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1 CHAPTER 1 INTRODUCTION This chapter consist of overall background, problem statement, objectives and Industry
information. 1.1 Background The aim of this chapter is to provide all the basic information about project background.
This chapter includes the theoretical and technical framework necessary for understanding the work during the
dissertation in the form of problem statement, objective, scope of work and methodology opted. The market demand of
the packaging products is a growing market in India. One of the products in the packaging is widely used knows as bags.
These bags are used widely in the agricultural and food products. One of the processes which are necessary in the
production of the pp woven bags is to cut their handle. There are so many types of punching machines available in the
market based on their compressor and hydraulics. Need of extra equipment with the machine increases its cost and
thereby production costs. In the mission of make in India we are using such Chinese machines. So, we are
manufacturing made in India product. In our project we will be developing an innovative heat treatment based punching
machines for same purpose of packaging industries. Heat treatment will be able to cut and penetrate the bags easily.
Additionally, this heat will seal the cutting edges properly. It will make the cut stronger to carry the bag and material
weight. This make in India technology will need only one labor to operate the machine which will help to reduce the
productivity cost and expenses. Small and compact size will make machine transportation and installation easier. Quick
and higher productivity of our innovative D Cut machine will make is extremely beneficial in the woven bag industries. 1.2
Problem Statement In today’s era automation plays a very important role in all engineering applications and Industries.
The small-scale packaging industries manufacture pp woven bags and handle of the bags are cut manually. Due to this
the manufacturing time increases as well as labour cost increases. The accuracy due to manual cutting gets reduced. To
overcome all these problems faced by packaging industries we decided to manufacture a machine to cut pp woven bags
automatically using heat treatment process.
2 1.3 Objectives The problem of manually cutting handle of pp woven bags leads to decrease in accuracy, increase
manufacturing time, labor cost. To overcome all these problems this kind of specially designed machines will be
extremely useful in all kinds of packaging materials processing industries. To optimize the time required, increase the
productivity, accuracy and quality. 1.4 Type of Project This project of Design and Development of D cut machine is a
Industry Sponsored Project 1.4.1 Industry Information [Link] Paykia Established in the year 2014, [Link] is a
paramount organization affianced as Manufacturer, Wholesaler and Trader of an extensive range of Mulching Paper,
Bopp Tape, Stretch Films, PP Strapping Roll, Tarpaulin Roll, Bubble Roll, Corrugated Paper Roll, Garbage Bags, Sutli, PVC
Pipe, Tadpatri, Cling Film, Seed Tray, Roofing Sheet, and Engineering Books. The array made available by them is designed
using top notch quality basic material at vendors end. All the products are applauded by customers owing to their
intrusive specifications such as fine finishing, hygiene, resistance against heat, non- toxicity and dimensional accuracy.
Owner of the firm: Mr. Pramod. Dorik Address: Shop no 103, Plot No.23, 24, Gangamai Construction & Industries, Satpur,
MIDC, Nashik, Maharashtra 422007. Figure. 1.1 Industry Overview
3 CHAPTER 2 LITERATURE REVIEW This section presents and discuss a detailed literature review related to design and
development of automatic heat treatment-based D-cut machine for various applications that is available in published
literature. High Density Polyethylene/Polypropylene Plastic Bags Production “Most Profitable Business Opportunities of
Startups”. Woven polypropylene bags, also known as woven PP bags, are the toughest packing bags available, and are
commonly used to pack materials for the grain, milling, and sugar industries. Furthermore, these bags are commonly
used in the four, pesticides, and fertilizer industries, as well as the HDPE/PP Bags industry and other applications such as
sand, metal parts, and concrete. The detailed project report covers all aspect of business, from analyzing the market,
confirming availability of various necessities such as Manufacturing Plant, Detailed Project Report, Profile, Business Plan,
Industry Trends, Market Research, Survey, Manufacturing Process, Machinery, Raw Materials, Feasibility Study, Investment
Opportunities, Cost and Revenue, Plant Economics, Production Schedule.[1] Project report for non-woven fabric bag
making machine. This machine is adopting computer orientation, photocell tracking, operation by man-machine
interface touch. It’s adopting high wave band ultrasonic heat-sealing principle. It has functions like hem in bag orifice,
punching, ultrasonic heat sealing, cold cutting etc. It’s advanced machine for all kind of non- woven fabrics handle
shopping bag, shoes bag, haversack as 20-100 grams. Required space to keep non-woven bag making machine. →
Water and moisture proof shade → 10×40 square feet space for machine Total space in loading Row material and finish
Product 1000 square feet → RCC surface Required additional implement → Compressor: (2 HP) → Stabilizer: (12 KW)
Required Workers → 3 (1 skilled and 2 unskilled) [2] Semi-Automatic non-woven bag making machine Non-Woven Bag
Making Machine is a Breakthru' modern Design to deliver Diverse needs of Worldwide Consumers for heavy production
at very economical running cost. Wide range of Non-Woven Bag Making Machine is suitable to make bags with D-Cut,
without D-Cut, U-Cut / Vest Type Bags with Side Gusset etc. Non-Woven Bag Making Machine is suitable for Mass
volumes and results in fast turnaround. Advance Technology PLC controlled Touch Screen Panel allows customer for
Managing the machine parameters easily thus helping in good quality.
4 Automatic roll feeding through pneumatic arms non-woven roll is passed to folder unit where it is folded from center
to form a tube Side sealing of tube is done through ultrasonic welding non-woven tube moves in boat structure unit to
form side gusset through wheels Side gusset formed non-woven tube moves under ultrasonic and sealer for sealing Bag
is formed after cutting controlled by panel. [3] INTERFERENCE FROM LITERATURE REVIEW Careful review of the
literature finds that very few researchers are working on developing on design and development of D-cut machine.
However, few attempts have been made to apply the system and maximize the potential of this design and development
of D-cut machine. The following observations have been made based on the literature review discussed in earlier
