project report

CHAPTER-1

INTRODUCTION

Metal is frequently machined using many processes in order to create pieces of

specific shape and size. For example, metal may be welded, moulded, cast, trimmed, slit

or sheared. These procedures often create ragged edges or protrusions. The raised

particles and shavings that appear when metal blanks are machined are referred to as

burrs, and the process by which they are removed is known as deburring.

A burr is a raised edge or small pieces of material remained attached to a work

piece after a modification process. It may be present in the form of a fine wire on the

edge of a freshly sharpened tool or as a raised portion on a surface, after being struck a

blow from an equally hard or heavy object. A normal burr from well-maintained tools is

usually less than 10% of material thickness. If burrs are not acceptable (burr-free

requirement), then deburring needs to be done. Typically deburring results in a rounded

edge with a radius of 0.05 to 0.075 mm (0.002 to 0.003 in).

Burr formation in machining accounts for a significant portion of machining costs

for manufacturers throughout the world. Drilling burrs, for example, are common when

drilling almost any material. The Boeing 747 airplane has approximately 1.3 million

holes drilled in it,[ most of which have to be deburred to some extent. As one could

imagine, the cost and time needed to perform these drilling and deburring operations is

significant.

In addition to drilling, milling is also a source of burr formation in machining.

One good example of unwanted burrs is in the automotive industry where cylinder

blocks, pistons and other engine components are cast then milled to a specific

dimension. With higher and higher demands placed on accuracy and precision, burr

formation is of critical importance because it can affect engine performance, reliability,

and durability.

1

Deburring is important for quality, aesthetics, functionality and smooth operation

of working parts. It is also important for safety. Even a small notch can cause moving

parts to catch, creating the potential for accident, injury or unnecessary delay in

production. Rough edges can also cause injury when individuals are required to handle

blanks. Each of these preventable problems can cost companies a great deal of money.

Deburring is done by tumbling parts in a barrel or a vibratory bowl, along with

finishing media. Ceramic media is often used for steels. For softer materials, plastic

media, walnut shells etc can be used. This type of deburring is usually confined to

unfinished materials. For materials that are already finished, such as pre-plated or pre-

painted materials bulk deburring operations are not suitable, because the deburring will

remove the finish along with the burrs. For these materials, other forms of deburring

such as belt sanding or hand filing will have to be done with the associated higher costs.

2

1.1 DESIGN FLOW CHART:

Fig 1.1 Design flowchart.

3

PROBLEM IDENTIFIED -BURR

BURR REMOVAL

DRILL HEAD FOUND

PILLAR TYPE OR INCLINED ONE

INCLINED TYPE SELECTED

SEARCHING OF THE AVAILABLE MATERIALS FROM JUNK YARD

SELECTING THE SEQUENCE

FABRICATION

FINAL TRIALS

CHAPTER-2

CASTLE NUT

2.1 DEFINITION:

A slotted nut that allows insertion of a cotter pin to prevent rotation. Usually

manufactured from metal with various sizes.

A castellated nut, also called a castle nut or slotted nut, is a nut with slots

(notches) cut into one end. The name comes from the nut’s resemblance to the

crenellated parapet of a medieval castle.

The bolt or axle has one or two holes drilled through its threaded end. The nut is

torqued properly and then, if the slot isn't aligned with the hole in the fastener, the nut is

rotated to the nearest slot. The nut is then secured with a cotter pin or safety wire which

passes through the lateral aperture in the bolt and through corresponding diametrically

opposite slots in the nut.

Castellated nuts are used in low-torque applications, such as holding a wheel

bearing in place.

2.1.1 History of this Word

"castle" is from "castellum" (fortress), spoken by ancient people in central Italy around

700 B.C.

"slot" is from "esclot" (horse's hoofprint), spoken in France

which is from "slodh" (track), spoken by people in North England about 800 A.D.

"nut" is from "hnutu", spoken by people in England during 450-1100 A.D.

