favorably aligned
ones will cut effectively, while the less favorably aligned ones will tend to produce grooves and
frictional heat. The heat generated by the contact of abrasive particles in contact with the work would
at first appear to be a significant problem. Actually, this very heat aids in keeping the abrasive wheel
cutting rather than working the surface. The specimen is protected from excessive heating by the
action of the coolant system of the cutter.
Figure 2.2.1: basic principle of abrasive cutting
2.2.2 Types of Abrasive Machining Processes

1. Grinding
2. Honing
3. Lapping Superfinishing
4. Polishing Buffing
5. Abrasive water jet machining
6. Ultrasonic machining
2.3 Vibration
Vibration defined as when an elastic body such as spring, a beam, and a shaft are displaced from the
equilibrium piston by the application of external forces and then released they executive as vibratory
motion, When body particles are displaced by the application of external force, the internal force in the
form of elastic energy are present in the body, tries to bring the body to its original position. At
equilibrium position, the whole elastic energy is converted into kinetic energy and the body continues
to move in the opposite direction of it. The whole of kinetic energy is again converted into elastic or
strain energy due to which the body again returns to its equilibrium position.
2.3.1 Types of vibration
1. Free vibration occurs when a mechanical system is set in motion with an initial input and
allowed to vibrate freely. Examples of this type of vibration are pulling a child back on a swing

and letting it go, or hitting a tuning fork and letting it ring. The mechanical system vibrates at
one or more of its natural frequencies and damps down to motionlessness.
2. Forced vibration is when a time-varying disturbance (load, displacement, velocity, or

acceleration) is applied to a mechanical system. The disturbance can be a periodic and steady-
state input, a transient input, or a random input. The periodic input can be a harmonic or a non-
harmonic disturbance. Examples of these types of vibration include a washing machine shaking
due to an imbalance, transportation vibration caused by an engine or uneven road, or the
vibration of a building during an earthquake. For linear systems, the frequency of the steady-
state vibration response resulting from the application of a periodic, harmonic input is equal to
the frequency of the applied force or motion, with the response magnitude being dependent on
the actual mechanical system.
3. Damped vibration: When the energy of a vibrating system is gradually dissipated by friction
and other resistances, the vibrations are said to be damped. The vibrations gradually reduce or
change in frequency or intensity or cease and the system rests in its equilibrium position. An
example of this type of vibration is the vehicular suspension dampened by the shock absorber
2.3.2 What Is Vibration Analysis?

Vibration analysis is defined as a process for measuring the vibration levels and frequencies of
machinery and then using that information to analyze how healthy the machines and their components
are. While the inner-workings and formulas used to calculate various forms of vibration can get
complicated, it all starts with using an accelerometer to measure vibration. Anytime a piece of
machinery is running, it is making vibrations. An accelerometer attached to the machine generates a
voltage signal that corresponds to the amount of vibration and the frequency of vibration the machine
is producing, usually how many times per second or minute the vibration occurs.
All data collected from the accelerometer goes directly into a data collector (software), which records
the signal as either amplitude vs. time (known as time waveform), amplitude vs. frequency (known
as fast Fourier transform), or both. All of this data is analyzed by computer program algorithms, which
in turn is analyzed by engineers or trained vibration analysts to determine the health of the machine
and identify possible impending problems like looseness, unbalance, misalignment, lubrication issues
and more. Vibration analysis can detect problems such as:
 Imbalance
 Bearing failures
 Mechanical looseness
 Misalignment

 Resonance and natural frequencies

 Electrical motor faults
 Bent shafts
 Gearbox failures
 Empty space or bubbles (cavitation) in pumps
 Critical speeds
2.3.3 Vibration Analysis Methodology

While accelerometers are still the most common tool used to collect vibration data, modern
technology and improved sensor technology have allowed for non-contact, high-speed laser sensors
that can detect issues accelerometers can't. This allows for a more accurate and more localized
analysis, and opens up vibration analysis to more methodology. Vibration analysis is generally broken
down into four principles, and each principle gives you specific information on the working
conditions and features of the vibrating parts.
1. Time domain: When a vibration signal is picked up from a transducer (device that converts a
physical quantity into an electrical signal) and displayed on the screen of an oscilloscope, it's
called a waveform. This signal is in the time domain. The time domain is amplitude plotted
against time. While most machine vibration issues are detected using spectrum analysis, some
types are more easily seen in waveform.
2. Frequency domain: When the waveform discussed earlier is subjected to spectrum analysis, the
end result is a picture of frequency vs. amplitude, known as a spectrum. The spectrum is in the
frequency domain like the vibration is in the time domain. Most in-depth analysis of machinery
vibration is done in the frequency domain or using spectrum analysis.
3. Joint domain: Because vibration signals vary with time, calculating more than one spectrum at
once can be useful. To do this, a joint time technique called Gabor-Wigner-Wavelet can be
utilized. This technique is used to calculate variations of the fast Fourier transform (discussed
below), including short-time Fourier transform (STFT).
4. Modal analysis: Modal analysis takes measured frequency response functions of a piece of
machinery and puts them into a computer model. The computer model can be displayed with
animations of all the different vibration modes. The model can be adjusted by either adding to or
taking away things like mass or stiffness to see the effects.

