PROFILE CUTTING MACHINE
PROJECT REPORT
On
PROFILE CUTTING MACHINE
B.S. PATEL POLYTECHNIC, KHERVA
Project group:
(1)Kaila UmangGunvantbhai
(126440319085)
(2) ModipoojanBharatbhai
(126440319116)
(3) ModiAkashyNileshbhai
(126440319120)
(4) MistariUtsavKamlesbhai
(126440319121)
(5) Patel ShubhamKanaiyalal
(126440319126)
Internal /External guide: (1) Prof :K.P.Patel (H.O. D)
(2) Mr.Anil Sharma
B.S.P.P. 2014-15
Page 1
PROFILE CUTTING MACHINE
Certificate
This is to certify that Mr.KailaUmangGunvantbhaihaving Enrolment No :126440319085
has completed Part-I IDP Project work having title PROFILE CUTTING MACHINE. He has
undergone the process of Shodhyatra, literature survey and problem definition. He is
supposed to carry out the residue IDP Part-II work on same problem during Semester-VI
for the final Fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering.
Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel
B.S.P.P. 2014-15
Page 2
PROFILE CUTTING MACHINE
Certificate
This is to certify that Mr.ModiPoojanBharatbhaihaving Enrolment No :126440319116 has
completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has
undergone the process of Shodhyatra, literature survey and problem definition. He is
supposed to carry out the residue IDP Part-II work on same problem during Semester-VI
for the final Fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering.
Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel
B.S.P.P. 2014-15
Page 3
PROFILE CUTTING MACHINE
Certificate
This is to certify that Mr..ModiAkshayNileshbhaihaving Enrolment No : 126440319120 has
completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has
undergone the process of Shodhyatra, literature survey and problem definition. He is
supposed to carry out the residue IDP Part-II work on same problem during Semester-VI
for the final Fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering.
Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel
B.S.P.P. 2014-15
Page 4
PROFILE CUTTING MACHINE
Certificate
This is to certify that Mr.MistriUtsavKamleshbhaihaving Enrolment No : 126440319121
has completed Part-I IDP Project work having titlePROFILE CUTTING MACHINE. He has
undergone the process of Shodhyatra, literature survey and problem definition. He is
supposed to carry out the residue IDP Part-II work on same problem during Semester-VI
for the final Fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering.
Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel
B.S.P.P. 2014-15
Page 5
PROFILE CUTTING MACHINE
Certificate
This is to certify that Mr. Patel ShubhamKanaiyalalhaving Enrolment No : 126440319126
has completed Part-I IDPProject work having title PROFILE CUTTING MACHINE. He has
undergone the process of Shodhyatra, literature survey and problem definition. He is
supposed to carry out the residue IDP Part-II work on same problem during Semester-VI
for the final Fulfillment of the IDP work which is prerequisite to complete Diploma
Engineering.
Guide – Prof.K.P.PatelH.O.D.-Prof.K.P.Patel
B.S.P.P. 2014-15
Page 6
PROFILE CUTTING MACHINE
INDUSTRY DEFINED PROBLEM/PROJECT (IDP) STATEMENT FORM
STUDENT PARTICULARS-1
FIRST NAME
Umang
LAST NAME
Kaila
MOBILE NO.
1
.
EMAIL
Kailaumang107@gmail.com
2
9974787809
.
ENROLLMENT NO. 126440319085
COLLEGE
NAME
B.S.Patel Polytechnic, Ganpat University.
ADDRESS
107 VrundavanSociety,Viramgam,Ahmedabad
BRANCH
Mechanical Engineering
SEMESTER
5th Sem.
TEAM NAME
G-1
Year
2013-2014
SIGNATURE
OF STUDENT
B.S.P.P. 2014-15
Page 7
PROFILE CUTTING MACHINE
STUDENT PARTICULARS-2
FIRST NAME
Poojan
LAST NAME
Modi
MOBILE NO.
1
.
2
9662053129
.
EMAIL
ENROLLMENT NO.126440319116
COLLEGE
NAME
B.S.Patel Polytechnic, Ganpat University.
ADDRESS
D/26 ,AvadhapuriSociety,Behind Galaxy Cinema,Naroda,
Ahmedabad-382330
BRANCH
Mechanical Engineering.
SEMESTER
5th Sem.