section. According to the literature review, the bag materials are the commonly used materials and the conventional
methods are used to cut the handle. It has been discovered that the majority of the existing design and machines are
based on pneumatic and hydraulics. Few machines are working on semi-automatic way. As a result, increase emphasis
on this area is required. Thus, it is proposed to design and construct a versatile automatic D-cut machine.
5 CHAPTER 3 METHODOLOGY This section describes the step wise processes in the design development of automatic
D- cut machine. The steps of the approach are illustrated in the figure 3.1 3.1 Methodology Methodology used for whole
processing of Automatic D-cut machine is given below; this methodology gives us path about how work is to be carried
out in systematic way. Figure.3.1. Methodology As shown in figure 3.1, following steps were attempted for the
completion of the project.
6 3.2 Project Planning 3.2.1 Problem Identification The problem in the industry was identified by us, and the problem was
analysed by doing market research. 3.2.2 Literature Review By studding Literature reviews necessary information was
been extracted from it. 3.2.3 Studying Existing Technology and Current methods From this study, for cutting handles of
PP wowen bags, we took into account both the traditional method and the current situation. 3.2.4 Preparation of Action
plan Preparation of an action plan for completing the project started once the project idea was finalized. 3.2.5 Design of
Components Each component was drafted using different design software and then assembled according to industry
guidelines. 3.2.6 Selection of Standard parts The design was finalized and the standard parts, such as motors and heaters,
were purchased after the designing process. 3.2.7 Manufacturing of Components and Assembly For the assembly of D
cut machines, different processes and methods were used to fabricate the components needed. Assembly of the
machine was carried out once all the components (purchased and manufactured) were available. 3.2.8 Testing and
Inspection A successful project implementation was followed by testing and inspection based on different parameters.
Various tests and inspections were conducted to conclude the results.
7 CHAPTER 4 CONCEPT DESIGN The concept diagram for the project is shown in figure 4.1, and the description as well
as operational process for the block diagram is mentioned below. 4.1 Block Diagram Figure.4.1 Block Diagram of Working
Mechanism 4.1.1 Block diagram Description 1) Die – The die is used for cutting the bag its heated and sharpened at one
end and thermally insulated at one end. 2) Linear Mechanism – The linear mechanism is used to move the die UP-
DOWN in precise way. 3) Stepper Motor – The motor is used to power the uptown movement of the die precisely. 4)
Heater and temperature controller – Used to heat the die. 5) Control panel – Used to control the temperature and
uptown movement of the bags.
8 4.1.2 Operational Process First the worker kept the bag on the platform to cut the handle. Then the sensor senses the
material is kept under the die as shown in figure 4.2. The Up down Mechanism in which the stepper motor rotates and
using lead screw the rotational moment converted into linear moment. Then the die is heated by using the Nichrome
wire single phase heater up to 200 degrees. By using heat treatment process the die is heated and the cut is made.
Electric power supply to nichrome wire-based heater is provided. Heater converts electricity into heat. This heat is
reached to a certain limit and controlled by temperature controller. The heat is transferred to PP woven material, and it
gets cut as it is heat sensitive. Sealing of the material is done simultaneously cutting makes cut super strong and
improves cut quality. Figure. 4.2 Concept Diagram As shown in figure 4.2, it consists of concept diagram of Automatic
Heat Treatment Based D-cut Machine.
9 Table No 4.1 Concept Drawing Details The names of the parts are shown in the above table no.4.1. The materials used
and the quantity of parts are also mentioned in the table. 4.2 Requirement Specification 4.2.1 Solid Edge (Design of
mechanical components) Solid Edge is a 3D CAD. parametric feature and synchronous technology solid modeling
software. It runs on Microsoft Windows and provides solid modeling, assembly modelling and 2D orthographic view
functionality for mechanical designers. Through third party applications it has links to many other Product Lifecycle
Management (PLM) technologies. Originally developed and released by Intergraph in 1996 using the ACIS geometric
modeling kernel, it changed to using the Para solid kernel when it was purchased and further developed by UGS Corp in
1998. In 2007, UGS was acquired by the Automation & Drives Division of Siemens AG. UGS company was renamed
Siemens Digital Industries Software on October 1, [Link] September 2006, Siemens has also offered a free 2D
version called Solid Edge 2D Drafting. Solid Edge is available in Design and Drafting, Foundation, Classic or Premium. The
"Premium" package includes all of the features of "Classic" plus mechanical and electrical routing software, and
engineering simulation capabilities for Computer Aided Engineering (CAE). 4.2.2 Proteus Design Suite (Circuit design
software) The Proteus Design Suite is a proprietary software tool suite used primarily for electronic design automation.
The software is used mainly by electronic design engineers and technicians to create schematics and electronic prints
for manufacturing printed circuit boards. It was developed in Yorkshire, England by Lab center Electronics Ltd and is
available in English, French, Spanish and Chinese languages. Sr. No Part Name Material Quantity 1 D-Shaped Die Mild
Steel 1 2 Die holder Mild Steel 1 3 Bush Fixture Mild Steel 1 4 Support Rod Mild Steel 1 5 Base Plate Mild Steel 1 6 Bearing
Stainless steel 1
10 Schematic capture in the Proteus Design Suite is used for both the simulation of designs and as the design phase of a
PCB layout project. It is therefore a core component and is included with all product configurations. 4.2.3 PCB Design
The PCB Layout module is automatically given connectivity information in the form of a netlist from the schematic
capture module. It applies this information, together with the user specified design rules and various design automation
tools, to assist with error free board design. PCB's of up to 16 copper layers can be produced with design size limited by
product configuration. Programming Software Software name – Arduino Lab IDE Software version – Arduino – 1.8.8
General information:
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The Arduino Integrated Development Environment (IDE) Is a cross-platform application (for Windows, macOS, Linux)
That is written in functions from C and C++. It is used to write and upload programs to Arduino compatible boards, but
also, with the help of 3rd party cores, other vendor development boards. 11

