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Titan Industries Limited Hosur, Tamil Nadu Design and Analysis of EC 6 Press Machine

Final Project Doc

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Page 1: Final Project Doc

Titan Industries Limited Hosur, Tamil Nadu

Design and Analysis of EC 6 Press Machine

Page 2: Final Project Doc

CONTENTS

Serial No Topic Page No 1. Synopsis i 2. Abstract ii 3. Acknowledgement iii 4. Company Overview iv 5. Watch Manufacturing v 6. Departments and their functions vi 7. Parts of the Dial vii 8. PHASE I 1-12

9. EC 6 Press Machine 1 10. Description 1

11. Technical specification of ESSA EC 6 1

12. Parts of ESSA EC 6 1

13. Clutch Mechanism 2

14. Alternative Solution- Pneumatic Clutch and Brake 3

15. ORTLINGHAUS CLUTCH/BRAKE UNIT 4 16. Part list of Clutch/Brake Unit 6

17. ASSEMBLY 7

18. Development of design 8 19. PART DESIGNS 9 20. ASSEMBLY DRAWINGS 12 21. PHASE II 1-27

22. Design Analysis 1 23. Suspected vulnerabilities in the mentioned parts 1 24. STRESS ANALYSIS- FABRICATED PLATE 2

25. STRESS ANALYSIS- ECCENTRIC BLOCK 13

26. STRESS ANALYSIS- SHAFT ASSEMBLY 16

27. Conclusion viii 28. Bibliography ix

Page 3: Final Project Doc

i Synopsis

NEED FOR THE PROJECT

The existing EC 6 Press Machine in Titan Industries uses a rolling-key mechanism to transmit the drive to the shaft-assembly of the machine from the electrical motor through the flywheel. However, this arrangement caused a lot of problem in the manufacturing cycle of the industry due to erratic breakdown of the rolling-key mechanism. Hence a change in the existing mechanism was required for decreasing the time consumption in production due to constant breakdown of the machine.

OBJECTIVE OF THE PROJECT

The project is divided into 2 phases: Phase I: This phase aims at designing a modified version of the EC 6 Press Machine, replacing the rolling-key mechanism by introducing a pneumatic clutch (single plate). Phase II: This phase aims at finding out whether the design modifications made were correct on the basis of stress analysis of the each of the part of machine and the entire assembly as well. Dynamic simulation of the moving parts of the machine under various loads and different working conditions is also put into consideration for the analysis and the correct design for the modified version of the EC 6 Press Machine from the stress analysis and dynamic simulation reports is hence obtained.

TECHNICAL DETAILS

The spring attached to the rolling-key in the existing model of the EC 6 Press Machine generally fractures during its use frequently causing a breakdown. This flaw in the machine can be corrected by replacing the rolling-key by a pneumatic clutch. The pneumatic clutch is engaged by supplying compressed air at 5 bar pressure which transmits the power from the flywheel to the shaft assembly which in turn will rotate the cam and the cam transmits the required reciprocating motion to the tool of the machine.

# All the designing jobs involved are carried out in AutoCAD Inventor Professional Suite 2011.

CURRENT STATUS OF DEVELOPMENT

The existing model has been dismantled for the purpose of modification. Designing of the modified

version is done on the basis of stress analysis and dynamic simulation of the entire assembly. The

modified parts of the assembly is under is under fabrication. After the completion of the

fabrication of the various modified parts the machine will be assembled and it will be up and

running.

Page 4: Final Project Doc

Broad academic area of work: Mechanical designing and stress analysis

ii ABSTRACT

This brief about the project carried out at Titan Industries Limited (watches division), Hosur, is to

address the frequent breakdown of EC 6 press in the Module plant.

The following activities were carried out in the course of the project:

Detailed study was carried out on the existing process to identify the major cause for the breakdown of the machine.

Rolling key clutch mechanism was identified as the constraint for increase in frequent problems that lead to the breakdown of the EC 6 press.

Brainstorming was carried out to generate ideas and alternatives were short-listed for analysis.

The alternatives were analysed based on cost, investment, lead-time and change in process design and ranked with the input from functional experts. The optimal solution was selected based on the rankings.

The optimal solution found was “Pneumatic Clutch/Brake Mechanism”.