2.4 servo motor

The servo motor is most commonly used for high technology devices in the industrial application
like automation technology. It is a self-contained electrical device that rotate parts of a machine with
high efficiency and great precision. The output shaft of this motor can be moved to a particular angle.
Servo motors are mainly used in home electronics, toys, cars, airplanes, etc.in this discusses about
what is a servo motor, servo motor working, servo motor types and its applications.
2.4.1 Types of Servo Motor

Servo motors are classified into different types based on their application, such as AC servo motor,
DC servo motor, brushless DC servo motor, positional rotation, continuous rotation and linear servo
motor etc. Typical servo motors comprise of three wires namely, power control and ground. The
shape and size of these motors depend on their applications. RC servo motor is the most common
type of servo motor used in hobby applications, robotics due to their simplicity, affordability and
reliability of control by microprocessors.
1. DC Servo Motor
The motor which is used as a DC servo motor generally have a separate DC source in the field of
winding & armature winding. The control can be archived either by controlling the armature current
or field current. Field control includes some particular advantages over armature control. In the same
way armature control includes some advantages over field control. Based on the applications the
control should be applied to the DC servo motor. DC servo motor provides very accurate and also
fast respond to start or stop command signals due to the low armature inductive reactance. DC servo
motors are used in similar equipment’s and computerized numerically controlled machines
Figure 2.4.1: dc servo motor
2. AC Servo Motor
AC servo motor is an AC motor that includes encoder is used with controllers for giving closed loop
control and feedback. This motor can be placed to high accuracy and also controlled precisely as
compulsory for the applications. Frequently these motors have higher designs of tolerance or better

Bearings and some simple designs also use higher voltages in order to accomplish greater torque.
Applications of an AC motor mainly involve in automation, robotics, CNC machinery, and other
applications a high level of precision and needful versatility.
Figure 2.4.2 ac servo motor
3. Positional Rotation Servo Motor

Positional rotation servo motor is a most common type of servo motor. The shaft’s o/p rotates in about
180o. It includes physical stops located in the gear mechanism to stop turning outside these limits to
guard the rotation sensor. These common servos involve in radio controlled water, radio controlled
cars, aircraft, robots, toys and many other applications.
Figure 2.4.3: positional rotation servo motor
4. Continuous Rotation Servo Motor

Continuous rotation servo motor is quite related to the common positional rotation servo motor, but it
can go in any direction indefinitely. The control signal, rather than set the static position of the
servo,is understood as the speed and direction of rotation. The range of potential commands sources
the servo to rotate clockwise or anticlockwise as preferred, at changing speed, depending on the
command signal. This type of motor is used in a radar dish if you are riding one on a robot or you
can use one as a drive motor on a mobile robot.

Figure 2.4.4: continuous rotation servo motor
5. Linear Servo Motor

Linear servo motor is also similar the positional rotation servo motor is discussed above, but with an
extra gears to alter the o/p from circular to back-and-forth. These servo motors are not simple to find,
but sometimes you can find them at hobby stores where they are used as actuators in higher model
airplanes.
Figure 2.4.5: linear servo motor
2.5 Induction Motor
2.5.1 What is an Induction Motor?

An induction motor (also known as an asynchronous motor) is a commonly used AC electric motor.
In an induction motor, the electric current in the rotor needed to produce torque is obtained via
electromagnetic induction from the rotating magnetic field of the stator winding. The rotor of an
induction motor can be a squirrel cage rotor or wound type rotor
Figure 2.5.1: induction motor

