JITHIN S NAIR

SHINE RAJAN
LIJIN JOSE
MANU GOPINADH
SYNOPSIS
 Use of sledge hammer is essential in workshops and by blacksmiths
for forging and tempering operations, the sledge hammer will usually
be 4 kg weight and requires sufficient energy for its effective use. In
workshops and smithy shops the sledge hammering operation
requires a minimum of 2 persons and even with this much of labour
process cannot be continuous, because of the lack of skill on the part
of the person hammering, the quality of the job will suffer.
 The foot operated sledge hammer mechanism mainly consists of shaft,
and foot pedal is connected to the end of the shaft. Also, other end of
the shaft is connected by a crank, which transmits motion to the
connecting rod. The top end of the connecting rod is connected to the
hammer rod. The hammer rod is pivoted at the center of the small
shaft, in turn is supported by two bearing, suitable springs are used
for retracting the position of the hammer. Sufficient force at the
hammering point is obtained by suitable application of the foot lever.
 The mechanism is compact and a person can stand on the floor and
carry on the work of the forging without any necessity of another
person for hammering.
 
 
The Working Principle

A shaft is mounted in the journal bearings, which is a

self aligning pillow block. A pedal rod is welded to the
shaft. One end of the shaft is fixed to a crank by
welding. The crank is fastened to the connecting rod.
Connecting rod is fastened to the hammer rod.
When the force is applied on the pedal, the shaft
rotates (in the anticlockwise direction) as it is welded
to the pedal rod. The bearings permit support as well
as smooth rotation of the shaft and the support is
minimized. The crank converts the rotary motion of
the shaft into oscillating motion of the connecting rod.
Force applied on the pedal forces the connecting rod
in the downward direction and hence the hammer
rod moves down and the job, which is placed on the
anvil plate. Tension springs provided at the other end
of the hammer rod is elongated. When the force is
released from the pedal rod, the tension springs pull
the hammer rod to its original position and pedal
comes back to its own position.
The height of the pedal rod from the floor is
proportional to the height of hammer weight from the
anvil plate.
FABRICATION
Framework: The framework is made up of 10 no. of L –
angles. Which are butt – welded. The material of the L
– angles is mild steel (mild steel is a low carbon steel
with 0.25 to .035%)
Bearings: Pillow blocks self – aligning journal bearings
are used. Four bearings are fit to the framework with
of fasteners. Two bearings for main shaft and the
other two bearings for the hammer rod. Bearings are
EN8 (medium carbon series and wear resistant)
 
Anvil Plate: Anvil plate is welded to vertical
column and it is 10mm thick. It is used to place
the job over it. Anvil plate is made up of En 8.
Hammer: Hammer head of four kg made high
carbon steel is fixed to M S rod. The free end of
M S rod is connected to 2 tension springs for self
returning action.
Connecting Rod: It is made up of mild steel flat.
One end is fastened to hammer rod and other
end is connected to main shaft.
Main Shaft: It is made up of circular cross
section and is made up of En 8. It passed
through two Bearings
Pedal rod: It is made up of M S flat. One end is
welded to the shaft and the other end is foot
operated.
Springs: Tension springs are fixed to the fixed to
the end of hammer rod for self – returnable
action. Springs are made up of patented and coil
steel wire (unalloyed)
Why En 8 Material?
En series where EN stands for “Euro – Norm” were
found in Britain from Britain standards. En 8 is
economically available and is also a wear resistance.
This material is appropriate for fabrication work and
has the properties required.
 #Composition: C 0.35 - 0.45%; Si 0.05 - 0.35%; Mn 0.6
- 1.0%; S, P < 0.06%. In condition HR -> CD (thin);
Yield Stress x 10^6 Pa: 530; Tensile Stress ,MPa: 660;
Elongation %: 7.
Design of hammer rod
Let the weight of the hammer = 40N
By considering the height of falling , velocity of falling
We assume the impact factor =5
Equivalent static force =40*5=200N
Bending moment , M =200*475=9.5*10^3N-mm
Allowable stress, ‘σ’ allowable=M/Z ’
Yield stress , ‘σ’y=294n‘σ’/mm^2 (from data hand book table 5 page 6)
‘σ’allowable= ‘σ’y/fos=294/3=98n/mm^2
Section modulus, Z=M/‘σ’allowable
=9.5*10^3/98
=969.38N/mm^3
Z=970mm^3
Z=(3.14159d^3)/32
D=21.45 mm