CHAPTER 5 DETAILED DESIGN In this chapter all the required design considerations are taken into account as shown
below. 5.1 Design Consideration Design consists of application of scientific principles, technical information and
imagination for development of new or improvised machine or mechanism to perform a specific function with
maximum economy and efficiency. Hence a careful design approach has to be adopted. The total design work has been
split up into two parts; 5.1.1 System Design System design mainly concerns with various physical constrains, deciding
basic working principle, space requirements, arrangements of various components etc. Following parameters are looked
upon in system design. Selection of system based on physical constraints. The mechanical design has direct norms with
the system design hence system is designed such that distinctions and dimensions thus obtained in mechanical design
can be well fitted in to it. Arrangement of various components made simple to utilize every possible space. Ease of
maintenance and servicing achieved by means of simplified layout that enables quick decision assembly of components
Scope of future improvement. 5.1.2

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Mechanical Design In mechanical design the components are listed down and stored on the basis of their
procurement in two categories, 5.1.3 Designed Parts

and Parts to be purchased For designed parts detailed design is done and dimensions there obtained are compared to
next dimensions which are

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already available in market. This simplifies the assembly as well as the post production and maintenance work.

The various tolerances on work are specified. The

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process charts are prepared and passed to manufacturing stage. The parts to be purchased directly are selected from
various catalogues and

are specified so as to have case of procurement in mechanical designed at

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the first stage selection of appropriate material for the part to be designed for specific application is

done. This selection is based on standard catalogues or data books; E.g.: - PSG Design Data Books, SKF Bearing
Catalogue etc.
12 5.1.4 Motor Calculation Calculating load torque is determined by the force in the system and the logical distance
between the motor shaft and the where the force is acting T = F x r = F x D/2 r = distance between center of rotation F =
force point 5.1.5 Load Torque - Actual Measurement If you can measure the force, that is the most accurate way to find
the force since it takes care of all the efficiency and coefficient of frictions on the every part. FB = Force when the main
shaft begins to rotate
13 Forces There are three types of forces; vertical, horizontal and incline. A force varies depending how it acts. Vertical
Force Calculation Based on above reference: - 1) Weight of the die(m1) – 550 Gram 2) Weigh of the guideways(m2) –
approximately 100 grams 3) Weight of the motor (m3) – 250 grams 4) Friction factor – 1.25 5) Diameter of lead screw –
8mm M = m1+m2+m3 = 550+100+250 = 900gram F = W= mg = (900*9.81) = 8829 = 0.8829Kgcm = 0.9Kgcm Fb =
F*Friction factor = 0.9*1.25 = 1.125N Load torque = (Fb*D)2 KGCM = (1.125*8) / 2 = 45 = 4.5Kgcm
14 5.1.6