TEAM NAME
G-1
Year
2013-2014
SIGNATURE
OF STUDENT
B.S.P.P. 2014-15
Page 8
PROFILE CUTTING MACHINE
STUDENT PARTICULARS-3
FIRST NAME
Akshay
LAST NAME
Modi
MOBILE NO.
1
EMAIL
Modiakshay50@yahoo.com
7802925942
2
ENROLLMENT NO. - 126440319120
COLLEGE
NAME
B.S.Patel Polytechnic, Ganpat University.
ADDRESS
A/12/134,Krisnanager HouseingColony,Krisnanager,Naroda
Ahmedabad-382345
BRANCH
Mechanical Engineering
SEMESTER
5th Sem.
TEAM NAME
G-1
Year
2013-2014
SIGNATURE
OF STUDENT
B.S.P.P. 2014-15
Page 9
PROFILE CUTTING MACHINE
STUDENT PARTICULARS-4
FIRST NAME
Utsav
LAST NAME
Mistry
MOBILE NO.
1. 8735867636
EMAIL
mistriutsav1996@gmail.com
2
.
ENROLLMENT NO.126440319121
COLLEGE
NAME
B.S.Patel Polytechnic, Ganpat University.
9/ kirtikungsoc.Dhobigatroad,oppositeshahpurgate,Ahmedabad.
ADDRESS
BRANCH
Mechanical Engineering
SEMESTER
5th Sem.
TEAM NAME
G-1
Year
2013-2014
SIGNATURE
OF STUDENT
B.S.P.P. 2014-15
Page 10
PROFILE CUTTING MACHINE
STUDENT PARTICULARS-5
FIRST NAME
Shubham
LAST NAME
Patel
MOBILE NO.
1
.
EMAIL
Shubham1997patel@gmail.com
2
7698280814
.
ENROLLMENT NO.126440319126
COLLEGE
NAME
B.S.Patel Polytechnic, Ganpat University.
ADDRESS
52 JayNagerSociety,Mhadevnager,Vastral Road, Ahmedabad382418.
BRANCH
Mechanical Engineering.
SEMESTER
5th Sem.
TEAM NAME
G-1
Year
2013-2014
SIGNATURE
OF STUDENT
B.S.P.P. 2014-15
Page 11
PROFILE CUTTING MACHINE
INDUSTRY PARTICULARS
---------------INDUSTRY COORDINATOR--------------NAME
Mr.Anilbhai P. Sharma.
A/ 938 Ambicanagar society,
Odhav Road,
CONTACT ADDRESS
Ahemadabad.
MOBILE NO.
9998425663
EMAIL
---------------INDUSTRY--------------NAME
ShriShivam Industries.
B/4, Ambica Industries, Estate,
CONTACT
Near, Ambica Nagar,
ADDRESS
G.I.D.C. Road, Odhav,
Ahemadabad- 382415.
CONTACT NO.
NAME OF INDUSTRIAL ESTATE
MOBILE
9998425663
Ambica Industrial Estate
COMPANY LOGO
B.S.P.P. 2014-15
Page 12
PROFILE CUTTING MACHINE
INDEX
SR.
TOPICS NAME
NO.
PAGE
NO.
1.
Introduction.
2.
Company Profile.
3.
Project Description.
4.
Design Calculation.
5.
2D Drawing & 3D Modelling.
6.
Cost Estimation Calculation.
7.
Conclusions.
8.
Future Scope.
9.
References.
B.S.P.P. 2014-15
Page 13
PROFILE CUTTING MACHINE
INTRODUCTION
ABTRACT
Project is predefined process which is Applicable on any Application.In that we include all
details about our planning of application. There are two types of project one is IDP and
other is UDP. IDP is industry defined project and UDP is user defined project.
We are making profile cutting machine. It is used for cutting the material in circular shape
upto 7 inches. It is used in utensils industry. With this machine unskilled worker can also
produce perfect shape and lots of time and material can be saved. In lathe machine
process which material removes it is in powder form and it is useless. In our machine
material is removed in chip form which can be sold and profit is earned.