4

2.1.2 Slotted Hex Nut Lock Nuts Properties - ANSI / ASME B18.2.2

Description

A hex nut with opposed slots cut into the top of the nut

through the centers of the flats. The slots are on the end

opposite the bearing surface.

Applications

&

Advantages

The slots are for the insertion of a cotter pin to secure the nut

when used with a drilled shank fastener. Commonly used in

the automotive industry to secure front wheel bearings /

wheel hubs to spindles on cars and trucks.

Material

Nuts shall be made from a low carbon steel which conforms

to the following chemical composition requirements:

Carbon:  0.47% max;

Phosphorus:  0.12% max;

Sulfur:  0.23% max;

Hardness Rockwell C32 maximum

Proof Load 72,000 psi

2.2 BURR FORMATION:

Due to the slot formation in the nut the metal at the inner side of the work tends to fold

which will form the burr at the inner face. This burr is formed before the threading

operation.

5

CHAPTER-3

NEED FOR DEBURRING AND DEBURRING METHODS

1. Deburring is important for quality, aesthetics, functionality and smooth operation

of working parts. It is also important for safety.

2. Even a small notch can cause moving parts to catch, creating the potential for

accident, injury or unnecessary delay in production.

3. Rough edges can also cause injury when individuals are required to handle blanks.

4. Each of these preventable problems can cost companies a great deal of money.

3.1 METHODS OF DEBURRING

1. Abrasive substances may be applied, or abrasive cloths may be used to rub the

metal in order to remove thin shavings and small notches, as well as to polish the

piece.

2. Water under high pressure is forced at the targeted area.

3. By repetitive filing or use of a grinder to smooth away nicks and fragments.

4. Deburring can also be done by designing a machine with a deburring unit.

5. The most common methods of deburring are sanding and filing. Sanding may be

accomplished with a power sander, or simply by touching up the worst spots by

hand. Edges may also be finished with a router.

6. Deburring can be done by using wire brushes.

7. Deburring can also be done by manual operation

6

Fig no 3.1 Deburring tools.

7

3.1.1 Deburring Using Wire Brushes.

Abrasive Nylon Deburring Brushes available In

Aluminum Oxide, Silicon Carbide, Ceramic &

Diamonds in Various shapes like -

Disc Circular

Inside Deburring (I.D.) End Brush

Tufted (staple set) Miniature

Spindle Mounted Cup type

Strip Brush Spiral Brush

Manual Tied Profile Brush

Fig 3.2 Wire brushes.

8

CHAPTER-4

MECHANICAL PHASE

4.1 MECHANICAL PHASE

The mechanical part of our project actually consists of the following steps.

1) Setting up a suitable guide arrangement for the drill head.

2) Arranging guiding setup for work piece.

3) Fixing the two guide plates with the base.

4) Aligning the centre point of the tool with that of the work centre.

5) Drilling holes and placing the cylinders to full fill the sequence.

6) Making the guide ways according to the requirement.

4.2 MECHANICAL OPERATIONS

1. Milling the base plate .

2. Brazing the end effecters of the cylinders.

3. Grinding the extra metal in the end effecters.

4. Drilling the plates for fastening.

9

4.3 FABRICATION PROCESS

1. The machine which is made using a dismantled drill head attachment of a US

based machine. The guide ways are also fabricated based upon the availability.

The guide ways is bolted to the guide plate. The pneumatic cylinders are bolted to

the guide plate.

2. The guide plate which is used is then attached to the supporting plate with an

inclination of 35 degree for gravity feed of work. The drill head is also attached to

its inclined guide base and to then bolted to the supporting base.

3. Four separate cylinders are used to fulfill the sequence of operation out of which

two are single acting and two are double acting cylinders.

4. The single acting cylinders are used for the stopping action and is controlled by a

3/2 DCV.

5. The double acting cylinders are used for tool feeding, separating and for the

clamping action and is controlled by a 5/2 DCV.