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Bearing selection: As shaft dia. – is 8mm so we have selected linear ball bearing having shaft outer dia. – [Link]
selection of ball bearing the main governing factor

is the system design of the drive i.e.; the size of the ball bearing is of major importance; hence we shall first select an
appropriate ball bearing. Taking into consideration convenience of mounting of ball bearing. As shaft diameter is 8mm to
it &selected a pedestal ball bearing having shaft outer dia-8mm ball bearing to support the shaft of 8mm. Total Axial load
on bearings is = weight of shaft assume = 180 N Axial load on each bearing Fa = 180/2 = 90 N. (
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Bhandari V. B., Design of machine elements, Third edition, MC Graw-hill Companies.

Page no.-573)

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Equivalent dynamic load Pe = V×Fa×Ka = 1 X 90 X 1.5 Pe = 135 N bearing life is, = L h10 from graph 4.6 PSG Design
data book for 1000 rpm maximum speed of ball bearing is 175000 Hours. = 175000 200 L 10 = millions of revolutions.
C = (L10) (10/3) X

Pa

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C = (2100) (0.3) X 135 C = 1337.5 N. ≤ 10000N (Bearing 6204 is safe.) (PSG Design data book Pg. No. 4.13.) [19] 15 5.2

Physical System Modelling Figure.5.1 Actual Drawing The figure.5.1 shows the actual drawing of the model used in the
project. Different types of parts are mentioned in the below. Table No 5.1 Detailed Information of actual drawing The
names of the components used in the actual drawing are shown in the above table no.5.1. Sr. No Part Name 1 Stepper
Motor 2 Lead Screw 3 Die Holder 4 Die with Heater 5 Base plate 6 LED Display
16 5.3 Components of D-cut machine 5.3.1
Stepper Motor A stepper

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motor is a brushless DC electric motor that divides a full rotation into several equal steps. The

motor's

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position can be commanded to move and hold at one of these steps without any position sensor for feedback (an
open-loop controller), as long as the motor is correctly sized to the application in respect to torque and speed.
The stepper motor used is 24V DC

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motor. An electric motor is an electrical machine that converts electrical energy into mechanical energy. Figure.5.2
Stepper Motor. 5.3.2

Guideway Rod Linear Guideway is one of the important elements of the machine tool. Its main function is to make sure
that the machine tool element moves along a predetermined path. Guideway provides smooth and linear motion in
machine tools, due to which higher accuracy and precision can be obtained. Material of Guideway Rod As per the
application the material preferred for Guideway Rod was Mild Steel (MS). Figure.5.3 Guideway Rod.
17 5.3.3 Linear Ball Bearing Linear ball bearings provide linear movement in one direction. Linear bearings are used where
reducing friction and guiding linear motion is needed. Most linear-bearing suppliers offer selection guides that step the
user through the design problem. Considerations include the precision of the application, from lowbrow operations such
as drawer slides, to semi-precision operations such as saw guides, to exacting applications such as machine tools.
Bronze bushings might be appropriate where loads are high, smooth motion is required, but neither speed nor accuracy
is important. On the other hand, where loads are high and accuracy is necessary, a recirculating roller bearing and profile
rail might be the preferred choice. Figure.5.4 Linear Ball Bearing. 5.3.4 Single Phase Pin type Heater Single-phase
industrial heaters feature a two-wire alternating current (AC) power circuit. This type of power distribution system has a
power wire (or phase wire) and a neutral wire, with electric current flowing between the two of them. Figure.5.5 Single
Phase Pin type Heater.
18 Specification Dimensions 1) Diameter – 12MM 2) Length – 50mm Electrical Specification 1) Voltage – 230V 2)
Wattage – 125Watt Heater type – Nichrome heating element-based heater. The heater is a single-phase pin type of
230v. 5.3.5

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Lead Screw A leadscrew (or lead screw), also known as a power screw [1] or translation screw, [2] is a screw used as a
linkage in a machine, to translate turning motion into linear motion. Because of the large area of sliding contact
between their male and female members, screw threads have larger frictional energy losses compared to other
linkages. They are not typically used to carry high power, but more for intermittent use in low power actuator and
positioner mechanisms. Leadscrews are commonly used in linear actuators, machine slides (such as in machine tools),
vises, presses, and jacks. [3] Leadscrews are a common component in electric linear actuators.

Specification Pitch-1.5mm Diameter – 8mm Figure.5.6 Lead Screw.

19 5.3.6 Washer A washer is
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a thin plate (typically disk-shaped) with a hole (typically in the middle) that is normally used to distribute the load of a
threaded fastener such as a screw or nut. Other uses

are as a spacer, spring (wave washer), wear pad, preload indicating device, locking device, and to reduce

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vibration (rubber washer). Washers usually have an outer diameter (OD) about twice the width of their inner diameter
(ID).