2.5.2 Working Principle of Induction Motor

We need to give double excitation to make a DC motor to rotate. In the DC motor, we give one supply
to the stator and another to the rotor through brush arrangement. But in induction motor, we give only
one supply, so it is interesting to know how an induction motor works.
It is simple, from the name itself we can understand that here, the induction process is involved. When
we give the supply to the stator winding, a magnetic flux gets produced in the stator due to the flow
of current in the coil. The rotor winding is so arranged that each coil becomes short-circuited.
The flux from the stator cuts the short-circuited coil in the rotor. As the rotor coils are short-circuited,
according to Faraday’s law of electromagnetic induction, the current will start flowing through the
coil of the rotor. When the current through the rotor coils flows, another flux gets generated in the
rotor.
Now there are two fluxes, one is stator flux, and another is rotor flux. The rotor flux will be lagging
with respect to the stator flux. Because of that, the rotor will feel a torque which will make the rotor
to rotate in the direction of the rotating magnetic field. This is the working principle of both single
and three-phase induction motors.
2.5.3 Types of Induction Motors

The types of induction motors can be classified depending on whether they are a single phase or three
phase induction motor.
Single Phase Induction Motor

The types of single phase induction motors include:
1. Split Phase Induction Motor
2. Capacitor Start Induction Motor
3. Capacitor Start and Capacitor Run Induction Motor
4. Shaded Pole Induction Motor
Three Phase Induction Motor

The types of three phase induction motors include:
1. Squirrel Cage Induction Motor
2. Slip Ring Induction Motor

CHAPTER 3
PROJECT METHODOLOGY
3.1 Project Definition

From the literature, it is observed that in metallurgical operations the cutting surface should be smooth
and it should not alter the microstructure of a sample for that abrasive cutting machine offers the best
solution to eliminate these undesirable features the resultant surface is smooth and the sectioning tasks
is quickly accomplished. There for the research is focus is on developing abrasive cutting machine to
cut larger specimen and the machine is to semiautomatic.
3.2 Project Methodology

The project is started with conceptual mechanical design, it means the conceptual design phase results
in a description of the proposed system in terms of a set of integrated ideas about what it should do,
how it should behave, and what it should look like. Visualizing your product is an important aspect of
verifying the complete design intent. And next step is understanding the basic specifications of
machine and then design and its calculation of machine element like speed of abrasive wheel, feed
speed, feed rate, depth of cut, width of cut, power required , total tangential cutting force, radial force,
shaft design, and then next step is making 3d model in solid works and then convert to 2d drawings
and next step is material selection and then vibrational analysis using Ansys if the result resonance
frequency is equal to natural frequency we should redesign if it is not and then we proceed to next step
fabrication and then automation , assembly and final step performance analysis.

3.3 Flow Chart of Project Methodology
Conceptual mechanical design
Understanding the basic

Specifications of machine
elements
NO
Fabrication
Design and it's calculation of Yes

machine Automation
Making 3d cad model Assembly
Resonance
frequency is equal
to natural
Convert to 2d drawing using frequency Performance analysis
solid works
Material selection
Vibration analysis
Figure 3.3: Flow Chart of Project Methodology

CHAPTER 4
DESIGN OF ABRASIVE CUTTING MACHINE
4.1 Conceptual Mechanical Design
Conceptual design phase results in a description of the proposed system in terms of a set of
integrated ideas about what it should do, how it should behave, and what it should look like,
in conceptual mechanical design. I designed a machine in 3 different ways which follows as
version 1 which is handle operated, version 2 which is belt and gear operated, and version
3which is gear operated.
Version 1
Figure 4.1.1: Different Views Abrasive Cutting Machine

Figure 4.1.2: Bill of Material of Abrasive Cutting Machine

Version 2
Figure 4.1.3: Abrasive Cutting Machine Operated by Belt and Pulley
Version 3
Figure 4.1.4: Abrasive Cutting Machine Operated By Bevel Gear

4.2 Parameters Consider and Its Calculation
4.2.1 Speed of Abrasive Wheel (N)
Jain (2008) stated that the rubber bonded abrasive wheel of up to 0.1 mm thickness can be
operated at speeds ranging from 3000 to 5000 m/min. Expressed in revolutions per minute, using
Where, U = Linear Velocity at the Circumference of the Wheel, AndD = Diameter of the
Abrasive Cutter I.E.500 Mm
The Range of Speed Is Thus 1591 To 2652 Rpm. A Speed of 2500 Rpm Is SelectedWhich
Corresponds To 65.4 M/S.
4.2.2 Feed Speed (fV)

Nagpal (2005) and Jain (2008) noted that a typical value of feed ranges between 0.2 to 0.6 m/s.
A feed speed of 0.6 m/s, which corresponds to 100 mm/min, is chosen
4.2.3 Feed Rate (f)

This is the feed of the cutter in one revolution and is obtained using
But fV = 30 mm/min; and N = 2500 rpm.Therefore
4.2.4 Depth of Cut (t)