PROBLEM DEFINITION
We can use the lathe machine also for cutting, but in lathe machine there is need skill
workers for single lathe work and may be very long process and time consuming. And it
also need more man power. In that spinning process with different types of dies are
required. Profile cutting machine overcomes the lathe machine problem. It needs less
man power and gives mass production. It takes less time for processing. It gives more
profit than lathe machine. And not needed skilled worker only, there can be unskilled
worker also.
SCOPE
During execution of this project, we will implement following areas:
•
•
•
•
•
•
•
•
•
Design / Selection of main components.
Material selection.
Detailed 2D drawings of all components.
3D models using parametric modelling software.
Select machines and manufacturing processes.
Prepare operation process chart, flow process chart, flow diagram.
Prepare operation and route sheets for various components.
Manufacturing and assembly of different parts.
Testing and problem solving.
B.S.P.P. 2014-15
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COMPANY PROFILE:
PROFILE CUTTING MACHINE
Shivam Industries is middle scale industry established in year 2000 and is owned by Mr.
Anil Sharma. They are pioneer in manufacturing of various machines like power press,
deep drawing machines, preshearingprepartation machines and other job works.
Machines:
1. Lathe Machine (3 Nose) - 12 Feet
2. Lathe Machine (1 Nose) - 04 Feet
3. Horizontal Shaper Machine (1Nose) - 7 Feet
4. Verticle Shaper machine- (1Nose)- 5.5 Feet
5. Power press Machine (1 Nose) - 10 Feet
6. Drilling Machine (1 Nose) - 4 Feet
7. Drilling Machine (1 Nose) - 6 Feet
8. Arc Welding Machine (1 Nose) - 2 Feet.
B.S.P.P. 2014-15
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Lathe machine specification:
PROFILE CUTTING MACHINE
Lathe machine size 12 feet: (3 Nose.)
Max. swing over bed- 280 mm. dia.
Max. swing over cross slide- 150 mm.
dia.
Distance between centers- 610 mm.
Width of bed- 180 mm.
Spindle bore- 26 mm.
Inch thread can be cut- 8-35 TPI.
Max. travel of cross slide- 110 mm.
Max. travel of slide- 70 mm.
Motor power- 750 W.
Lathe machine 4 feet: (1 Nose.)
Max. swing over bed- 210 mm.
Max. length of work piece- 450 mm.
SpIndLe Bore- 20 mm.
Inch thread can be cut- 8-24 TPI.
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PROFILE CUTTING MACHINE
Output power- 1000 W.
Diameter of chuck- 100 mm.
Voltage- 100-120V AC.
Spindle speed- 100-2000 rpm.
Frequency- 50/60 Hz
Horizontal shaper machine specification:
Horizontal shaper machine size 7 feet: (1 Nose.)
specification
Table size
Front Extension
support
Height of work
table
Spindle
Dimension
Diameter
stroke
Speed(RPM)
Motor
B.S.P.P. 2014-15
SP-475
39”1/2*271/2”
SP-910
98”*271/2”
98”
331/2”
331/2”
11/4”
8”
3500/7000/1000
71/2 HP,3 PH
11/4”
8”
2900/4400/6000/7800/10000
10 HP,3 PH
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PROFILE CUTTING MACHINE
Verticle Shaper Machine:
Verticle Shaper Machine Size 5.5 Feet: (1 Nose.)
Length of Ram Stroke- 660 mm.
Length of Ram- 1225 mm.
Width of Ram- 300 mm.
Max.DistanceFrom Table to Ram- 450 mm.
Min. Distance From Table to Ram- 50 mm.
Verticle Travel to Tool Slide- 140 mm.
Table Size- 610*380 mm.
Horizontal Travel to Table- 600 mm.
Verticle Travel to Table- 350 mm.
B.S.P.P. 2014-15
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PROFILE CUTTING MACHINE
Power Press Machine Specification:
Power Press Machine Size 10 Feet: (1 Nose.)
Table length
1500
Table width
150
Clear pass
1060
Open height
250
Throat Depth
100
Weight
1500
Power
2 HP
B.S.P.P. 2014-15
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PROFILE CUTTING MACHINE
Drilling Machine Specification:
Drilling Machine Size 4 Feet: (1 Nose.)
Max. drilling capacity- 32 mm.
Spindle stroke- 115 mm.
Spindle bore taper- MT3
Spindle speed (L) 55-350 r.p.m
Spindle speed (350-2300)
Coiumn Diameter 120 mm.