6. Pencil cylinder is used to control the mechanical actuator switch in the tool

cylinder.

10

CHAPTER-5

ELECTRICAL AND ELECTRONICS PHASE

1. Selecting the appropriate motor for the spindle.

2. Fixing a DOL starter for the main spindle motor.

3. Wiring the solenoid coil for actuation.

4. PLC.

11

5.1 PLC STRUCTURE

Fig 5.1 PLC structure

5.2 BASIC COMPONENTS

The basic components of a PLC are listed below

i. Power supply

ii. Central Processing Unit (CPU)

iii. Inputs Modules

iv. Outputs Modules

12

The general structure of programmable logic controller is as follow:

Fig 5.2 General Structure Of PLC

5.2.1 Power supply mode:

There are several types of power supply mode

1. 240V ac supply

2. 110V ac supply

3. 24V ac supply

13

5.2.1.1 Function:

Provides all the voltage level needed to operate the PLC. Converts 110V AC or

240V AC into the DC voltage required by the CPU, memory, I/O interface

Fig 5.3 Example of a power supply module

5.2.2 Central Processing Unit (Cpu)

5.2.2.1 Function:

Receives information from input interface, process according to the program

stored, update the output information.

5.2.2.2 Memory

Memory location is an address in RAM or ROM where a group of bits can be stored

14

Grouping of bits depending on PLCs:

i. 8 bits per word

ii. 16 bits per word

iii. 32 bits per word

LSB : Least Significant Bit - Digit that represents the smallest value

MSB : Most Significant Bit - Digit that represents the largest value

5.2.3 Inputs Module

To receive and convert field signals from pushbuttons, sensors or

switches into a form that can be used by the CPU

Fig 5.4 Input module

5.2.4 Outputs Module

Takes signal from the CPU and translates them into forms that are appropriate to

produce control actions by external devices such as indicator lights, solenoids or

motor starters.

15

Fig 5.5 Outputs module

16

Fig 5.6 Input/output processing

5.3WORKING OF PLC

1. Bringing Input signal status to the memory of CPU

Fig

5.7 Input signal status to the memory

17

Input

module

CPU

PII PIQ

Field signals

2. Processing of signals using program

Fig 5.8 Processing of signals

3. Spring the result of processing in the internal memory

Fig 5.9 Internal memory processing

18

User program

CPU

PII PIQ

Internal timer

Internal counters

CPU

PII

PIQ

4. Sending process output image to module

Fig 5.10 Signals to output module

19

CPU

PII PIQ

Output

module

Field control

CHAPTER-6

PNEUMATICS PHASE

The pneumatic section consists of the following steps.

1) Selecting the cylinder based upon the maximum pressure.

2) Selecting the directional control valve based upon the cylinders used.

3) Placing the FRL unit and silencers.

4) Connection of tubes.

5) Clamping at the areas at which two tubes are connected.

6.1 PNEUMATIC COMPONENTS USED

The following are the pneumatic components used to satisfy the sequence.

1) Pneumatic cylinders -4

i. Clamping cylinder.

ii. Separating cylinder.

iii. Stopper cylinder.

iv. Forward and retract motion of drill head.

2) 5/2 Directional control valves-2

3) FRL unit

4) Air compressor.

5) Tubes .

20

6.2 PNEUMATICS BASICS

1. The term double acting is used when the control pressure are applied to each side

of the piston.

2. A difference in pressure between the two sides then results in motion of the

piston, the piston being able to move in either direction along the cylinder as a

result of high pressure signals.

3. For the double acting current through one solenoid causes the piston to move in

one direction with the current through the other solenoid reversing the direction of

motion.

4. The choice of the cylinder is determine by the force required to move the load and

the speed required. Hydraulic cylinders are capable of much layer forces than

pneumatic cylinders. However pneumatic cylinders are capable of greater speeds.