Washers are usually metal or plastic. High quality bolted joints require hardened steel washers to prevent the loss of pre-
load due to Brinelling after the torque is applied. Rubber or fiber gaskets used in

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taps (or faucets, or valves) to stop the flow of water are sometimes

referred to colloquially as

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washers; but, while they may look similar, washers and gaskets are usually designed for different functions and made
differently. Washers are also important

for
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preventing galvanic corrosion, particularly by insulating steel screws from aluminum. Figure.5.7 Washer 5.3.7 Nut and
Bolt As nuts and bolts are not perfectly rigid, but stretch slightly under load, the distribution of stress on the threads is
not uniform. In fact, on a theoretically infinitely long bolt, the first thread takes a third of the load, the first three threads
take three-quarters of the load, and the first six threads take essentially the whole load. Beyond the first six threads, the
remaining threads are under essentially no load at all. Therefore, a nut or bolt with six threads acts very much like an
infinitely long nut or bolt. Figure5.8 Nut and Bolt 20 5.3.8

Frame The body frame is made of mild steel with specification of 15*15mm MS Square channel. The height of the frame
is 6 feet. The frame is the main component of the machine which supports the machine. Figure.5.9 Frame 5.1 Design
analysis 5.1.1 Stress Strain Deformation of base plate Figure.5.10 Cad Drawing of Base Plate The base plate was designed
in the ansys software and analysis was done on the base plate for determining the maximum loads and stress on the base
plate. The dimensions of base plate are 300 X 280mm
21 Figure.5.11 Total deformation Figure.5.12 Maximum Principal Stress of Base Plate Analysis of Base Plate Figure.5.13
Maximum principal strain analysis of Base Plate
22 The deformation and maximum principal stress analysis of the base plate was done on the Ansys software. This test
was conducted to determine the maximum stress, strain and deformation that occurs on the base plate. 5.1.2 Stress
Strain Analysis of Die Figure.5.14 Cad Drawing of Die The die was designed in the CAD software and analysis was done
on the die for determining the maximum loads and stress on the die. Figure.5.15 Total Deformation of Die Figure.5.16
Maximum Principal Stress Analysis of Die
23 Figure.5.17 Maximum principal Elastic Strain Analysis of Die The deformation and maximum principal stress analysis of
the die was done on the Ansys software. This test was conducted to determine the maximum stress, strain and
deformation that occurs on the die. 5.1.3 Thermal Analysis Figure.5.18 Temperature Analysis of Die Figure.5.19 Total Heat
Flux Analysis of Die Thermal Analysis of the die was done for determining the maximum temperature that the die can
sustain as shown in the figure 5.18 and 5.19 and the temperature that will be used for cutting the handle of the bags
precisely.
24 CHAPTER 6 PROJECT IMPLIMENTATION This Section Describes the Experimental setup, its working, Tools and
technology used in manufacturing of Automatic Heat Treatment Based D-cut Machine. 6.1 Experimental Setup Figure.6.1
Experimental Setup Figure.6.1 shows the actual experimental setup of D-cut machine. 6.1.1 Working of Automatic Heat
Treatment Based D-cut Machine Switch on the power supply button. After switching on the electric power supply, the
nichrome wire-based heater gets heated up to the desired temperature. The heater converts electricity into the form of
heat. The heater is reached to the desired temperature and controlled by the temperature controller as shown in the
figure 6.1. After this the heat is transferred to the die. The PP woven bags are placed on the base plate where the sensor
senses the bags is placed on the base plate then this information is sent to stepper motor through MCU and then lead
screw moves downside simultaneously die holder slides down through bearing and the bag gets cut as it is heat
sensitive. The sealing of pp woven material is occurred simultaneously the cutting makes the cut precise and accurate
which makes cut super strong and improves cut quality.
25 6.2 Modular testing 6.2.1 The bag is placed on base plate Figure.6.2 Placing of Bag When it displays place the bag on
the LCD display, The bag should be placed on the base plate as shown in figure 6.2 6.2.2 The process of cutting takes
place Figure.6.3 Cutting of Bag After placing the bag on base plate, the sensor senses the bag and process of cutting
takes place as shown in fig 6.3
26 6.2.3 D shape cut takes place Figure.6.4 Cutting of Handle Once the cutting process is done the D cut shape occurs
on the bag as per figure 6.4 6.3 Tools Used 6.3.1 Measuring and Marking All the dimensions of the body as well as other
components such as Base Plate, Body Frame, Guide Ways etc. All the dimensions were decided according to the design.
According to the decided dimensions marking was done on the raw material. All the dimensions were finalized and were
sent for cutting. Figure.6.5 Measuring and Marking
27 6.3.2 Cutting of Body The measured and marked dimensions of the project were sent for cutting. The body frame was
cut using cutting machine. The base plate was cut by the cut-off machine. The rectangular hollow sections used for
base plate were cut using cut-off machine. Figure.6.6 Cutting 6.3.3 Welding It is machine used to join two metals. In
following project, the welding used is arc welding. This welding is used to join the body frame and plate. Welding is a
common process for joining metals using a large variety of applications. The metals are heated to their melting point
while being shielded from the air, and then a filler metal is added to the heated area to produce a single piece of metal.
Figure.6.7 Welding
28 6.3.4 Grinding of Components The components after cutting as well as some errors in dimensions were reduced by
grinding. Grinding machine as well as hand grinder was used for removal of extra material. Some dimensions were
inaccurate so they were reduced using grinding machine. It was used to remove the extra welding material as well as
reduction of some dimensions of components. Figure.6.8 Grinding 6.3.5 Tool Used • Measuring tape - Used to measure
the dimensions of shaft, right angular body rods, fixtures. Figure.6.9 Measuring Tape
29 • Set-square – Used to set 90° angle between the body rods. Figure.6.10 Set Square • Spanner – Used for tightening
the nut and bolt. Figure.6.11 Spanner Set
30 • Hammer – Used for hammering and flattening components. Figure.6.12 Hammer • Screw Drivers – Used for fitting