Net / gross weight- 310/360 kg.
B.S.P.P. 2014-15
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PROFILE CUTTING MACHINE
Drilling Machine Size 6 Feet: (1 Nose.)
Drilling hole diameter- 400- 800 mm.
Drilling depth- 20 mm.
Machine Weight- 40 kg.
Max. drilling rod speed- 24.2 mm.
Max. MotorTorque- 29.2 mm.
B.S.P.P. 2014-15
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PROFILE CUTTING MACHINE
Arc Welding machine specification:
Arc Welding machine size 2 Feet:
Input power- 50/60 Hz.
Rated input capacity- 53
Rated input current- 80
Efficiency- 0.88 %
Welding Speed- 43-250.
Insulation Grade- IP21S.
Weight- 60 kg.
Wire Feed Speed- 8-170.
Voltage Adj.Range- 24-44.
B.S.P.P. 2014-15
Page 22
PROFILE CUTTING MACHINE
PROJECT DESCRIPTION
Profile cutting machine can be work by 1 hpmotor.In this machine motor connected with
driving pully and Driving Pully connected with Driven Pully with help of V- Belt. Driven
pully connected with pinion and pinion connected with main big gear. Main big gear
connected with shaft 4 Adjustable gear.This gear box used in machine to reduce the rpm
(1400 rpm covert in to the 350 rpm) Gear is connected to 2 shaft and 2 shaft connected
with cutter. 2 cutter in between moved on work plate. Cutters are rotate in opposite
direction. Work plate connected with table and chuck is fitted on work plate. We can
increase and decrease the depth of cut by adjusting screw under the work plate. Work
piece is moved due to the rotating of the cutters then after circular cutting can be cut. In
this machine maximum circular profile cutting up to 7 inches.
In this project Following parts are Required to Manufacturing.
1.Table.
2. Work Plate.
3. Verticle Plate.
4. Shafts.
5. Gear.
6. Cutter.
During 5th Semester We have Concentrated on Designing and Drafting Aspects and Cost
Estimation.
B.S.P.P. 2014-15
Page 23
PROFILE CUTTING MACHINE
DESIGN CALCULATION
GEAR:
1. MAIN BIG GEAR:
Tooth= 75
Tooth Thickness= 30
Module= 2.5
Outer diameter= 192.5
Root diameter= 181.25
Pitch diamerter = 2 m
= 2 *2.5
=5
Addendum= m
= 2.5
Dedendum= 1.25*m
=1.25*2.5
= 3.125
P.C.D.= No of teeth* Module
= 75 * 2.5
= 80
Pitch circle= 8.063
B.S.P.P. 2014-15
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PROFILE CUTTING MACHINE
Shaft Adustiable Gear (2 Nose)
Tooth= 32
Tooth Thickness= 30
Module= 2.5
Outer diameter= 85
Root diameter= 73.75
Pitch diamerter = 2 m
= 2 *2.5
=5
Addendum= m
= 2.5
Dedendum= 1.25*m
=1.25*2.5
= 3.125
P.C.D.= No of teeth* Module
= 32 * 2.5
= 80
Pitch circle= 8.344
B.S.P.P. 2014-15
Page 25
PROFILE CUTTING MACHINE
Adustiable Gear (2 Nose)
Tooth= 32
Tooth Thickness= 30
Module= 2.5
Outer diameter= 85
Root diameter= 73.75
Pitch diamerter = 2 m
= 2 *2.5
=5
Addendum= m
= 2.5
Dedendum= 1.25*m
=1.25*2.5
= 3.125
P.C.D.= No of teeth* Module
= 32 * 2.5
= 80
Pitch circle= 8.344
B.S.P.P. 2014-15
Page 26
PROFILE CUTTING MACHINE
PINION
Tooth= 20
Tooth Thickness= 30
Module= 2.5
Outer diameter= 55
Root diameter=46.38
Pitch diamerter = 2 m
= 2 *2.5
=5
Addendum= m
= 2.5
Dedendum= 1.25*m
=1.25*2.5
= 3.125
P.C.D.= No of teeth* Module
= 20 * 2.5
= 50
Pitch circle= 8.639
B.S.P.P. 2014-15
Page 27
PROFILE CUTTING MACHINE
InvoluteGears
Introduction
Thislessoncoversthedevelopmentof‘involute’gears.Aninvolutegearisbasedonaninvolute
curve,whichisamathematicalshape.Tounderstandwhataninvoluteis,considerasimplecylinderandastr
ingasshownbelow.Wrapthestringaroundthecylinder.Whilemaintainingtensiononthestring,tracethep
aththattheendofthestringmakeswhileun-wrappingitaroundthecylinder.Thispathisaninvolutecurve.
