Professional Documents
Culture Documents
PROJECT REPORT
ON
SUBMITTED BY
---------------------------------------------------------------PRINCIPAL
--------------
HOD
PROF. ---------------------
PROJ. GUIDE
PROF. -------------
POLYTECHNIC
YEAR 2007-2008
ACKNOWLEDGEMENT
are
also
grateful
for
the
co-operation,
valuable
THANKS
---------------------
INDEX
Page.N
o
1
2
3
4
5
6
7
8
9
10
11
12
13
14
Page
No.
15
CHAPTER NO1
ABSTRACT
REGENERATIVE SHOCK ABSORBER
electricity. The regenerative shock absorbers can harvest the power in a continuous
way. On the smooth highway road, the regenerative shock absorbers can improve
the fuel efficiency by 2%, and on bumpy roads up to 10% increase can be
expected.
column
Support
Base
CHAPTER-02
THE SCOPE FOR PROJECT
CHAPTER-03
SELECTION OF PROJECT
We the group of young engineers found that, there is an impending need to make
much more forays to make Non Conventional energy attain popular acclaim. This is
also very essential to preserve the conventional sources of energy and explore
viable alternatives like sustainable energy (the energy which we are already utilizing
but for some safety of other uses we are suddenly wasting it, that can be reutilized),
solar, wind and biomass that can enhance sustainable growth. What is more, such
alternatives are environment friendly and easily replenish able. Therefore, they
need to be thoroughly exploited with a functionally expedient, energy matrix mix.
The engineer is constantly conformed to the challenges of bringing ideas and design
into reality. New machines and techniques are being developed continuously to
manufacture various products at cheaper rates and high quality.
Growing economies, especially of Asia are gifted with sufficient resource base and
non-conventional energy technologies are consistent both for grid linked energy
generation and transmission in out of the way locales that are islanded from the
grid. Adaptation of technology and employing them should be pursued right from
this moment to have a head start, be informed of the barriers in technology
applications of the renewable variety and synergizing them with the existing,
traditional power production technology and T&D networks. It is known that in
coming times, wind energy will be the most cost-effective renewable resource. Yet,
it is doubtful if any individual technology would hold centre-stage.
Thus we selected kinetic generator means the Energy in motion when it is
suddenly applied with a sort of obstacle, then according to Newtons law
for every action there is an equal and opposite reaction. Utilization of this
reaction is the basic reason behind the selection of this project work.
CHAPTER-04
INTRODUCTION TO NON CONVENTIONAL ENERGY
The development planning process designs strategies and activities to use, enhance
or conserve both natural and economic goods and services. In big modern cities,
economic goods and services almost completely replace the natural ones.
Energy is the prime source of all socio-economic activities of the human community.
The demographic rate of growth globally and the widening spectrum of economic
growth would result in demands of energy at an incremental rate of 7 to 8%
annually. This can easily support a GDP growth of 8 to 9% per annum. Projections
point toward a doubling of global energy demands in the decade starting 2020.
There will be a marked shift in patterns of energy consumption whereby developing
economies of the world would have a share exceeding two-third of global energy
consumption by that period.
Fossil fuels' consumption would remain the major source of energy generation and
globally employed power generation technologies. The apportionment of renewable
energy in the entire energy supply will continue to be marginal in the real sense.
The contribution of renewable energy-excepting hydel energy and conventional
mills. There is substantial leverage as regards to deducing energy from urban and
industrial wastes. The National Programmed lays special emphasis on supplying
energy to rural areas. Close to 2.75 million biogas plants and over 28 million
upgraded wood-stoves are also in use in the country.
In the sphere of solar energy use, solar photovoltaic and solar thermal technologies
are gaining immediate reception for a host of industrial and commercial
applications, as well as in Non Electrified and Rural Zones (NERZ). The country has
the world's largest assemblage of solar photovoltaic, consisting of about 500,000 PV
systems totaling to 39 MW, and encompassing over 30 variegated operations.
There is an added emphasis on venturing into grid quality power generation
Programmed oriented on solar thermal and solar photovoltaic technologies. A 140
MW Integrated Solar Combined Cycle (ISCC) Power Project is being accorded
conclusive shape to be established at Mathania near Jodhpur in Rajasthan. This will
be the first of its kind, and the largest such project in the world.