screws. Figures.6.13 Screw Driver
31 6.4 COST ESTIMATION Table no. 6.1 Cost Estimation Sr. No Name Of the Material Specifications Quantity Cost Total 1
Body Frame Channels 15*15mm MS Square channels 6 feet 240 2 Sheet Metals 2mm Mild Steel 1.5S [Link] 400 3 Lead
screw 8mm ss Lead screw 1 840 4 Motor 24v, DC stepper Motor 1 650 5 Welding Rods 3mm Mild Steel welding rods 20
200 6 Cutting Wheels 110mm, Green 5 125 7 Linear Bearings 8mm linear bearings 2 340 8 Guideway rod 8mm, mild
steel 280 mm 120 9 Electric control panel box ---- ---- --- 1 0 Motor driver TB6600 Stepper motor driver 1 800 1 1
Heater 230v, Single phase pin type 1 650 1 2 Relay module 5v SPDT relay 1 230 1 3 PCB Board 4*7 cm, Single Side
Copper Clad PCB 3 60 1 4 ON/Off Switch 6 Amp, ON/OFF Type Switch 1 12 1 5 Connecting Wires [Link], Red &
Black Zinc Coated Copper Wire 10 Met er Roll 200 1 6 PVC Connectors 6Amp PVC Multi Pole Connector 1 Strip 22 1 7
Mains Power Cord [Link], 1.5 Meter, PVC 2 Pin Cord cable 1 60
32 Table 6.1Consist of the total cost estimation of machine 1 8 Fitting Screws and fasteners 3mm screw nuts with spacer
10 20 1 9 Mounting Board 1.5*1.5 feet, PVC Coated 3 mm Hardener Sheet Board 1 230 2 0 Miscellaneous Cable Ties
Insulation Tapes Shrink Sleeves Glue Sticks Color Oil Paint Solder Wire --- 400 Total 5399
33 CHAPTER 7 RESULT AND DISCUSSION This chapter contains the results for the various types of tests conducted on
the project. Different test results are calculated based on the various parameters. The performance parameters are also
included based on which the results are calculated. 7.1 Performance Parameter 1) Initiate the system variables and sensor
Pins. 2) Check input Sensor Value 3) Check and calibrate temperature. 4) If temperature is less than 220 degrees Celsius
the turn heater on else turn off 5) Display the process and press to start indication. 6) Display the values on the display. 7)
If object sensor detects the bag, then turn solenoid relay on which will give air inlet to the pneumatic cylinder. 7.1 Test
Results 7.2.1 Test – 1 (Test on single bag at a time) 1) Heating time – 20 Minutes 2) Testing temperature – 225-degree
Celsius for better quality finishing is set through the code 3) Cycle time = 3 Seconds / bag 4) Per minute bag cutting
capacity = 60/Time per bag = 60/3 = 20 Bags per minute Bags per Hour = Bags per minute * 60 Minutes = 20*60 =
1200 Bags Bags per day (10 hours working Shift) = Bags per hour * Total hours = 1200*10 = 12000 Bags per day
34 7.2.2 Test result 2 (Result on multiple bags a time 2 – 3 Bags) During this test result the cut is not achieved precisely
due to die temperature limitations and if temperature is exceeded then finishing and heater life will be compromised.
Electrical Energy economy Heater wattage = 500 Watts KW = 0.5 KW Energy consumption Units for 10 hours working =
KW*hr. = 0.5*10 = 5 Units per day Energy bill (Considering industrial unit rates Rs 7.5) = Units* Rates = 5*7.5 = 37.5 Rs per
day Approximate pay scale for labor per day = 400 Rs Total per day charges = 400+37.5 = 437.5 Per bag cutting charges
= 437.5 / 12000 0.0364 Rupees per bag (Economical for our sponsor company) 7.2.3 Conclusion of test results A total of
2 tests were conducted and results were concluded. The test was conducted to compare the results for the cutting of
bags precisely and accurately. The test on the bag was conducted twice, firstly one bag was cut and then 2-3 bags were
taken simultaneously. Firstly, only one bag was placed on the base plate and the cutting of the bag was done by the die
and the test results were taken. 1) From the first test result we concluded that the worker could make cut of the handle of
bag in very less time. This test result gave us a result that we can make 20 bags per minute with precision and accuracy.
This test was more productive and will be generally considered for the project. 2) The second test was conducted in
which 2-3 bag handles were cut simultaneously. During test result the cut is not achieved precisely due to die
temperature limitations and if temperature is exceeded then finishing and heater life is compromised. This test gave us
the result that cutting 2-3 bags simultaneously was not precise due to temperature
35 limitations and cuts were not accurate. The analysis of test 1 was that the handle of bag cut was more accurate, and
20 bags were cut per minute. Test 2 conducted gave us the result that the handle of the bags when cut simultaneously
did not gave accurate and precise results as compared to test 1.
36 CHAPTER 8 ADVANTAGES, DISADVANTAGES AND APPLICATIONS 8.1 Advantages: 1) Make in India
product/technology. 2) Only one operator for machine operation. 3) Low-cost machine. 4) Small compact size of the
machine. 5) Ease of transportation. 6) Higher productivity. 7) Energy efficient 8) Can be used for cutting of any kind of
packaging material 9) Die can be changed according to application 8.2 Disadvantages: 1) There is no any critical
limitation of this project except electricity cut. 2) Electricity cut can affect the production through the machine. 3)
Nichrome wire may get corroded or oxidized if operated in high humid atmosphere. 8.3 Application: 1) Packaging
product manufacturers 2) PP Woven bad manifesting unit 3) Small Gruha Udyog’s working related to bag packaging
making 4) Woven bag manufacturing firms 5) Packaging department/Production department
37 CHAPTER 9 CONCLUSION AND FUTURE SCOPE This project makes use of made in India technology which promotes
Indian machine development and manufacturing units. This kind of machines reduces the production cost to a very
great extent which makes the product competitive in consumer market and maximizes the profitability. This low-cost
machine will solve problem with manual process in small and medium scale industries and proves to be a very useful
innovation for all. This machine will be an extremely day to day useful machine for all things of packaging operations.
This machine is beneficial in terms of increased productivity and reduced cost of resources such as manpower and time
and money saving. Also, the cut pieces produced will be more precise and accurate to the dimensions as per the product
requirements. This energy and cost- effective cutting machine will be applicable at variety of applications and make use
of proper resources. This technology will help packaging industries. Future Scope 1) Safety – For operator safety we need
a safety curtain in automatic machine version. In semiautomatic version we need to instruct the operator for careful
usage 2) Scale – For proper centering the bag scale needed to be added to the foundation. 3) Heating time can be
reduced by adding higher capacity of heater and temperature sensor.

