DESIGN AND FABRICATION

OF MECHANICAL
MULTIPURPOSE OPERATING
MACHINE
 BATCH NO:

ROLL NUMBER NAME OF THE STUDENT

22KN5A0365 P.PHANINDRA KUMAR
22KN5A0359 N.SAMPATH KUMAR
22KN5A0385 V.SRINIVAS RAO

Under the Guidence of

Mr.G.S.R.N.MALLESWARA RAO Sir, M.tech
 ABSTRACT
This project deals with the design, development and fabrication of
‘MULTIPURPOSE OPERATING MACHINE’. This machine performs multi
operations like Drilling, Grinding, Hacksaw cutting, Shaping. We have
individual machines in manufacturing industries to carry out individual
machining operations, which takes more space requirement, time and higher
investments. This multipurpose operating machine performs multi
operations in a single frame and reduces the time and give quick output. This
machine can be used for domestic purposes also with low man power. This
machine is going to be operated with the help of a scotch yoke mechanism
for shaping, Hacksaw cutting, gears for drilling and belt drive for
grinding. This machine is planned for both metal and wooden works.
 LITERATURE REVIEW
Some research papers which have led us to approach to the idea of a
machine which may give solution to all these factors are as follows:
● R. Vijayakumar et.al found that how to increase the productivity by
fabricating a Motorized Multipurpose machine that could perform four
machining operation (Drilling, Sawing (Using Hacksaw), Grinding &
Sheet Metal Cutting) at a time. The Bevel gear mechanism, Rack &
pinion mechanism were used in our project to make the Multi-
operations possible with a single input.

● Singh ankitkumar awadhesh et.al deal with design, development and

fabrication of “Multipurpose Mechanical Machine”. This machine is
designed for the purpose of multi operations. They are as follows:
1. Drilling, 2. Cutting, 3. Grinding & 4.Shaping
This machine perform multipurpose operation at same time
with required speed & this machine is automatic which is controlled or
operated by motor which is run with the help of current. This machine
is based on the mechanism of whit worth return and belt drive.
 INTRODUCTION
In this ever changing environment need for manufacturing of
products and higher rate is greatly enhanced by the market trend and
demand. Industries are basically meant for Production of useful goods and
services at low production cost, machinery cost and low inventory cost. In
an industry a considerable portion of investment is being made for
machinery installation. So in this project we have a proposed a machine
which can perform operations like drilling, grinding, cutting, shaping
simultaneously which implies that industrialist have not to pay for
machine performing above tasks individually for operating operation
simultaneously. The project focuses on fabrication of machine which can
be used to perform different operations required in small fabrication shops
in a single machine. This would not only cut down the cost of operations
of four machines but also the cost of setting up a fabrication shop.
 METHODOLOGY
In this project, we will give the power supply from the
electric motor to the compound shaft by pulley and belt drive
mechanism. From the compound shaft, three secondary shafts
(namely grinding shaft, drilling shaft, scotch yoke crankshafts)
are connected using secondary pulley-belt drives. A grinding
wheel is mounted on the grinding shaft. Two bevel gears at a
right angle to each other are mounted on a drill shaft to which a
drilling chunk having drill bit is being attached. One end of the
third shaft is being joined to a circular disc, through this circular
disc scotch yoke mechanism is being performed (rotary motion is
being converted to reciprocating motion). This reciprocatory
motion is utilized to connect shaper and hacksaw attachments.
PLANNING OF THE PROJECT
STUDY OF DIFFERENT MODELS

LINE DIAGRAM OF THE MACHINE

DESIGN OF THE MACHINE

PROCUREMENT OF MATERIALS

FABRICATION OF THE MACHINE

TESTING AND MODIFICATIONS

The following figure shows the sketch of the proposed
working model at the earlier stage
 DESIGN OF CAD MODEL
The following figures shows the 3d view, Top view
and Front view of the working model developed
from the layout using the mechanisms and
standard part dimensions .
Top View Front View
 WORKING PRINCIPLE

The arrangement has Bevel gears, electrical motors, long shaft, scotch

yoke mechanism, drilling and Grinding setup. The power is transmitted to the

compound shaft from the electrical motor Which is driven by the electric current.