This is the thickness of the layer removed in one pass in a direction perpendicular to the direction
of feed motion (Nagpal, 2005). The feed is across the cross section of the work piece. Hence, the
depth of cut equals the thickness of the abrasive cutter. t = 4 mm
4.2.5 Width of Cut (W)

This is taken as the greatest width of the work piece to be cut. A maximum width of 100 mm is
selected for the design

4.5.6 Volume of Material removed per Unit Time (V)

According to Singh, 2008 and Jain, 2008this can be derived using
4.5.7 Power Required (P)
Where = specific energy of the material = 5.5 J/mm3 for steel with BHN 400 (Singh, 2008) Therefore,
4.2.8 Total Tangential Cutting Force

This is evaluated by using (Jain, 2008; Singh, 2008)
Ft=10.504N
4.2.9 Radial Force (F)

This is the force perpendicular to the total tangential force (Jain, 2008) and is taken as the
required feed force. It is evaluated, Singh, 2008, using

4.3 Bevel gear design calculation
No. Item Symbol Formula Example

Pinion (1) Gear (2)
1 Shaft Angle Σ 90 Deg
2 Module M Set Value 4
3 Reference Pressure Angle Α 20 Deg
4 Number Of Teeth Z 30 30
5 Reference Diameter D Zm 120 120
Δ1
6 Reference Cone Angle Δ2 45 Deg 45 Deg
7 Cone Distance R 84.858
8 Face Width B It Should Not Exceed R / 3 28.286
Ha
9 Addendum 1 4 4
Ha
2
10 Dedendum Hf 2.188m – Ha 4.752 4.752
11 Dedendum Angle Θf Tan^-1(Hf / R ) 3.20 Deg 3.20 Deg
12 Addendum Angle Θa1 Θf2 3.92194 Deg 2.15903 Deg

Θa2 Θf1
13 Tip Angle Δa Σ + Θa 30.48699 Deg 65.59398 Deg
14 Root Angle Δf Σ – Θf 24.40602 Deg 59.51301 Deg
15 Tip Diameter Da D + 2ha Cos Σ 67.2180 121.7575
16 Pitch Apex To Crown X R Cos Σ – Ha Sin Σ 58.1955 28.2425
17 Axial Face Width Xb 19.0029 9.0969
18 Inner Tip Diameter Di 44.8425 81.6609

CHAPTER 5
CONCLUSION
1. Feed of the cutter in single revolution is .12mm/rev.
2. Power required to cut is 687.5W.
3. The gear chosen is bevel gear module 4 of 1:1 ratio and having 30 gear teeth.
4. Initially at conceptual design phase we designed side handle operated abrasive cutting
machine and then updated that to abrasive cutting machine operated by belt and pulley system
and again this is modified to abrasive cutting machine operated by bevel gear system.

REFRENCES
1) Blackburn, J. (2000). Abrasive Can Be Good. The Tube and Pipe Journal, Croydon groupLtd.,
Illinois, Pp 50-52.
2) Doe (2001). Department Of Energy Fundamentals Handbook: Material Science, Volume 1 of 2,
Doe-Hdbk1017/1-93, Washington D.C.
3) Everett, J. (2007). Abrasive Cut-Off Machines and Wheels. Everett Product Catalogue, Everett
Industries, Inc., Ohio, U.S.A
4) Gill, M. C. (2005). High Performance Composite Products. Mc Gill Corp.Ltd. California.
5) Jain, R. K. (2004). Machine Design (Seventh Edition). Khanna Publishers, Delhi.
6) Jain, R. K. (2008). Production Technology (Sixteenth Edition), Khanna Publishers, Delhi.
7) H. Vollsta¨Dt, E. List, H. Recht, Characterization Of Industrial Diamonds On The Basis Of