To give a fillip to power generation from renewable energy, State Governments and
utilities provide remunerative power purchase agreements and arrangements for
wheeling, banking and buy back of power. 12 States have so far announced policies
for non-conventional energy based power generation. The Indian Renewable Energy
Development Agency (IREDA), the corporate financing arm of the Ministry, is the
only Agency of its kind in the world dedicated to financing of renewable energy
projects. Interest rates vary from 0% to 16%, with special rates being offered for
projects.
There is an impending need to make much more forays to make Non Conventional
energy attain popular acclaim.
conventional sources of energy and explore viable alternatives like solar, wind and
biomass that can enhance sustainable growth. What is more, such alternatives are
environment friendly and easily replenish able.
The immediate
challenge is to reconcile the reduced budgetary allocations in the 9th Plan due to
fiscal control.
propping up 24,000 MW from Renewable and Non Conventional Energy by the year
2012.
The need is however to have adequate policy framework to be in place with an aim
to provide impetus through streamlining the structure of Renewable and Non
Conventional Energy. The high potential is what should spur maximum efforts. The
bottlenecks are that although there are good plans, we often fall short in measuring
up to meet the desired levels of optimization of our potential. If there is a strict
regiment by which Renewable and Non Conventional Energy Sources are utilized,
India is sure to have adequate measure of success. The Numero Uno position in
Renewable and Non Conventional Energy is well within reach with a little bit of
concerted effort.
CHAPTER -05
WORKING OF PROJECT
Here first important point is how we get reciprocating motion, which is prime input
in the system. For that we use weight of moving vehicles that run on roads. We put
our mechanism on bike suspension, the head of rack with pinion. When vehicles
move on speed breaker rack will be reciprocate. The rack is attached with pinion
that rotates in one direction only. The rack & pinion arrangement convert
reciprocating motion in to rotary motion.
This rotary motion is further magnified using chain drive. The output of free wheel is
attached with flywheel which stores kinetic energy and transfer to dynamo which
generate electricity with zero cost.
A "generator" and "motor" is essentially the same thing: what you call it depends on
whether electricity is going into the unit or coming out of it. A generator produces
electricity. In a generator, something causes the shaft and armature to spin. An
electric current is generated, as shown in the picture (lightning bolt).Lots of things
can be used to make a shaft spin - a pinwheel, a crank, a bicycle, a water wheel, a
diesel engine, or even a jet engine. They're of different sizes but it's the same
general idea. It doesn't matter what's used to spin the shaft - the electricity that's
produced is the same.
CHAPTER-06
METHODOLOGY
The set up is tested for checking whether it performing its intended task or
not.
Under this method the fly wheel is the key component for energy
transformation.
Flywheel
Introduction
Flywheel is a device to smoothen the cyclic fluctuation of speed change when
delivering constant output power from the engine. It has no influence on the mere
speed of the prime mover. It has no influence on the varying load demand on the
prime mover or the delivered power from the prime mover. In is the forgoing
discussion, it is observed that turning moment diagrams for the cycle show period
during which torque is in excess of the mean torque responsible for the constant
power output and also periods during which the torque is less than the mean
torque. Thus the speed of the flywheel would increase during period of excess of
torque during the cycle and the speed will fall during the period of the deficit torque
during the cycle. Thus a flywheel stores energy and releases energy during the
cycle without affecting mean energy output. Thus a properly designed flywheel has
to ensure the cyclic fluctuations of speed within prescribed limits preferably as small
as possible.
Definition of the flywheel:A flywheel used in machine serves as a reservoir which stores energy during the
period when the supply of energy is more than the requirement and releases it
during the period when the requirement of energy is more than the supply.
Working of the flywheel:The excess energy is developed during power stroke is absorbed by flywheel and
releases it to the crankshaft during the other stroke in which no energy is
developed, thus rotating the crankshaft at a uniform speed. A little consideration
will show that when the flywheel absorbs energy, its speed increases and when it
releases energy, the speed decreases. Hence a flywheel does not maintain a
constant speed; it simply reduces the fluctuation of speed. In other words, a
flywheel controls the speed variations caused by the fluctuation of the engine
turning moment during each cycle of operation.