5. The force produced by a cylinder is equal to cross sectional area of the cylinder

multiplied by the working pressure, (i.e) the pressure difference between two sides

of the piston in cylinder.

6.3 INSTALLATION OF THE FRL UNIT

1. The filter is installed upstream from other conditioning components. This protects

internal moving parts in the regulator from harmful contaminants and avoids

fouling the lubricator reservoir.

2. Large capacity filters are available to protect a pneumatic network, but it is more

common practice to install filter in each branch. Likewise regulators are installed

at each branch which requires a specified pressure setting.

3. Some pressure regulators are designed to be mounted on valve manifolds.

4. Lubricators are installed at downstream end of the FRL unit. Just after the

regulator and should be placed as close to the equipment as possible.

21

6.4 AIR CYLINDERS

Air cylinders are the final component in a pneumatic or compressed air control or

power system. They are used in the food processing and packaging, metal working,

automotive, mining, textile, and forest industries. Also referred to as compressed air

cylinders or pneumatic cylinders, air cylinders are devices that convert compressed air

power into mechanical energy. This mechanical energy produces linear or rotary motion.

In this way, the air cylinder functions as the actuator in the pneumatic system, so it is

also known as a pneumatic linear actuator.

The air cylinder consists of a steel or stainless steel piston, a piston rod, a cylinder

barrel and end covers. As compressed air moves into a cylinder, it pushes the piston

along the length of the cylinder. Compressed air or a spring, located at the rod end of the

cylinder, pushes the piston back. Valves control the flow of compressed air to the

cylinder.

There are two basic types of air cylinders-double acting cylinders, which are able

to perform an operating motion in two directions and single acting cylinders, which are

able to perform in one. Other types include rotary cylinders, cable cylinders and rodless

cylinders. They are housed in different styles and named accordingly. These include

stainless steel cylinders, brass cylinders, compact cylinders, miniature air cylinders and

small air cylinders.

6.5 SINGLE-ACTING CYLINDER

The single-acting piston-type cylinder is similar in  design  and  operation  to  the

single-acting ram-type  cylinder.  The  single-acting  piston-type cylinder uses fluid

pressure to provide the force in  one  direction, and spring tension, gravity, compressed

air, or nitrogen is used to provide the force in the opposite direction.

In  some spring-loaded  cylinders  the  spring  is  located  on the  blank  side,  and

the fluid  port  is  on  the  rod side  of  the  cylinder. A   three-way   directional control

valve is normally  used  to  control  the  operation  of  the single-acting piston-type 22

cylinder. To extend the piston  rod,  fluid  under  pressure  is  directed through the port

into the cylinder .

This pressure acts on the surface area of the blank side of  the  piston  and forces

the  piston  to  the  right. This  action  moves  the  rod  to  the  right,  through the end of

the cylinder, thus moving the actuated unit  in  one  direction.

 During  this action, the spring is compressed between the rod side of the piston

and the end of the cylinder. The length of the stroke depends upon the physical limits

within the  cylinder  and  the required  movement  of  the actuated unit.

To   retract   the   piston   rod,   the directional control  valve  is  moved  to  the

opposite  working position,  which  releases  the pressure  in  the cylinder. The spring

tension forces the piston to the left, retracting the piston rod and moving the actuated

unit in the opposite direction.

The fluid is free to flow from the cylinder through the port, back through the

control valve to the atmosphere  in pneumatic  systems. The end of the cylinder opposite

the fluid port is vented to the atmosphere.

This prevents air from being trapped in this area. Any trapped air would

compress   during   the   extension   stroke, creating  excess  pressure on  the  rod  side

of  the piston.  This  would  cause  sluggish  movement  of the piston and could

eventually cause a complete lock,  preventing  the  fluid  pressure from moving the

piston.  