Asimplecylinderandastring.
Wrapthestringaroundthecylinder.
Pull
Involute
curve
Pullthestringtightandkeepittangenttothecylinder.
Tracetheendofthestringwhileun-wrappingit around
thecylinder.Theresultingtrajectoryisaninvolute
curve.
Therearetwokeyparametersthatcontroltheinvolutecurve:thediameterofthecylinderandtheanglethatt
hestringisun-wrapped
aroundthecylinder.Intheexampleabove,thestringisunwrapped90º
aroundthecylinder.
B.S.P.P. 2014-15
Page 28
PROFILE CUTTING MACHINE
TheInvoluteCurve
Developmentofthemathematicalequationsfortheinvolutecurveusessimpletrigonometry.We
willdeveloptheequationsfor90ºofonefullinvolute.Inotherwords,weareun-wrapping the string90º
aroundthecylinderinacounterclockwisedirection.
Thecircumferenceofacircleisdefinedby:
c=2 * π* r
One quarter(90º) of thecircumferenceofacircleisthen: c= π* r/2
Inthefigurebelow,theline‘s’isthesamelengthasthepartofthecircumferencethestringhasbeenunwrapped(s’).
xc, yc
θ
s
r
x, y
s’
θ
Wearetryingtodefinet
hiscurvebyfindingeq
uationsforxandyasθ
changes
0, 0
Usingtrigonometry,wefindthat:
xc=r * cosθ
yc=r * sinθ
B.S.P.P. 2014-15
x =xc+( s * sinθ )
y=yc– ( s * cos θ )
Page 29
PROFILE CUTTING MACHINE
DatumCurvesFromEquation
InPro/ENGINEER, datumcurvescanbedefinedusingmathematicalequations.Whenusingthisfeature,
asystemvariable‘t’isused,thatvaries
from0to1overthelengthofthecurve.Forthe
involutecurve,lettheangle(ang)be
equalto‘t’times90.
Thismeansthatthevariable‘ang’will
varyfromzeroto90º.
Todefine‘s’, we combinethecircumferenceequationand‘t’toform:
s =( π* r /2 ) * t
Inthisexample,thediameterofthecylinderis1.500.Thisisthebasediameteringeardesignterminology.T
heradius(r) of thecylinderis 0.75 inches.
Theequationsfor Pro/ENGINEERare:
r =0.75
ang=t* 90
s =(PI* r * t) /2
xc=0.75 * cos(ang)
yc=0.75 * sin(ang)
x=xc+( s * sin(ang))
y=yc– ( s * cos(ang))
z=0
Theresultingdatumcurveisshowninboldbelow.
B.S.P.P. 2014-15
Page 30
PROFILE CUTTING MACHINE
CreatingtheGear
InPro/ENGINEER,thegearisstartedbymodelingacylinderattheoutsidediameterofthegear,
seeFigure1.Severalsketchesarecreatedtodefinetherootdiameter,
basediameter,
andpitch
diameterofthegear,seeFigure2.Next,theinvolute
shapeddatumcurveiscreatedandmovedintothecorrectpositiontodefineonesideofonegeartooth,
seeFigure3.Thecurve
ismirroredandthegeartooth
iscutintothecylinderusingtheedgeoftheinvolutedatumcurves,seeFigure
4.Thecutispatternedandroundsareaddedatthebaseofthegear.Thecompletedgearis shown in Figures5
and6.
Figure1
Figure2
Figure3
Involute
curve
Figure4
B.S.P.P. 2014-15
Figure5
Figure6
Page 31
PROFILE CUTTING MACHINE
GearParameters
Thefollowingaregeometricparametersingeardesign:
PitchDiameter
RootDiameter
OutsideDiameter
BaseDiameter
Addendum
Dedendum
ToothThickness
ToothThicknessAngle
FilletSize
DiametralPitch=PitchDiameter+( 2 * Addendum)
CircularPitch=π/PitchDiameter
NumberofTeeth=DiametricalPitch* PitchDiameter
Pressure Angle
Thefiguredescribessomeofthegearparameters.