Application:Flywheel are mostly used in machine where the operation is intermitted like
punching machines, shearing machines, riveting machines, crushers etc, the
flywheel stores energy from the power source during the greater portion of the
operating cycle and gives it up during a small period of the cycle. Thus the energy
from power source to the machines is supplied practically at a constant rate
throughout the operation.
column
Support
Base
CHAPTER-07
LITERATURE SURVEY
WHAT IS ELECTRICITY?
Electricity is a form of energy. Electricity is the flow of electrons. All matter is made
up of atoms, and an atom has a center, called a nucleus. The nucleus contains
positively charged particles called protons and uncharged particles called neutrons.
The nucleus of an atom is surrounded by negatively charged particles called
electrons. The negative charge of an electron is equal to the positive charge of a
proton, and the number of electrons in an atom is usually equal to the number of
protons. When the balancing force between protons and electrons is upset by an
outside force, an atom may gain or lose an electron. When electrons are "lost" from
an atom, the free movement of these electrons constitutes an electric current.
Electricity is a basic part of nature and it is one of our most widely used forms of
energy. We get electricity, which is a secondary energy source, from the conversion
of other sources of energy, like coal, natural gas, oil, nuclear power and other
natural sources, which are called primary sources. Many cities and towns were built
alongside waterfalls (a primary source of mechanical energy) that turned water
wheels to perform work. Before electricity generation began slightly over 100 years
ago, houses were lit with kerosene lamps, food was cooled in iceboxes, and rooms
were warmed by wood-burning or coal-burning stoves. Beginning with Benjamin
Franklin's experiment with a kite one stormy night in Philadelphia, the principles of
electricity gradually became understood. In the mid-1800s, Thomas Edison changed
everyone's life -- he perfected his invention -- the electric light bulb. Prior to 1879,
electricity had been used in arc lights for outdoor lighting. Edison's invention used
electricity to bring indoor lighting to our homes.
HOW ELECTRICITY IS MADE?
Electricity can be made or generated by moving a wire (conductor) through a
magnetic field.
The amount of pressure or voltage depends on the strength and position of the
magnetic field relative to the coil, as well as the speed at which the coil is turning.
As the amount of electricity changes so does its voltage.
FIG 5(d)
FIG 5(e)
In the diagram above, the coil of wire is rotating in a clockwise direction. When the
coil of wire is in the horizontal position 1the voltage is greatest (diagram 4) because
the coil is passing through the strongest part of the magnetic field. At this stage the
current flows from 1 to 2 to 3 to 4, out through terminal A, through the globe and
back into terminal a. When the coil of wire is in the vertical position (2), no
electricity is produced because the coil does not cut the magnetic field, and no
current flows. When the coil of wire is in the horizontal position again 3 the voltage
is at its maximum (3), however the current flows in the opposite direction 4 to 3 to 2
to 1, out through terminal a, through the globe, and back into terminal A.
The current produced changes direction every half turn (180 degrees). This is called
alternating current or AC. The generators at large power stations produce nearly all
the electricity we use in this way.
IMPORTANCE OF SYSTEM
This system very suitable for our country because we have wide range of road.
State/UT
(sq.km) (million)
(per
100
(per 1 million
sq.km)
of population)
A & N Islands
1224
8249
Andhra Pradesh
172669
15
3497
27506
73
8
63
2354
83743 1
12
9394
Assam
68079
78438 25
87
2693
Bihar
85565
17387
95
7
49
898
Chandigarh
1723
114
1511
2127
D & N Haveli
518
491
105
3047
Delhi
26582
1483
13
1792
2132
Goa
7457
3814
196
5108
Gujarat
133850
19602
46
4
68
2883
Haryana
27907
44212 19
63
1467
55673 6
53
4753
J&K
13042
22223
9
6
1408
Karnataka
142754
19179
50
1
74
2839
Kerala
141856
38863 32
365
4509
Madhya Pradesh
198936
44344
76
6
45
2617
Maharashtra
359262
30769
88
0
117
4070
Manipur
10760
22327 2
48
4678
Meghalaya
8391
22429 2
37
3780
Mizoram
6910
21081 1
33
7943
Nagaland
13732
16579 2
83
8975
Orissa
210238
15570
35
7
135
6015
Pondicherry
2343
495
473
2320
Punjab
58151
50362 23
115
2550
Rajasthan
134632
34223
51
9
39
2638
Sikkim
1834
7096
26
3596
Tamil Nadu
205706
13005
60
8
158
3412
Tripura
14726
10486 4
140
4256
Uttar Pradesh
237358
29441
161
1
81
1477
West Bengal
77579
88752 76
87
1019
CHAPTER 8
MATERIAL SELECTION
The proper selection of material for the different part of a machine is the main
objective in the fabrication of machine. For a design engineer it is must that he be
familiar with the effect, which the manufacturing process and heat treatment have
on the properties of materials. The Choice of material for engineering purposes
depends upon the following factors:
1. Availability of the materials.
2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.