The rolling key mechanism was replaced by the Pneumatic Clutch/Brake Mechanism and the modified version of the press machine was made with modifications in the shaft assembly and a new fabricated plate was introduced to give the brake plate of the shaft assembly a permanent fixture.

The designing was done part wise and then all the parts were assembled together.

Once the designing job was over stress analysis of the various parts and sub-assemblies were carried out.

Based on the stress analysis reports the various changes were made in the dimensions in the design to eliminate all the anomalies.

Page 5: Final Project Doc

iii ACKNOWLEDGEMENT

The success of any project depends largely on the encouragement and guidelines of many people. I

take this opportunity to express my gratitude to the people who have been instrumental in the

successful completion of this project.

I would like to show my greatest appreciation to Mr Ganesan N, (Project Guide) Manager –

Maintenance (Module & Assembly), Titan Industries Limited, Hosur for accommodating my

request and giving me this challenging project to undertake. Without his encouragement and

guidance this project would not have materialised.

I would also like to take this opportunity to forward my deepest appreciation to Mr Sathish P,

Senior Engineer- Maintenance (Module & Assembly), who motivated and encouraged me

throughout the project and provided me with adequate time and resources to successfully

complete the project.

The guidance and support received from all the members who contributed and who are

contributing to this project, was vital for the success of the project. I am grateful for their constant

support and help.

Page 6: Final Project Doc

iv Company Overview

Titan Industries is the organisation that brought about a paradigm shift in the Indian Watch market when it introduced its futuristic quartz technology, complemented by international styling. With India’s two most recognized and loved brands Titan and Tanishq to its credit, Titan Industries is the fifth largest integrated Watch manufacturers in the world.

The success story began in 1984 with a joint venture between the Tata group and the Tamil Nadu Industrial Development Corporation. Presenting Titan quartz watches that sported an international look, Titan Industries transformed the Indian Watch market. After Sonata, a value brand of functionally styled watches at affordable prices, Titan Industries reached out to the youth segment Fastrack, its third brand, trendy and chic. This company has sold over 100 million watches world over and manufactures 12 million watches annually.

With a license for premium fashion watches of global brands, Titan Industries repeated its pioneering act and brought international brands into Indian market. Tommy Hilfiger and Hugo Boss, as well as the Swiss made watch-Xylys owe their presence in Indian market to Titan Industries.

Entering the largely fragmented Indian jewellery market with no known brands in 1995, Titan Industries launched Tanishq, India’s most trusted and fastest growing jewellery brand. Gold Plus, the later addition, focuses on the preferences of semi-urban and rural Indian. Completing the jewellery portfolio is Zoya, the latest retail chain in the luxury segment.

Titan Industries has leveraged its manufacturing competencies and branched into Precision Engineering Components and sub-assemblies, machine building and automation solutions, tooling solutions and electronic sub-assemblies in 2002. Titan Industries has also made its foray into prescription eyewear, launching the Titan Eye+ chain of world class optical stores in 2007.

With over 500 retail stores across a carpet area of 6, 60,000sq.ft. Titan Industries has emerged as India’s largest retail network. The company has over 290 exclusive “World of Titan”, “Helios” a Fastrack showroom and 745 after-sales-service centres. Titan Industries is also the largest jewellery retailer in India with over 140 Tanishq boutiques, Zoya and Gold Plus stores and over 75 Titan Eye+ stores.

Backed by over 4,300 employees, two exclusive design studios for watches and jewellery, over 5 manufacturing units and innumerable admirers world over, Titan Industries continues to grow and set new standards for innovation and quality. The organisation is all geared to the Titan and Tanishq success story with each new offering.

Page 7: Final Project Doc

v Watch Manufacturing

The Watch Manufacturing comprises of 3 basic units: 1. Module Unit

2. Casing Section

3. Strapping Section While the casing and strapping sections deals with the external components of the watch, the module manufacturing unit handles the internal components of the watch. Depending on the style and size, the modules are classified as a variety of series. At Titan Industries these are 5000, 6000, 7000 and 7100 series. Brief description of the components of Watch modules are as follows: 1. MINERAL GLASS: This is the component located at the extreme end of the front face of a module. This is attached to a bezel ring by means of a mineral glass gasket.