Tooththicknessangle
Outsidediameter
Pitchdiameter
Tooththickness
BasediameterRoot
Addendum
diameter
Dedendum
Filletsize
GearParameters
B.S.P.P. 2014-15
Page 32
INVOLUTEGEARS
Task1:
PROFILE CUTTING MACHINE
Create adatumcurvedrivenbyanequation.
•
PickFile,New, thenenter<involute_gear>for thenameofthenew part
•
PickOKintheNewdialogbox
•
PickInsert, ModelDatum,Curve,FromEquation,Done
•
Selectthedefaultcoordinatesystem,thenpickCartesian
•
In theNotepadwindow, enterthefollowingequations:
r =2.819
ang=t* 90
s =(PI* r * t) /2
xc=r * cos(ang)
yc=r * sin(ang)
x=xc+( s * sin(ang))
y=yc- ( s * cos(ang))
z=0
•
PickFile,SaveandFile,ExitinNotepad
•
PickOKinthedialogbox
•
Theresultisshown here
•
Thiscurvewillbeusedtocreateaninvolutegear
B.S.P.P. 2014-15
FRONT
CSYS_DEF
RIGHT
TOP
Page 33
PROFILE CUTTING MACHINE
Task2:
Create acylinder.
•
SelecttheFRONTdatumplane
•
PicktheExtrudeicon
•
Press andholdtherightmousebuttonandselectDefineInternalSketch
•
PickFlipintheSketchdialogbox
•
PickSketchintheSketchdialogbox
•
Sketchacirclecenteredonthereferences,withadiameterof6.500,torepresentthe
outsidediameterofthegear(seethefigureonthepreviouspage)
•
Pickthecheckmarktocompletethesketch
•
Enter<1.750 >for thedepththenpickthecheckmarkinthedashboardtool
•
PickView,Orientation,StandardOrientation
•
Theresultisshownbelow,besurethecurveisinfrontofthecylinderas shown
FRONT
TOP
A_1
RIGHT
B.S.P.P. 2014-15
Page 34
PROFILE CUTTING MACHINE
Task3:
Create threecirclesrepresentingthemajordiameters.
•
CreateacircularsketchontheFRONTdatumplanewithadiameterof5.376to
representtherootdiameterofthe gear
•
CreateacircularsketchontheFRONTdatumplanewithadiameterof5.638to
representthebasediameterofthe gear
•
CreateacircularsketchontheFRONTdatumplanewithadiameterof6.000to
representthepitchdiameterofthe gear
•
Theresultisshown below
Task4:
Create adatumpoint.
•
SettheselectionfiltertoDatums,picktheinvolutecurveand
the6.000diameter
circularsketch,thenpickthePoint icon
andthenpickOKtocreateadatumpointas
shown below
B.S.P.P. 2014-15
Page 35
PROFILE CUTTING MACHINE
Task5:
Create anotherdatumpointandadatumcurve.
• BesuretheselectionfilterissettoDatums
• Pick RIGHT, TOP, andFRONTthenpickthePointicon
• PickInsert, ModelDatum,Curve,Done
thenpickOK
• PickthetwodatumpointsthenpickDoneandOK
• Theresultisshown below
Task6:
Create adatumevaluatefeature.
•
PickInsert, ModelDatum,Evaluate
•
Enter<measure>forthenameofthefeature
•
PickCreate, thenenter<angle>forthenameofthemeasurementparameter
•
PickAngle,thenpicktheTOPdatumplaneandthecurveyoujustcreatedthroughthe points
•
PickDonethenreadthemessagewindowandlookatthemodeltree
•
Savethepart
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PROFILE CUTTING MACHINE
Task7:
Copytheinvolutecurve.
•
SettheselectionfiltertoFeatures
•
PicktheinvolutecurvethenpickEdit,Copy
•
PickEdit,PasteSpecial
•
AddthecheckmarknexttoApplyMove/Rotate
transformationstocopiesinthedialogboxthenpickOK
•
PickRotateintherightmousebuttonpopup menu
•
Picktheaxisinthecenterofthecylinderthenenter< -30 > for therotationangle
•
Pickthecheckmarkinthedashboardtool
•
Theresultisshown
Task8:
Addarelationandregeneratethepart.