The mechanical properties of the metals are those, which are associated with the
ability of the material to resist mechanical forces and load. We shall now discuss
these properties as follows:
1. Strength : It is the ability of a material to resist the externally applied forces
2. Stress: Without breaking or yielding. The internal resistance offered by a
part to an externally applied force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses.
The modules of elasticity of the measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape after
deformation when the external forces are removed. This property is desirable
for material used in tools and machines. It may be noted that steel is more
elastic than rubber.
5. Plasticity: It is the property of a material, which retain the deformation
produced under load permanently. This property of material is necessary for
forging, in stamping images on coins and in ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire
with the application of a tensile force. A ductile material must be both strong
and plastic. The ductility is usually measured by the terms, percentage
temperature for long period of time, it will undergo a slow and permanent
deformation called creep. This property is considered in designing internal
combustion engines, boilers and turbines.
12.
Share scaleroscope.
1. Energy transmitted
2. Weight of machine
3. Frictional resistance
4. Inertia of reciprocating parts
5. Change of temperature
6. Lack of balance of moving parts
The selection of the materials depends upon the various types of stresses that are
set up during operation. The material selected should with stand it. Other criteria for
selection of metal depend upon the type of load because a machine part resist load
more easily than a live load and live load more easily than a shock load.
Selection of the material depends upon factor of safety, which in turn depends upon
the following factors.
1. Reliabilities of properties
2. Reliability of applied load
3. The certainty as to exact mode of failure
4. The extent of simplifying assumptions
5. The extent of localized
6. The extent of initial stresses set up during manufacturing
BRIGHT MATERIAL:
It is a machine drawned. The main basic difference between mild steel and bright
metal is that mild steel plates and bars are forged in the forging machine by means
is not forged. But the materials are drawn from the dies in the plastic state.
Therefore the material has good surface finish than mild steel and has no carbon
deposits on its surface for extrusion and formation of engineering materials thus
giving them a good surface finish and though retaining their metallic properties
BILL OF MATERIAL
SR NO
PART NAME
MATERIA
L
QTY
FRAME
MS
40kg
FLYWHEEL
MS
15kg
SHAFT
EN8
BIG SPROKET
MS
SMALL SPROKET
MS
DYNAMO
STD
BELT
------
CHAIN
BIKE SUSPENSION
STD
10
RACK
MS
11
HANDEL
MS
12
STD
12
13
SUPPORT
MS
14
FREE WHEEL
STD
15
WELDING ROD
5 /pcs
25
16
COLOUR
300/lit
0.75 lit
CHAPTER 9
COST ESTIMATION
The machine tool designer must furnish the management with an idea of how
much tooling will cost, and how much money the productions methods save over a
specified run. This information is generally furnished in a form of cost worksheets.
By referring to the cost worksheets the final cost of machine is calculated.
Cost estimation is defined as the process of forecasting expenses that are
incurred to manufacture a product.
expenditure involved in designing and manufacturing with all the related service
facilities such as material handling, heat treatment and surface coating, as well as
portion of general administrative and selling costs.
ELEMENTS OF COST ENCOUNTERED IN THE PROJECT:The cost encountered in this project is material cost, labour cost, cost of standard
parts, designing cost and cost of indirect expenses.
1) DESIGN COST:The designing cost is calculated by considering the amount taken by the designer (if
so) and the cost of designing material.
2) MATERIAL COST:The material cost can be calculated by finding the total volume of the material used
and the weight of the material.
While calculation the volume the triangle shaped parts and the T shaped
parts are considering as rectangular or square plates.
The weight of the parts is calculation by multiplying the total volume and the
density of the material (M.S.) which is equal to 7.76665x10 3 Kg/Cc.
The total cost can be obtained by multiplying the total weight by the rate of
material.