2. BEZEL RING: The ring is used to hold the mineral glass and is attached to the case centre by means of a bezel ring gasket.

3. CASE CENTRE: The case centre has components both within and outside it. It has a crown that can be pulled and turned over a case pipe.

4. SPRING BAR: This is a thin metal bar that is in either side of the module, it is used for strap attachment.

5. HANDS: Every analog watch has the hour hand, the minute hand. The second hand is optional and depends on the style and model of the watch module.

6. DIAL: There are a variety of dials with colours, numbering styles and dates, etc. depending on the series. EXAMPLE- In the 5000 series, model 5120 has 2 hands 7120 has no date. 7121 has date only. 7122 has date & mouth. 7. MOVEMENT MODULE: This is a long stem that does the job of a crown before watch module is cased. The movement module is also used to raise the module while shifting it to different sections during manufacturing. This is set in a plastic movement holder.

8. MAIN PLATE: It is used to support the whole assembly.

9. BACK COVER: The back cover of a Watch is attached to a plastic movement holder by means of a back cover gasket. The movement module or the main plate of the watch has 2 sides:

DIAL SIDE

BRIDGE SIDE

Page 8: Final Project Doc

vi Departments and their Functions 1. AUTO-TURNING: All the turned components from movement are made in this shop.

2. GEARS & SUB-ASSEMBLY: The production of all wheels and pinions required for movement are made in this shop.

3. PRESS SHOP: The production of sheet metal component required for the manufacture of a watch module.

4. EBAUCHE: The manufacture of the main plate and its sub-assemblies.

5. TREATMENT: Complete surface and heat treatment process in the manufacture of watches.

6. CASE MACHINE SHOP: Machining of watch case parts.

7. CASE POLISHING: Buffering and polishing watch cases to improve surface finish.

8. CASE PLATTING: Providing various surface coating to case, case parts and straps.

9. ASSEMBLY: Planning and supervising process assembly watch case parts.

10. DESIGNS: Design innovation and the preparation of standard technical designs incorporating manufacturing details of finished products.

11. INSPECTION & QUALITY CONTROL: Complete quality control through to all stages of manufacturing and assembly.

12. TRAINING: To ensure that the new employees are provided with appropriate training and information to enable them to perform their duties effectively, to continue further to update each one’s knowledge and skills from time to time.

13. PERSONNEL: To recruit right people capable of performing the organisation’s specific tasks, to utilize available human resources effectively and to act as a catalyst in the individual development of the people in the organisation. Employees, their family and their well-being are prime concern of the personnel department.

14. MEDICAL CENTER: Health care of all employees and medical aid at time of emergencies.

15. ADMINISTRATION: Enduring prompt services on security, transport, housekeeping, canteen, communication network, etc.

16. PROJECT: Planning scheduling and ionizing with external and internal sources for the establishment and smooth functioning of the project.

17. PLANT SERVICES: Monitoring and maintaining the essential services like power supply, compressed air supply, etc.

18. MACHINE MAINTENANCE: The regular maintaining of the essential services like power supply, compressed air-supply, etc.

19. INDUSTRIAL ENGINEERING: Studying the economics of production from work studies to job description. Enduring high production efficiency and promoting value engineering. 20. PURCHASE: The procurement of materials, tools, machinery and consumables required for the manufacturing and administration.

21. STORES: Storing and releasing materials, tools and consumables to the various departments to ensure uninterrupted functioning of organisation.

Page 9: Final Project Doc

vii PARTS OF THE DIAL

a) HSTC SCREW: This connects the hand setting train cover or the date plate to the dial side of the main plate.

b) DATE PLATE: The date plate is just below the dial, it is connected to the hand setting train wheel by means of a HSTC screw.

c) DAY INDICATOR: The day indicator is placed just below the date plate. The indicator is used to display different days of the week, the day indicator is the assembly of the day disc and the day star. There are 2 series of the day indicator, i.e. 7022 and 7122. The difference lies in the diameter of the discs.

d) HOUR WHEEL: The hour wheel is a circular toothed component that is used to move the hour hand.

e) MINUTE WHEEL: This also has teeth and is placed in such a way that the teeth of the hour wheel come in contact with that of the minute wheel this controls the movement of the minute hand.

f) CENTRE WHEEL: This component consists of the train wheel and a pinion. It is placed at the centre of the main plate. It also has teeth which fit into those of the minute wheel and rotate along with it.

g) YOKE: The yoke is below the centre wheel and is held in place by the yoke spring screw.

h) SETTING LEVER: The setting lever is placed directly on the main plate and is used while the watch is being set. It also houses the setting lever jumper for the purpose of the day and date jumping.

i) STEM: There is a stem which fits into a sliding pinion (also known as the drum wheel). This is used for stopping the watch when the hands need to be adjusted.