Fig 6.1 Single acting cylinder

23

6.6 DOUBLE-ACTING  CYLINDER

Most   piston-type   actuating   cylinders   are double-acting,   which   means   that

fluid  under pressure can be applied to either side of the piston to  apply  force  and

provide  movement. One  design  of  the  double-acting  cylinder  is shown in figure 6.2.

This cylinder contains one piston and piston rod assembly. The stroke of the piston  and

piston  rod  assembly  in  either  direction is  produced  by  fluid  pressure.

Fig no 6.2 Double acting cylinder

6.7 DIRECTIONAL VALVES

Valves are necessary to control the pressure, flow rate and direction of the fluid.

Pneumatic systems are low pressure systems. Pneumatic valves are made from cheaper

materials (e.g. aluminium and polymer) and are cheaper to manufacture.

The basic symbol for a valve is a rectangle to which external connections are

drawn. Inside the rectangle, the internal connections are shown for the normal position

of the valve.

6.7.1 3/2 Solenoid Valve:

24

Fig 6.3 3/2 Solenoid Valve

3/2 DC valve is used to control single acting cylinder. The term  solenoid may also

refer to a variety of transducer devices that convert energy into linear motion.

Fig 6.4 Solenoid Valve.

The term is also often used to refer to a solenoid valve, which is an integrated

device containing an electromechanical solenoid which actuates either a pneumatic or

hydraulic valve, or a solenoid switch, which is a specific type of relay that internally

uses an electromechanical solenoid to operate an electrical switch; For example,

an automobile starter solenoid, or a linear solenoid, which is an electromechanical

solenoid.

Fig 6.5 Magnetic Field Created by a Solenoid.

6.7.2 5/2 SOLENOID VALVE:

25

A B

PEA EB

Fig 6.6 5/2 Solenoid Valve

The two dark blocks represent the two possible valve positions. Actuator symbol

with a diagonal line indicates solenoid operations, return spring symbol indicates at rest

position. The arrow symbols indicate the direction of Gas Flow through the valve.

Letters A and B indicate the Output Port connections for the pneumatic actuators

(cylinders). EA and EB are exhaust ports. P is the fluid supply port.

Besides showing the internal connections, a valve symbol must show how the

valve element is moved. This is done by adding a small box at each end containing the

symbol showing how it is done. Some examples are shown below.

Fig 6.7 Types of operating control valve

26

Note: The center port with the brass One Touch Fitting is the

supply or pressure port.

A Hand lever operated and pilot return. B Pilot operated and pilot return. C Push knob

operated and spring return. D 3 position valve pilot/pilot with spring centring.

E Solenoid operated and solenoid return. F Roller operated and spring return.

6.7.3 Valve Bases

Directional and other valves are usually designed to be mounted on a separate

base. The external pipe work is connected to the base. The advantage of this is

standardisation of designs and it allows the valve to be removed without disconnecting

the pipe work. Hydraulic bases to ISO size 6 and 10 are shown below

Fig 6.8 Valve bases

Machines used in industrial applications use several valves and it is convenient to mount

them on a manifold so that supply and exhaust connections are common to all.This is a

common design for air valves.

6.7.4 Cartridge Valves

These are forms of poppet valve designed to fit into a manifold block. Just about all

valve types can be designed as a cartridge to fit into a block specially machined to accept

it. In this way a bank of valves may be built into one block. The block might contain

directional valves, relief valves, flow dividers, one way valves and so on.

27

6.8 OPERATION OF DIRECTIONAL VALVES

6.8.1 Solenoid Operated Valves

A solenoid is a coil with an iron plunger inside it. When current flows in the coil,

the plunger becomes magnetized and tries to move out of the coil. If a spring is used to

resist the movement, the distance moved is directly proportional to the current in the

coil. Solenoids are used in relays where they operate an electric switch. They are also

used in hydraulic and pneumatic valves to move the valve element.

A direct acting solenoid valve would have the plunger pushing directly on the

valve element as shown. This is more common in pneumatic valves.