PART NAME
RATE
QTY
TOTAL
FRAME
50/ kg
40kg
2000
FLYWHEEL
50/ kg
15kg
750
SHAFT
150
300
BIG SPROKET
20/teet
h
24teeth
480
FREE WHEEL
100
100
DYNAMO
600
600
BELT
125
125
CHAIN
350
350
BIKE SUSPENSION
1500
1500
800
800
10
RACK
11
HANDEL
45/kg
2 KG
90
12
--------
-------
200
13
SUPPORT
----------
450
14
WELDING ROD
10 /pcs
25
250
15
COLOUR
300/lit
1 lit
300
TOTAL
SR. NO.
1.
2.
3.
4.
5.
6.
7.
OPERATION
HOURS
RATE /
LABOUR
AMOUNT
Turning
10
150
1500
Milling
150
300
Drilling
100
700
Welding
16
175
2800
Grinding
60
180
Tapping
40
120
Cutting
40
320
8.
9.
10.
Gas cutting
50
400
Assembly
100
200
Painting
100
200
TOTAL
6720/-
INDIRECT COST
Transportation cost = 500/Coolent & lubricant = 100/Drawing cost = 500/Project report cost = 2000/TOTAL INDIRECT COST = 2100/-
TOTAL COST
Raw Material Cost + STD Parts Cost + Direct Labor Cost +Indirect Cost
Total cost of project = A + B +C
Total cost of project = --------- /-
CHAPTER NO 10
MACHINE DESIGN
Rigid Members: The entire structure or parts of the structure are considered
by members that can deform, but in limited ways. Examples of this members
trusses, beams and plates.
3
In selecting a model of the structure, the designer also must consider type of
analysis
to be performed. Four typical analysis that designers perform are :
The subject of MACHINE DESIGN deals with the art of designing machine of
structure. A machine is a combination of resistance bodies with successfully
constrained relative motions which is used for transforming other forms of energy
into mechanical energy or transmitting and modifying available design is to create
new and better machines or structures and improving the existing ones such that it
will convert and control motions either with or without transmitting power. It is the
practical application of machinery to the design and construction of machine and
structure. In order to design simple component satisfactorily, a sound knowledge of
applied science is essential. In addition, strength and properties of materials
including some metrological are of prime importance. Knowledge of theory of
machine and other branch of applied mechanics is also required in order to know
the velocity. Acceleration and inertia force of the various links in motion, mechanics
of machinery involve the design.
CONCEPT IN M.D.P.
ii)
Motion of the parts and kinematics of machine. This deals with the
type of motion i.e. reciprocating . Rotary and oscillatory.
iii)
iv)
v)
vi)
vii)
viii)
ix)
x)
ii)
iii)
iv)
Selection of material.
v)
vi)
vii)
viii)
Design of Rack
Design load
500kg
500 x 9.81
4905 N
Selecting Material as C 45
y =
360 N / mm
F.O.S. =
c =
2
360 / 2
c =
180 N / mm
5 x c
=
0.5 x 180 N / mm
90 N / mm
= F/A
= 4905 / (20 x 5) N / mm
= 49.05 N / mm
1) Speed of Pinion
34 RPM (MEASURED)
2.4
= T1 = 18
T1 x T.R
18 x 2.4
43.2 = 44 TEETH
34 RPM
34 x 2.4 RPM
81.6 RPM
FxR
=
T1
4905 x 25
=
122.63 x 10 N-mm
360 N / mm
2
c =
360 / 2
c =
180 N / mm
5 x c
=
0.5 x 180 N / mm
90 N / mm
( / 16) x d x
122.63 x 10
( / 16) x d x 90
19.07 mm
For 20 mm dia shaft we select pedestal bearing from design data book =
P204
Design of Flywheel
Dia of FLYWHEEL
_________________________
N (dynamo)
=
__________________
N (Flywheel)
D (flywheel)
500
___________
_____________
50
85
D (flywheel)
294 mm
100
FLYWHEEL
FREEWHE
EL
DIA=300m
m
SHAFT
We know
E = I Kw 2
I = m X k2
m=XV
V = (3.14 x d2 x t ) / 4
V = (3.14 x 302 x 10 ) / 4
V = 7065 cm3
m = 0.00078 X 7065
m = 5.5 kg
k2 = D2/8
k2 = 3002/8
k = 106mm
Kw = (1 - 2) /
= 2 x 3.14 x N / 60
= 2 x 3.14 x 85 / 60
= 8.90 rad/sec
1 = 9.9 rad/sec
2 = 7.9 rad/sec
Kw = 0.224
E = I Kw 2
E = 12.2 watt
For this transmission ratio number of teeth on pinion sprocket is in the range of 21 to 17 , so we
select number of teeth on pinion sprocket as 18 teeth.