•
Doublepickthecopiedinvolutecurve(theonecreatedintask7)
•
Doublepickthe30 dimension
•
In thesmalltextbox, carefullyenter:
angle:FID_MEASURE+(7.5 /2 )
•
PickYestoaddtherelation
•
PickEdit,Regenerate
•
Theresultisshown
B.S.P.P. 2014-15
Page-
PROFILE CUTTING MACHINE
Task9:
Mirrorthecopiedinvolutecurve.
•
Pickthecopiedinvolutecurve(theonecreatedintask7) thenpickEdit,Mirror
•
PicktheTOPdatumplanethenpickthecheckmarkinthedashboardtool
•
Theresultisshown
Task10: Copythecurveagain.
•
Pickthecopiedinvolutecurve(theonecreatedintask7) thenpickEdit,Copy
•
PickEdit,PasteSpecial
•
AddthecheckmarknexttoApplyMove/Rotate
transformationstocopiesinthedialogboxthenpickOK
•
PickRotateintherightmousebuttonpopup menu
•
Picktheaxisinthecenterofthecylinderthenenter< -15 > for therotationangle
•
Pickthecheckmarkinthedashboardtool
•
Theresultisshown
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PROFILE CUTTING MACHINE
Task11: Create anextrudedcut.
•
Createanextruded(throughall)cutusingtheedgesofthecurvesas shown below
•
Trimthesketchas shown below
•
Theresultisshownatthebottomofthepage
Add
thesetwolines,besuretog
etthetangencyconstraint
as shown
PicktheUseEdge
iconthenselectthesecu
rves
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Task12: Patternthecut.
•
SettheselectionfiltertoFeaturesthenpickthecutyoujustcreated
•
PickEdit,Pattern,thensetthetypeofpatterntoAxisinthedashboardtool
•
Selecttheaxisinthecenterofthecylinder
•
Enter<24 >forthenumberofinstancesinthepattern
•
Enter<15>fortheincrementangle
•
Pickthecheckmarkinthedashboardtooltocompletethepattern
Task13: Finishthepart.
•
Createa0.020 round atthebaseofthegeartooth
•
Patterntheround
•
Createacoaxialholewithadiameterof2.000
•
Use Layerstohidethedatumcurvesandsketches
•
Thecompletedpartisshown below
•
SavethepartandClosethewindow
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2D Drawing /3D Modeling
PINION :
55
5
20
3
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PINION
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SHAFT ADUSTIABLE GEAR (4 NOSE.)
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SHAFT ADUSTIABLE GEAR (4 NOSE.)
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MAIN BIG GEAR (1 NOSE.)
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MAIN BIG GEAR (1 NOSE.)
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CUTTER :
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TABLE :
900
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TABLE :
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WORK PLATE :
203,2
4064
4045
4064
101,6
2032
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WORK PLATE :
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VERTICLE PLATE :
150
47.5
400
60
45
30
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300
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VERTICLE PLATE :
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SHAFT : 1
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SHAFT 1 :
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SHAFT-2 :
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SHAFT-2 :
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Cost Estimation Calculation :
Table :
Matarial- M.S. /All slide
910*200 mm.
We are welding on two slide
Welding on both angle= 910+200
=1110 mm.
Total Welding = 1110*2
= 2220
Welding for supporting beam= 610 mm.
Total Welding length= 2220+610
= 2830 mm.
Labour cost= Rs. 250/ shift
= 250/8
= 31.25 Rs. Per/ hr.
= 0.52 RS/ hr.
Welding time= 2 m/ hr.
= 2000/60 mm/ h
= 33.33 mm/hr.
Total Welding time = Total Welding length/ Welding time
= 2830/33.33
= 84.90/60
= 1.415 hr.
Total labour cost= Total Welding time + labour cost
= 84.90* 0.52
= 44.148 Rs.
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Material cost :
Electrode used= Total Welding length/ Welding consumption/ mm welding.
= 2830/135
= 20.96 rod.
Total Matarial cost= use of welding rod* rate of rod.