Hit and source - focused comparison, Side by Side

Submitted text As student entered the text in the submitted document.
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Mechanical Design In mechanical design the Mechanical design: In mechanical design the
components are listed down and stored on the basis of components are listed down and stored on the basis of
their procurement in two categories, 5.1.3 Designed Parts their procurement in two categories. ? Design parts ?

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already available in market. This simplifies the assembly as already available in the market. This makes the assembly
well as the post production and maintenance work. easier as well as the production and maintenance work.

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process charts are prepared and passed to manufacturing Process charts are prepared and transferred to the
stage. The parts to be purchased directly are selected production stage. Parts to be purchased directly are
from various catalogues and selected from various catalogs and

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the first stage selection of appropriate material for the the first phase the selection of suitable components for
part to be designed for specific application is the part to be designed for a specific use is

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Bearing selection: As shaft dia. – is 8mm so we have Bearing selection: As a shaft dia. - is 20mm so we prefer a
selected linear ball bearing having shaft outer dia. – foot board with an external shaft dia. - 20 mm. In the
[Link] selection of ball bearing the main governing selection of the ball bearing the main factor
factor

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Bhandari V. B., Design of machine elements, Third edition, Bhandari V.B.,Design of machine elements,eighteenth
MC Graw-hill Companies. edition, MC graw-hill companies,2003. [10]