So , Z1 = 18 teeth
SELECTION OF PITCH OF SPROCKET
The pitch is decided on the basis of RPM of sprocket.
RPM of big sprocket is variable in normal condition it is = 34 rpm
For this rpm value we select pitch of sprocket as 12.7mm from table.
P = 12.7mm
Where C =
Dc1 + Dc2
2
C =
60 + 200
2
C = 130 mm
MINIMUM CENTER DISTANCE = 130 + (30 to 50 mm )
MINIMUM CENTER DISTANCE = 180 mm
Due to size of system restriction we select center distance = 400 mm
CALCULATION OF MODULE
We know module m = ( ( Z1-Z2 ) / 2 * 3.14 )2
We know module m = ( ( 44-18) / 2 * 3.14 )2
m = 17.14 mm
CALCULATION OF VALUES OF CONSTANTS K1 K2 K3 K4 K5 K6
Load factor K1 = 1.25 ( Load with mild shock )
= 2.9 rad
we know that,
T1/T2 = e
T1/T2 = e0.35 x 2.9
T1 = 1.1 T2
We have,
T = ( T1 T2 ) X R
98000= ( 1.1 T2 T2 ) X 100
T2 = 9800 N
T1 = 1.1 X 9800
T1 = 10780 N
So tension in tight side = 10780 N
Where ,
N = rpm of small sprocket
Q = minimum breaking load of chain
V = chain velocity
.n = allowable factor of safety
Ks = K1*K2*K3*K4*K5*K6
Q = 350*75*8.55*1.875 / 0.1
Q = 4208203.125 kgf
Q = 41.28 * 106 N
As minimum load bearing capacity is much more than applied load so design of chain is safe.
Design of bolt:Bolt is to be fastened tightly also it will take load due to rotation. Stress for C-25 steel ft =420
kg/cm2 . Std nominal diameter of bolt is 10mm. From table in design data book, diameter
corresponding to M12 bolt is 8.160mm
Let us check the strength :Also initial tension in the bolt when belt is fully tightened.
P = 2.5 kg is the value of force for belt
P = 2.5 kg Being the four bolts the load is shared as
P= p/4 =6.25 N.
Also, P = /4 dc2x ft
6.25 x 4
ft = ------------------------------ = 0.078 N / mm 2
3.14 x ( 12 x 0.84)2
the calculated ft is less than the maximum ft hence our design is safe.
CHAPTER- 11
MANUFACTURING
The process of conversion of raw material in to finished products using the three
resources as Man, machine and finished sub-components. Manufacturing is the term
by which we transform resource inputs to create Useful goods and services as
outputs. Manufacturing can also be said as an intentional act of producing
something useful. The transformation process is shown belowINPUT
Conventional process
OUTPUT
Element
Transformation
Useful product
Material
Machines
Products
Data
Interpretation
Knowledge
SR.NO.
DETAIL OPER.
1.
Marking on
M/C. USED
TOOL USED
ACCES
MEA.INST.
Scale
shaft
2.
3.
4.
Cutting as per
Power
Hock saw
Jig &
dwg
hack saw
blade
fixtures
Facing both
Lathe
Single point
Chuck
side of shaft
machine
cutting tool
Turning as per
Scale
Vernier
caliper
dwg size
5.
Filling on both
end
COMPONENT: FRAME
MATERIAL: - M.S. ANGLE
QUANTITY: -1
Flat file
Vice
SR.
DESCRIPTION
MACHINE
CUTTING
MEASUREMENT
TIME
NO
OF OPERATION
USED
Cutting the
Gas
Gas
Steel rule
15min.
angle in to
cutting
cutter
length as per
machine
Steel rule
15min.
File
Try square
15 min.
-------
Try square
20 min
Twist drill
Vernier calliper
10 min.
dwg
2
Cutting the
Gas
Gas
angle in to
cutting
cutter
number of
machine
piece as per
dwg
3
Filing
operation can
be performed
on cutting
Bench
vice
Weld the
Electric
angles to the
arc
required size
welding
as per the
machine
drawing
5
Drilling the
Radial drill
frame at
machine
required
points as per
the drawing.