From the compound shaft the power is transmitted to Drilling and Grinding shaft

by using Belt drives. For making drilling action, bevel gears are arranged at

another shaft to make the holes. The scotch yoke mechanism is placed on another

shaft by which the power is transmitted from drilling shaft. All the operations are

carried out by giving electric current to the motor. It coverts Electrical Energy into

Mechanical energy.Then the mechanical energy is transferred to the rotating shaft

 EXPERIMENTAL SETUP
• FRAME(L-Shape)
• BEVEL GEARS (2N)
• SCOTCH YOKE MECHANISM
• MOTOR (1HP)
• PULLEY(8N)
• BEARING (PILLO BLOCK)(10N)
• HACKSAW FRAME & BLADE(1N)
• GRINDING WHEEL(1N)
• DRILLING CHUCK(1N)
• DRILL TOOL(1N)
• SINGLE POINT CUTTING TOOL(1N)
• NUT & BOLTS (REQUIRED)
 ANGULAR FRAME

Angle Frame; The most common type of Steel Angles are

at a 90 degree angle. The legs of the “L” can be equal or unequal
in length. Mild Steel angles are used for various purposes in a
number of industries.
 C- CHANNEL

The structural channel, also known as a C-channel or Parallel

Flange Channel (PFC), is a type of (usually structural steel) beam, used
primarily in Commercial Industries, automotive manufacturing, Building
construction and civil engineering.
 Belt & Pulley drive
The most common systems for transmitting power from a drive
to a driven shaft are belt, gear, and chain drives. But V-belt drive systems,
also called friction drives (because power is transmitted because of the
belt's adherence to the pulley) are an economical option for industrial,
automotive, commercial, agricultural, and home appliance applications.
V-belt drives are also easy to install, require no lubrication, and dampen
shock load.
 BEVEL GEARS
Bevel gears are used as the main mechanism for a hand drill. As the
handle of the drill is turned in a vertical direction, the bevel gears change the
rotation of the chuck to a horizontal rotation. Bevel gears are also used as
speed reducers.Bevel gears are used most frequently for 90° drives, but other
angles can be used. The most typical application is driving a vertical pump
with a horizontal driver. Two major differences between bevel gears and spur
gears are their shape and the relation of the shafts on which they are
mounted.Bevel gears are power transmission components primarily used to
change the direction of shaft rotation and to decrease speed and increase
torque between non-parallel rotating shafts.
 SCOTCH YOKE MECHANISM
The Scotch yoke is a mechanism for converting the linear
motion of a slider into rotational motion or vice-versa. The piston
or other reciprocating part is directly coupled to a sliding yoke
with a slot that engages a pin on the rotating part. The shape of the
motion of the piston is a pure sine wave over time given a
constant rotational speed.The double slider crank mechanism is a
mechanism having two sliding pairs and two turning pairs. Scotch
yoke mechanism is formed when one of the two sliding pairs in a
double slider crank mechanism is fixed. It has got two turning
pairs, one sliding pair and a fixed link.
 MOTOR
The motor selected is a 1 horsepower 1 phase A.C. motor with
1450 RPM. The power of the motor is shared with one shaft from that
shaft the power is transferred into compound drive and then that power
is transferred to Grinding shaft between the compound drive shaft and
grinding shaft the power is transferred to scotch yoke mechanism shaft
and drilling shaft.
 PILLOW BLOCK BEARING
Bearings are used to help machines and objects rotate. They typically
consist of housing unit with a hole that supports a machine’s or object’s
shaft. The shaft is placed in the bearing’s hole where it’s able to easily
rotate. In turn, they reduce wear and tear on the connected machines
and objects. While all bearings consist of a housing unit that supports a
machine’s or object’s shaft, there are different types of them, including
pillow block bearings.A pillow block bearing consists of a mounting
bracket (pillow block) that houses a bearing and is used in low-
torque, light load applications.
 GRINDING WHEEL
A grinding wheel is a wheel composed of an abrasive compound and used for various
grinding (abrasive cutting) and abrasive machining operations. Such wheels are used
in machines. The wheels are generally made from a composite material consisting of
coarse-particle aggregate pressed and bonded together by a cementing matrix to form a
solid, circular shape. Various profiles and cross sections are available depending on the
intended usage for the wheel. They may also be made from a solid steel or aluminium
disc with particles bonded to the surface. Today most grinding wheels are artificial
composites made with artificial aggregates.
 DRILLING CHUCK
Drill Chucks are often connected to a machine's spindle
with a removable Drill Chuck Arbor. The arbor is simply a double-
ended shaft of steel, with one end machined to fit up into a
machine's spindle, and the other end machined to fit into the back
of a drill chuck. A second common type of machine has no
removable arbor: the chuck instead mounts directly onto a male
projection machined into the spindle itself.
SINGLE POINT CUTTING TOOL
Single point cutting tool consists of only one main cutting
edge that can perform material removal action at a time in a
single pass. It is to be noted that in insert based cutting tools,
multiple cutting edges may present in a single tool; however,
only one cutting edge can engage in material removal action
at a time.
 BENCH VICE
A vise, a common mechanical device that is used to hold a workpiece
stationary, is an integral tool in many woodworking, metalworking, and
other manufacturing applications. Bench vises (or workbench vice/vise), in
particular, attach directly to a workbench to hold the workpiece during
operations such as sawing, planing, and drilling. This article looks at the
different types of vises and breaks down the way vises work and what
materials are used to make them
 DRILLING OPERATION
Drilling is a cutting process that uses a drill bit to cut a hole
of circular cross-section in solid materials. The drill bit is usually
rotary cutting tool, often multi point. The bit is pressed against the
workpiece and rotated at rates from 150rpm to 1500 rpm. This forces
the cutting edges against the workpiece cutting of chips from the
hole as it is drill.