Fig 6.9 Solenoid operated valves

28

4 2

5

1

3

4 2

5

1

3

4 2

5

1

3

2

1 3

2

1

clamping cylinderseparator cylinder stopper cylinder

tool cylinder

FRL unit

air supply

Designation Component Description

3/2 Way Valve

5/2 Way Valve

5/2 Way Valve

5/2 Way Valve

FRL unit Air service unit, simplif ied representation

air supply Compressed air supply

clamping cylinder Cylinder, Double-acting, with Two Piston Rods and Single Trestle

separator cylinder Cylinder, Double-acting, with in and out Piston Rod

stopper cylinder Single acting cylinder

tool cylinder Cylinder, Double-acting, with in and out Piston Rod

Fig 6.10 Pneumatic circuit diagram

CHAPTER-7

DEBURRING UNIT

29

7.1 SUGINO NEWTRIC SELFEEDER DEBURRING UNIT

MODEL SN4U

SPECIFICATIONS

STROKE MAX.: 3.15" 

SPINDLE TAPER:  JT1

THRUST: 310 LBS.

COLUMN DIAMETER: 2"

MOTOR: HORSEPOWER: 1/2

R.P.M.: 1100 Fig 7.1 Drill head

VOLTS: 230/460

AMPS: 1.1/0.55

OVERALL DIMENSIONS: 10" X 5" X 22" TALL

7.2 HYDRO SPEED REGULATOR

1. The regulator will control the forward speed of the spindle to any desired rate.

30

2. The suitable feed can be set to the work piece.

3. A constant smooth rate of travel is obtained.

4. The regulator prevents sudden forward surge breakthrough and thus prevents the

drill damage.

5. It is a compact and essential unit for precision and maintenance of accuracy,clean

finish and long life.

6. It has also other application as like a shock absorber or a linear speed regulator.

Fig 7.2 Hydro speed regulator

CHAPTER-8

FABRICATION PROCESS

31

8.1 WORKING PRINCIPLE

1) The burr in the nut has to be deburred. So the guide ways for the work is

machined to satisfy the sequence.

2) The nut is then dropped in to guide ways and it flows in to the stopper cylinder

which is in extended position and prevents the work to be flow down.

3) Then continuous feeding of the nut is done.

4) The clamping cylinder extends to clamp the work.

5) The separator cylinder extends to separate the penultimate work.

6) The stopper cylinder retracts for effective clamping.

7) The main spindle extends and the deburring action is satisfied.

8) The clamping cylinder retracts to release the machined work which gets collected

at the collection box.

9) The stopper cylinder now extends to stop the flow of the work.

10) The separator cylinder retracts and the penultimate work becomes the ultimate

one.

11) The sequence is then repeated with a time interval of 5 seconds.

8.2 COMPONENTS DESCRIPTION:

8.2.1 Deburring Machine Base.

32

The machine base is used to withstand the whole weight of the machine.

Fig 8.1 Deburring Machine Base

8.2.2 Supporting Plate For Guide Ways

This is given with an inclination of 35˚ and it supports the guide plate over

which the guide ways for nut is placed.

Fig 8.2 Supporting Plate For Guide Ways

8.2.3 Supporting Plate For Drill Head.

33

This is given with an inclination of 55˚ and it supports the guide plate over which

the drill head is placed.

Fig 8.3 Supporting Plate For Drill Head

8.2.4 Guide Plate For Drill Head.

This is used to support the drilling unit and in turn bolted to the supporting plate.

Fig 8.4 Guide Plate For Drill Head

8.2.5 Guide Plate For Guide Ways.

34

This is used to support the guide ways which is used to guide the nut.

Fig 8.5 Guide Plate For Guide Ways

8.2.6 Guide Ways

The guide ways are also fabricated based upon the availability. The guide ways is

bolted to the guide plate. These are used to guide the nuts and the ways are designed to

the size of M10 with some clearance.