= 21*2.5
= 52.5 Rs.
Power cost :
Power cost= Total power consumption
= V*I/N*100 *Welding time
= 220*21/0.6*100*84.90/60
= 10.895. kwhr.
Total Power cost= Total Power consumption * Power rate.
= 108* 3.15
= 340.2 Rs.
Total Cost= labour cost + Total Material cost+ Total Power cost
= 44.148+ 52.5 + 340.2
= 436.84 Rs.
Other Overhead Cost/Tranportation :
Total Welding Cost of job= Total cost + Other Overhead cost
= 436.84 + 44
= 480 Rs.
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GEAR :
1. MAIN BIG GEAR: (1 Nose.)
No of index = 75
Tooth Thickness= 30
Feed= 35 mm/min.
Length= 30 mm.
Overall A+O= 10 MM.
Milling Time T= L+( A+O) / per minute.* No of Index.+Set up Time.
= 30+10/35*75+10
= 95 min.
PINION : (1 Nose.)
No of index = 20
Tooth Thickness= 30
Feed= 35 mm/min.
Length= 30 mm.
Overall A+O= 10 MM.
Milling Time T= L+( A+O) / per minute.* No of Index.+Set up Time.
= 30+10 / 35*20+10
= 32.85 min.
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Shaft Adustibalegear : (4 Nose.)
No of index = 32
Tooth Thickness= 30
Feed= 35 mm/min.
Length= 30 mm.
Overall A+O= 10 MM.
Milling Time T= L+( A+O) / per minute.* No of Index.+Set up Time.
= 30+32/35*32+10
= 66.68 min.
Pully :
Step-1= 3.14/4 400*1.5
= 471 cm.^3
Step-2= 3.14/4* 36*1.5
= 42.41 cm^3
Step= step 1- step 2
= 471- 42.41
= 428.59 cm^3.
Weight of step Pully= Weight of Pully * Density.
= 428.59* 7.2/1000
= 3.085 kg.
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COST ESTIMATION
Material
Estimation
Cutter box plate (2 nose)
1800
Upper cutter shaft safe Adjustiable plate (2
nose)
Upper shaft and lower shaft
800
1000
Lower shaft (Pully)
800
Shaft chuck (4 Nose)
400
Shaft bearing (4 Nose)
700
Main big drive gear
400
Pinion
100
Shaft adjustiable gear (2 Nose)
400
Adjustiable gear (2 Nose)
400
Adjustiable gear bearing (2 Nose)
200
Adustiable gear pin (2 Nose)
200
Adustiable gear plate,vertical plate
1500
Pinion gear shaft (1Nose)
600
Pinion gear shaft box (1 Nose)
300
Cutter (2 Nose)
1600
T-stand
1000
Key (6 Nose)
100
Pully
150
Motor (1hp)
2500
Total
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14,950
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CONCLUSION
In this project we learnt different design software for 2D and 3D drawing software
like, Autocad and Creo etc.
We understood concepts of Establish cost Estimation in our project.
In this project We learnt different parts of machine in industry.
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FUTURE SCOPE
In future we will make product’s design and working model in next six Months then
our project will complete.
In industry future scope.
To reduce the number of gear.
Less power motor can be used.
Machine can be make Automatic.
Large machine can be obtained.
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REFERENCES
 We have taken the reference from industrial visit in company shrishivam
industries.
 We have taken design data books like,
 Element of Machine Design :
Publication- Charotar.
Author- N.C. Pandya.
 Machine Design :
Publication- Sigma serious.
Author- S.K. Kulkarni.
 Design of Machine Element :
Publication- person.
Author- M.F. Spotts.
T.E. Shoup
L.E. Hornberger.
S.R. Jayaraman.
 A Text-book of metrology :
Publication- M. Mahajan.
Author- M. Mahajan.
Related links :
www.faadooengineers.com/.../14868-Machine-design-DATA-book.
seminarprojects.org/.../design-data-book technologies.
www.rpccbe.ac.in/wp-content/uploads/machine-design-databook.
www.engineering108.com/Data/.../Handbooks/machine_design_databook.
www.quora.com/From-where-can-I-get-a-design-data-book-of-machine-element.
accessengineeringlibrary.com/.../machine-design-databook.
www.conti-online.com/download /download / technical data book.
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