MECHANISM OF DRILLING:
The rotating edge of the drill exerts a large force on the workpiece
and the hole is generated. The removal of metal in a drilling
operation is by shearing and extrusion.
 GRINDING OPERATION
Grinding is an abrasive machining process that uses a
grinding wheel as the cutting tool. A Grinding wheel is an
expendable wheel used for various grinding and abrasive machining
operations. It is generally made from a matrix of coarse abrasive
particles pressed and bonded together to form a solid, circular
shapes. Each grain of abrasive on the wheel’s surface cuts asmall
chip from the workpiece via shear deformation.
 SHAPING OPERATION
Shaping machine is a reciprocating type of machine
designed for giving desired shapes to the surfaces hat may be
horizontal,vertical and flat. A shaping tool is used to cut in curve,
different angles, and many other shapes. A shaper is a type of
machine tool that uses linear relative motion between the wokpiece
and a single-point cutting tool to machine a linear toolpath. The
mechanism used in Shaping operation is Scotch Yoke mechanism.
 HACKSAW CUTTING OPERATION
A Hacksaw is a fine-toothed saw, originally and principally for cutting
metal. They can aslo cut various other materials such as plastic and wood.
The frames also be adjustable to accommodate blades of different sizes.
On hacksaws, with most frames saws,the blade can be mounted with the
teeth facing toward or away from the handle, resulting in a cutting action
on either push or pull stroke.The hacksaw was conected to one sie of the
scotch yoke. The scotch yoke was gives the reciprocating motion to the
hacksaw.
 DESIGN CALCULATIONS AND FORMULATION
Under no slip condition the velocity of the belt (Vb) connecting the driver and
driven pulley can be obtained using the formula [9],
Vb = π D1 N1 = π D2 N2
∴N1/N2=D2/D1
Speed of the compound shaft

Speed of the motor (Nm) = 1420 rpm

Diameter of the motor shaft(Dm) = 63.8 mm

Diameter of the compound shaft pulley (Dc) = 203.2 mm

Speed of the compound shaft (Nc) = ?

Nc/Nm = Dm/Dc

Nc = (Dm/Dc)Nm

Nc = (63.8/203.2)1420

Nc = 445.8 rpm
 Speed of the Grinding

Speed of the compound shaft (Nc) = 445.8rpm

Diameter of the compound shaft pulley (Dc) = 203.2mm

Speed of the Grinding shaft (Ng) = ?