Fig 8.6 Guide Ways

These are the problems faced during the fabrication process and the solution found to

overcome that. 35

Table 8.1 Problems faced

PROBLEMS

FACED

REASON FOR THE

PROBLEM

SOLUTIONS

FOUND

Pressure is not

maintained at constant

rate

Leakage of air at place of

joining the compressor tube

with the input to the DCV.

The joining is done

with a help of a

clamp.

Nut got stuck in the

guide ways.

Guide ways is not properly

aligned.

The guide ways is

adjusted.

Clamping cylinder not

retracting.

The end effecter of the

clamping cylinder is not

moving freely inside the guide

plate hole

Grinding is done at

the walls of the end

effecter.

Separating action is

not achieved

The top face of the end

effecter is locked with the

penultimate nut.

The top face of the

end effecter is

trimmed

The tool cylinder

extends with great

speed and damages

the work.

Hydro speed regulator is not

working.

Proper lubrication is

done and adjustment

is made.

The deburring action

is not done at the

required point.

The alignment of the inclined

guide base is been altered.

The alignment is

done properly with

respect to the tool

36

Fig 8.7 Functional diagram

BASIC SEQUENCE DIAGRAM

37

Fig 8.8 Basic sequence diagram

CHAPTER-9

AUTOCAD DIAGRAMS

38

9.1 FRONT VIEW - ASSEMBLY

9.2 BASE PLATE FOR CHUTE

39

9.3 BASE PLATE FOR DRILL HEAD

40

9.4 GUIDE WAYS

9.5 ASSEMBLY OF GUIDEWAYS UNIT

41

9.6 SUPPORTING PLATE FOR CHUTE

42

9.7 SUPPORTING PLATE FOR DRILL HEAD

9.8 DEBURRING MACHINE BASE

43

CHAPTER-10

44

CALCULATION

1) Area Of Chip = r θ t

= 5 30 0.5

= 235.6 mm2

Working force = area of chip

= 210 235.6

= 49476 N

Area of tool = d2

= 102

= 314.15 mm2

Tool force = area of the tool

= 220 314.15

= 69114 N

FOS = Tool force/Working force

= 1.5

FOS should be greater than 1. Thus the design is safe.

45

2) = 82; = 172.5;

Where,

- distance of the first bolt from the center of gravity of drill unit

- distance of the second bolt from the center of gravity of drill unit

Assume mass of the drill unit is 50kg

Moment = m g distance

= 500 172.5

= 86250 kgm

f =

=

= 1.872

Maximum loaded bolt = f

= f 172.5

= 322.98 N

FOS =

46

=

CHAPTER-11

TOTAL COST ESTIMATION:

Table no 11.1Total cost estimation

S.N.O CONTENTS COST IN Rs.

1) DRILL HEAD 125000

2) PNEUMATICS 16000

3) ELECTRICAL CONNECTIONS 9000

4) PUSH BUTTON BOX 3000

5) FABRICATION 8000

6) CONCEPT DEVOLOPMENT AND DESIGN 5000

7) PLC 10000

TOTAL 176000

47

CHAPTER-12

PHOTOS

FRONT VIEW LEFT SIDE VIEW

48

TOP VIEW ISOMETRIC VIEW

CHAPTER 13

APPENDICES

Feature Values

Standard Cylinder

Round Cylinder

49

CHAPTER-14

CONCLUSION

We have fabricated a deburring machine for the slotted nut of size M10. We planned to

have a vibratory bowl for the automatic work feed. In the mere future we will implement

the guide ways for different sizes and of adjustable type. The deburring machine reduces

the cost from Rs 0.10 by the present method to Rs 0.04 per work by our machine. And

hence we are planning to manufacture the machine in huge numbers and distribute it to

other plants.

50

REFERENCES

Mechanical Deburring And Surface Finishing Technology by Alfred F. Scheider.

Bollinger, J.G. and Duffie, N.A., Computer Control of Machines and Processes,

Addison-Wesley, 1989.

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