Mechanical Methods, In: Seminar Diabond ’99 Nu¨Rnberg, Germany (Diamante Application And
Tecnologia, Bremen, 1999), And Pp. 105–108.
8) Oberg, E. , Jones, D. F. (1996). Machinery Handbook, 25th Edition, National Publishing Company,
Philadelphia.
9) Radford, J.D. And Richardson, D.B. (2007). Production Engineering Technology, 9thedition.
Macmillan Press Ltd., Hong Kong.
10) Rajgopalan, R. (1970). Abrasive Cutting off Wheel, Proceedings of the Ivth AimtdrConference, Iit
Madras.
11) Sahu, P. (2001). Development And Characterization Of Fibre Glass/Epoxy Reinforced Composite
Parting-Off Wheel, National Conference Of Mech. Eng. Stud., College Of Engineering, Andhra
University, and Vishakhapatnam.
12) Sharma, P. C. And Aggarwal, D. K. (2006). Machine Design, Eleventh Edition, Khanna Publishers,
Delhi.
13) Shaw, M. C. (1975). The Rating Of Abrasive Cut-Off Wheels, Trans Asme 97:138- 146.
14) Shigley, J. E. And Mischke, C. R. (2003). Mechanical Engineering Design, Sixth Metric Edition,
Mcgraw Hill Companies Inc., New York.
15) Singh, S. (2008). Mechanical Engineer’s Handbook, Second Edition, Khanna Publishers, Delhi.
16) https://www.watelectrical.com/servo-motor-types-and-working-principle/
17) https://www.reliableplant.com/vibration-analysis-31569
18) Author Name, Utilization of Finite Element Method in Machine Design, Morikita Shuppan, 1997,
pp. 124-136 & 215-225.

Major Project Report 1rv20mpd08

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Major Project Report 1rv20mpd08

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Major Project: Phase-II Report

Under the Guidance of

Submitted in partial fulfillment for the award of degree

PRODUCT DESIGN AND MANUFACTURING

(Autonomous Institution Affiliated to

Dr. Nataraj J R Mr. Prakash Balasubramanian

Dr. Krishna M Dr. K N Subramanya

DEPARTMENT OF MECHANICAL ENGINEERING

I, BASAVARAJ G L, student of third semester MTech in PRODUCT DESIGN AND

Date of Submission: 24/01/2022 Signature of the Student

Department of Mechanical Engineering

Product Design & Manufacturing

DECLARATION ........................................................................................................................ III

TABLE OF CONTENTS .............................................................................................................V

LIST OF FIGURES .................................................................................................................... VI

LIST OF TABLES .................................................................................................................... Ⅶ

1.1 Background ....................................................................................................................................... 1

1.2 Literature survey.............................................................................................................................. 2

1.3 objectives of project ........................................................................................................................ 4

1.4 Problem definition.......................................................................................................................... 4

THEORY AND CONCEPTS

2.2 Abrasive machining process… ...................................................................................................... 5

2.2.1 Basic principal of abrasive cutting ............................................................................................. 4

2.2.2 Types of Abrasive Machining Processes .................................................................................... 5

2.3 Vibration .......................................................................................................................................... 5

2.3.1 Types of vibration ......................................................................................................................... 5

2.3.2 Vibration analysis methodology ................................................................................................... 7

2.4 Servo motor .................................................................................................................................... 8

2.4.1 Types of Servo Motor .................................................................................................................... 8

2.4.1.1 DC Servo Motor ..........................................................................................................................8

2.4.1.2 AC Servo Motor ......................................................................................................................... 8

2.4.1.3 Positional Rotation Servo Motor… .......................................................................................... 9

2.4.1.4 Continuous Rotation Servo Motor… ......................................................................................10

2.4.1.5 Linear Servo Motor… ............................................................................................................. 10

2.5 Induction motor .............................................................................................................................10

2.5.1 What is an Induction Motor… ................................................................................................. 11

2.5.2 Working Principle of Induction Motor .................................................................................... 11

2.5.3 Types of Induction Motors… .................................................................................................... 11

3.2 Project methodology...................................................................................................................... 12

3.3 flow Chart Of Project Methodology ............................................................................................ 13

4.1 Conceptual mechanical design .................................................................................................... 14

4.2 Parameters consider and its calculation ...................................................................................... 17

4.3 Bevel gear design calculation ........................................................................................................ 19

1.1 Abrasive Cutting Machine 1

2.2.1 Basic principle of abrasive cutting 5

2.4.1 Dc servo motor 8

2.4.2 Ac servo motor 9

2.4.3 Positional rotation servo motor 9

2.4.4 Continuous rotation servo motor 10

2.4.5 Linear servo motor 10

2.5.1 Induction motor 10

3.3 Flow Chart of Project Methodology 13

4.1.2 Bill Of Material of Abrasive Cutting Machine 15

4.1.3 Abrasive Cutting Machine Operated by Belt and Pulley 16

4.1.4 Abrasive Cutting Machine Operated by Bevel Gear 16

TABLE DESCRIPTION PAGE

1 Bevel Gear Design Calculation 19

Figure 1.1: ABRASIVE CUTTING MACHINE

Dept of Mechanical Engineering, RVCE Page 1

1.2 LITERATURE SURVEY

Dept of Mechanical Engineering, RVCE Page 2

1.3 Main objectives of project

1. To Design an Abrasive Cutting Machine Which Is Adjustable To Cut Larger Materials.