Diameter of the Grinding pulley (Dg) = 101.6mm

Ng/Nc =Dc/Dg

Ng = (Dc/Dg)Nc

Ng = (203.2/101.6)445.8

Ng = 890 rpm
 Peripheral Velocity of Grinding
Radius of the Grinding wheel (Rg)=75mm

Angular velocity (⍵) = 2π*Ng/60

= 2*π*890/60

⍵ = 93.20rad/sec

Linear velocity (v) = ⍵*Rg

v = 93.20*75

v = 6.99m/sec

According to the grinding wheel specifications, the maximum speed of

30 m/s is allowed. Hence it is within safe limits.
 Speed of the Drilling
Speed of the compound shaft (Nc) = 445.8rpm

Diameter of the compound shaft pulley (Dc) = 152.4mm

Speed of the Drilling shaft (Nd) = ?

Diameter of the Drilling shaft pulley (Dd) = 254mm

Nd/Nc = Dc/Dd

Nd = (Dc/Dd)Nc

Nd = (152.4/254)445.8

Nd = 267rpm
 Speed of Drilling
Speed of the Drilling shaft (Nd) = 267 rpm

Gear Train used = Bevel gears

Tooth on the drive (Tp) = 10

Tooth on the driven (Tg) = 14

N/Nd = Tp/Tg

N = (10/14)267

N = 210 rpm

Therefore speed of the drill chuck = 210 rpm without any speed
adjustments
 Speed of Scotch Yoke shaft
Speed of the Drilling Shaft (Nd) = 267 rpm

Diameter of the Drilling shaft pulley (Dd) = 101.6 mm

Speed of the scotch yoke shaft (Ns) = ?

Diameter of the scotch yoke shaft pulley (Ds)= 254 mm

Ns/Nd =Dd/Ds

Ns = (Dd/Ds)Nd

Ns= (101.6/254)267

Ns = 107 rpm
 DESIGN OF SCOTCH YOKE

L = 2r
Where r = radius
Therefore, r = 82.5mm
Diameter of scotch disc D = 165 mm
Thickness of disc, Ts= 0.022mm to 0.033mm
Considering standard size available in the market Ts=5mm
Outer diameter of yoke pin=2.5*Ts=10mm
Length of yoke, L = 165 mm
Angular velocity of scotch disc(⍵) = 2π*Ng/60
(⍵) = 2π107/60
(⍵) = 11.2 rad/sec
Velocity of Hacksaw and shaping

For scotch yoke mechanism one stroke is completed in one revolution of

disc K=1
Stroke length of scotch yoke mechanism L=2r
Radius r=80mm
Therefore we know that velocity of cutting mechanism(Vc)
Vc=[(L*Ns*(1+K))/1000]m/min
Vc=[(160*107*2)/1000]m/min
Vc=34.24m/min
Therefore, velocity of the cutting machine after substituting in the above
equation. Vc=34.24 m/min.
 Cost of Estimation
S. No. Component Name Quantity Estimation Cost

1 MOTOR (1HP,1420 rpm) 1 3500/-

2 ROLLER BEARINGS 10 1500/-

3 V PULLEY, V BELTS 8,4 2700/-

4 BEVEL GEARS 2 400/-

5 BENCH VICE 2 600/-

6 GRINDING WHEEL 1 800/-

7 SHAFTS AND FRAMES 4 800 + 2700 /-

8 HACKSAW FRAM, BLADE 1 250/-

9 SHAPING HOLDER AND TOOL 1 350/-

10 DRILL BIT AND CHUCK 1 350/-

11 SCOTCH YOKE LINKS 1 1000/-

12 NUTS AND BOLTS 300/-

13 FABRICATION PROCESS 3500/-

14 FINISHING WORK (PAINT, GREASE) 400/-

15 MISCELLANEOUS 2000/-

TOTAL AMOUNT (RUPEES) 21,150/-

 ADVANTAGES
1. Multi operations are performed at one time.
2. Our machine is used in return stroke
mechanism also.
3. All operations are performed in a single
motor.
4. Size is compact therefore it requires less
space.
5. Time saving.
6. Less manpower is required.
7. Low manufacturing and maintenance costs.
 DISADVANTAGES

1. In shaping setup there is no clapper Box placed

and can be implemented later.
2. Noisy Operation
Final Output of the Project
 FUTURE SCOPE
1. We can perform various operations like cutting,
drilling, and shaping individually by introducing
coupling between them.
2. We can perform grinding operations by introducing a
grinding tool on the main shaft.
3. We can perform boring operations by introducing a
boring tool by replacing the drilling tool setup.
4. We can change the motor speed by the voltage
regulator.
Thank you