COMPONENT: GEAR
MATERIAL: - M.S
QUANTITY: -1
SR.
NO
DESCRIPTION
MACHINE
CUTTING
MEASUREMENT
TIME
OF
USED
------
----------
-------------
---------
Lathe
Single
Vernier caliper
15 min.
of hub portion
machine
point
Vernier caliper
20 min.
Vernier calliper
10 min.
----------------
5 min.
OPERATION
1
Take standard
gear as per
design
cutting
tool
3
Hold it in
Lathe
Single
three jaw
machine
point
cutting
inner dia as
tool
Slotting
Single
as per dwg
machine
point
cutting
tool
Filling burrs
Flat fill
---------
COMPONENT: PULLEY
MATERIAL: - pvc
QUANTITY: -1
SR.
DESCRIPTION
MACHINE
CUTTING
MEASUREMENT
TIME
NO
OF OPERATION
USED
Take standard
------
----------
-------------
---------
Lathe
Single
Vernier caliper
15 min.
of hub portion
machine
point
Vernier caliper
20 min.
Twist drill
Vernier calliper
10 min.
Tap
Vernier calliper
10 min.
pulley as per
design
2
cutting
tool
3
Hold it in
Lathe
Single
three jaw
machine
point
cutting
inner dia as
tool
Drilling the
Radial drill
hub at
machine
required
points as per
the drawing
5
Hand tap
drill area.
set
COMPONENT: RACK
MATERIAL: - M.S
QUANTITY: -1
SR.NO.
OPERATION
MACHINE
TOOL /
TIME
GAUGE
1.
Cut the
Power saw
machine
H.S. blade
15 min
Try square
20 min
60 min
required length
2.
Straighten it and
Surface
grind it on surface
grinder
grinder
3.
Set it on milling
Milling
Indexing
machine
head, gear
tooth Vernier
Furnace
Tongue
25 min
Oil bath
Tongue
10 min
5.
Suddenly quench it
in oil bath
OPERATION
MACHINE
TOOL/GAUGE
TIME
1.
Hand lever
Steel rule
15 min.
3mm thickness of
cutting
required
machine
Hand press
Bending dies
20 min.
Welding
Welding rod
10 min.
edge
machine
-----------
Hand grinder
10 min.
Air
20 min
compressor
green paint
dimensions.
2.
It is bent at its
edges
3.
4.
off
5.
painted
CHAPTER 15
PREACUTIONS & SAFETY MEASURES
Following precautions and safety measures are taken to make our creation a grand
success.
PRECAUTION:-
SAFETY MEASURES:-
1. Do not touch the top plate when the system is in operating condition
2. Do not touch the transmission system.
CHAPTER 13
MAINTENANCE
Maintenance:No machine in the universe is 100% maintenance free machine. Due to its
continuous use it is undergoing wear and tear of the mating and sliding
components. Also due to the chemical reaction takes place when the material
comes in the contact with water, makes its corrosion. Hence it is required to
replaced or repaired. This process of repairing and replacing is called as
maintenance work.
CLEANING
Why cleaning?
Clean equipment
Thoroughly
Expose hidden
Defects
CLEANING PROCESS
8. Play or sloppiness
Minor repairs if
Trained
Experienced
Performs safety
LOSS IS
UNRECOGNISED
Remedial action
Unsuccessful
LOSS IS
RECOGNISED
Remedial action
Can not be taken
CRONIC DEFECTS
Failure prevention.
Failure resolution.
Inspection.
Equipment up keep.
Cleaning.
Lubricating.
Lightning fasteners.
Minor repairs.
Trouble shooting.
CHAPTER-16
BIBLIOGRAPHY
1. WORKSHOP TECHNOLOGY
HAZARA CHOUDHARY
A.K.SAWHNEY
R.S. KHURMI
4. PRODUCTION TECHNOLOGY
R.K.JAIN
LIST OF SUPPLIERS
ADDRESSES OF SUPPLIER
ESBEE ENGINEERING.
Authorized Dealer & Distributor; pumps & accessories
2, Amrapli, 90 Feet Road, Mulund (E) Mumbai 400081.