Consider d= 25

To check the design

Now, f1*475=f2*200
f2=238N
Bending moment, M = 475*200
M=9.5*10^4N-mm

Moment of inertia ,I =3.14159d^4/64

=3.14159*25^4/64
=19175mm^2

Induced stress, ‘σ’induced=M/Z=9.5*10^4/970

=97.88N/mm^2
Yield stress ‘σ’y=294Mpa
‘σ’allowable=‘σ’y/fos=294/3
=98Mpa
‘σ’ind=‘σ’allowable
There fore, the design is safe
Design of connecting rod
The stress induced in the connecting rod
‘σ’ind=load/area
=238/400
=.595Mpa
‘σ’y=294Mpa
‘σ’allowable= ‘σ’y/fos=294/3
=98Mpa
‘σ’ind< ‘σ’allowable
The design is safe
Design of Spring
Load acting on the spring
200*475=200*f
f=475N

Deflection of the spring

tan Θ=270/475=0.568
Θ=29.61
tan Θ=Y/200
Y=.568*200
Y=113.6=114mm
Stiffness of the spring,s =load / deflection
=445/114 = 3.90Mpa
Assume spring index , c=8
λ=8fDK/(3.14159d^3) {table 20-22 pge 286}
Stress factor , K={4c-1/4c-4}+{.615/c}
K=1.184
λ=794.33Nmm^2(induced shear stress for
spring material)
794.33=(8*475*8*1.184)/(3.14159d^2)
d=3.7mm
D=8*3.7=29.6=30mm
ID=D-2d=23mm
Active number of coils, i=yGd^4/(8FD^3)
i=114*79.34*10^3*3.7^4/(8*475*30^3)
i=17coils
Free length lo=(i+n)*d+y+a
=(17+1)*3.7+114+1
lo=181.6mm
Specifications
1. Number of coils=17
2.Material= general purpose spring steel
3.coil dia=D=30mm
4.wire dia ,d=3.7mm
5.deflection,Y=114mm
6.modulus of rigidity,G =79.34*10^3Mpa
7.length of ther spring,lo=181.6mm
8.stiffness of the spring =s=3.90n/mm^2
Design of main
Taking moment about C
shaft
(238*75)+(150*205)-(RB*370)=0
RB=131.35N
RC+RB=238+150
RC=256.65N

Bending moments
Bending moment at, A =0
Bending moment at ,C=238*75=17850N-mm Bending
moment AT,D=131.35*165=21672.75N--mm
The maximum bending moment occurs at D,
M=15138.75N-mm
Twisting moment at point D ,
Mi=680*150=102000 N-mm
Assuming permeable shear stress ,λed=55Mpa
According to maximum shear stress theory ,
d=[ (16/ λmax){(KbMb)^2+(KtMt)^2}^0.5 ]^1/3
(from table 14-2 page 188)
d=[(16/55){2*21672.75)^2+(1.5*102000)^2}^0.5]^1/3
d=24.51=25mm
Design of pedal
Bending moment at , B =0
Bending moment at ,A =150*68
Ma=102000N-mm
‘σ’y=294Mpa
‘σ’allowable= ‘σ’y/fos=294/3
=98Mpa
Maximum bending moment occurs at a,
Section modulus
Z=M/ ‘σallowable
=102000/98
=1040.81mm^3
Section modulus for a rectangular crssection,
Z=bd^2/6
1040.81=b*25^2/6
d=9.999
d=10mm
According to our design ,
Mechanical advantage =load obtained/effort
=200/150
=1.3333