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Equivalent dynamic load Pe = V×Fa×Ka = 1 X 90 X 1.5 Pe Equivalent dynamic load Pe = [Link] = 1 X 9.81 X 1.5 Pe =
= 135 N bearing life is, = L h10 from graph 4.6 PSG 14.715 N bearing life is, L¹⁰ = ℎ10 60 10⁶ Lh10 from graph
Design data book for 1000 rpm maximum speed of ball 4.6 PSG Design data book for 16000 rpm maximum
bearing is 175000 Hours. = 175000 200 L 10 = millions of speed of ball bearing is 315000 Hours. L10 = ⁶ L10 = 113.4
revolutions. C = (L10) (10/3) X millions of revolutions. L10 = ( )^(10/3) C = (L10)^(10/3) X

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C = (2100) (0.3) X 135 C = 1337.5 N. ≤ 10000N (Bearing C = X 14.715 C = 71.224 N. ≤ 1000 ( Bearing is safe) PSG
6204 is safe.) (PSG Design data book Pg. No. 4.13.) [19] 15 Design data book [Link]. 4.13.
5.2

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The Arduino Integrated Development Environment (IDE)

Is a cross-platform application (for Windows, macOS,
Linux) That is written in functions from C and C++. It is
used to write and upload programs to Arduino
compatible boards, but also, with the help of 3rd party
cores, other vendor development boards. 11

G5- 3 axis CNC machine black book [Link] (D164570885)

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motor is a brushless DC electric motor that divides a full

rotation into several equal steps. The

smart glass [Link] (D69360793)

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position can be commanded to move and hold at one of

these steps without any position sensor for feedback (an
open-loop controller), as long as the motor is correctly
sized to the application in respect to torque and speed.

smart glass [Link] (D69360793)

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Lead Screw A leadscrew (or lead screw), also known as a LEAD SCREW A leadscrew (or lead screw), also known as
power screw [1] or translation screw, [2] is a screw used a power screw or translation screw, is a screw used as a
as a linkage in a machine, to translate turning motion into linkage in a machine, to translate turning motion into
linear motion. Because of the large area of sliding contact linear motion. Because of the large area of sliding contact
between their male and female members, screw threads between their male and female members, screw threads
have larger frictional energy losses compared to other have larger frictional energy losses compared to other
linkages. They are not typically used to carry high power, linkages. They are not typically used to carry high power,
but more for intermittent use in low power actuator and but more for intermittent use in low power actuator and
positioner mechanisms. Leadscrews are commonly used positioner mechanisms. Leadscrews are commonly used
in linear actuators, machine slides (such as in machine in linear actuators, machine slides (such as in machine
tools), vises, presses, and jacks. [3] Leadscrews are a tools), vises, presses, and jacks. Leadscrews are a
common component in electric linear actuators. common component in electric linear actuators.

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motor. An electric motor is an electrical machine that

converts electrical energy into mechanical energy.
Figure.5.2 Stepper Motor. 5.3.2

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a thin plate (typically disk-shaped) with a hole (typically in a small plate (usually disk-shaped) with a hole (usually in
the middle) that is normally used to distribute the load of the middle) that is often used to distribute the load of a
a threaded fastener such as a screw or nut. Other uses cord binder such as a screw or nut. Other uses

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vibration (rubber washer). Washers usually have an outer vibration reduction (rubber washer) .Watchs usually have
diameter (OD) about twice the width of their inner an outer diameter (OD) about twice the width of their
diameter (ID). internal diameter (ID). ) .

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taps (or faucets, or valves) to stop the flow of water are taps (or taps, or valves) to stop the flow of water are
sometimes sometimes

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washers; but, while they may look similar, washers and washers; but, although they may look the same, washers
gaskets are usually designed for different functions and and gaskets are generally designed for different functions
made differently. Washers are also important and are made differently. Washers are also important

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preventing galvanic corrosion, particularly by insulating preventing galvanic corrosion, especially by insulating
steel screws from aluminum. Figure.5.7 Washer 5.3.7 Nut metal screws from the aluminum surface. Fig.5.9. Washer.
and Bolt As nuts and bolts are not perfectly rigid, but 5.10. Nut and Bolt: As nuts and bolts are not perfectly
stretch slightly under load, the distribution of stress on rigid, but stretch slightly under load, the distribution of
the threads is not uniform. In fact, on a theoretically stress on the threads is not uniform. In fact, on a
infinitely long bolt, the first thread takes a third of the theoretically infinitely long bolt, the first thread takes a
load, the first three threads take three-quarters of the third of the load, the first three threads take three-
load, and the first six threads take essentially the whole quarters of the load, and the first six threads take
load. Beyond the first six threads, the remaining threads essentially the whole load. Beyond the first six threads,
are under essentially no load at all. Therefore, a nut or the remaining threads are under essentially no load at all.
bolt with six threads acts very much like an infinitely long Therefore, a nut or bolt with six threads acts very much
nut or bolt. Figure5.8 Nut and Bolt 20 5.3.8 like an infinitely long nut or bolt. Fig.5.10. Nut and Bolt.

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