Page 10: Final Project Doc

1 Phase I

EC 6 Press Machine

Description

Essa EC 6 Press Machine is the main press used in the press shop to manufacture a number of components in the watch assembly. The standard components that are made using EC 6 arc, yoke, Battery Bridge, coil guard, center second stop lever, setting lever, etc. Essa EC 6, as in the name, is an Eccentric Crank

drive with a maximum working pressure of 6

tonnes. The transmission of energy stored in the

flywheel to the press is by means of a Rolling Key

clutch mechanism. It is a light duty press

providing shorter and quicker strokes.

Technical specification of ESSA EC 6

Pressure 6 tonnes

Execution: number of columns 2

Fixed table: Length 230 mm

Width 250 mm

Diameter 70 mm Number of strokes: up to 180 s/min

Fixed stroke 30 mm

Tool height 175 mm

Cutting area(50kg/mm2) 120 mm2

Distance between columns: Front

230 mm

Voltage(50Hz, 3∅) 380 V

Power 750 W (1 HP)

Overall machine dimensions:

Length 800 mm

Width 700 mm Height 1400 mm

Parts of ESSA EC 6

Base: The all machine tool base is one of the

parts of the press. It is the main supporting

member for workpiece holding dies and different

controlling mechanisms of the press. Size of the

table, limits the size of the workpiece that can be

processed.

Frame: The frame constitutes the main body of the press located at one edge of its base. It houses the support for the ram, driving mechanism and control mechanisms.

Balster plate: It is a thick plate attached to the bed or base of the press. It is used to clamp the die assembly rigidly to support the workpiece. The die used in working of the press may have more than one part that is why the phrase die assembly is used in the place of die.

Ram: This is the main operating part of the press which works directly during the processing of a workpiece. Ram reciprocates to and fro within its guide ways with prescribed stroke length and power. The stroke and power transmitted can be adjusted as per the requirements. Ram at its bottom end carries the punch to process the workpiece.

Pitman: It is the part which connects the ram and the eccentric shaft and creates linear movement.

Driving Mechanism: ESSA EC 6 is a flywheel driven press. This presses consists no gears so they are also called “No geared press”. For the transmission of power, motor pulley is connected to the flywheel driven eccentric shaft by Vee belt and pulley system. A clutch mechanism is used to engage or disengage the flywheel with the eccentric shaft.

Flywheel: In the EC 6 press machine, the driven

pulley is made of the shape of flywheel, which is

used for storing the energy reserve, for

maintaining constant speed of ram when punch is

pressed against the workpiece. The flywheel is

placed in the driving mechanism just before the

clutch in sequence of power transmission.

Page 11: Final Project Doc

2 Phase I

CLUTCH MECHANISM Rolling Key Clutch: The clutch mechanism used in the ESSA EC 6 is a rolling key clutch. Rolling key clutch is a type of full revolution clutch. It is a simple mechanical design that operates by means of engaging a rolling key. Once engaged, it disengages only after a full revolution of the shaft. The engaging mechanism is actuated manually by means of a lever. An obvious disadvantage is the inability to stop the press before top of stroke in the event that a misfeed is detected.

Engaging Device and Hand Guard When the guard BU, is at the top, the ram is blocked by the stop A1. As the guard is lowered, the stop A1 is forced down via the connecting rod US and rocking lever KH, and the eccentric shaft is freed for one revolution, i.e. the ram performs one stroke. After freeing the rotation of the eccentric shaft, the connecting rod US is forced back via the stop A2, so that the rocking lever KH disengages. The spring F1 fitted in the stop forces the stop to catch up again, so that the next stroke can be released only by pressing down the guard BU. The tension spring F2 connects the connecting rod with the stop, and re-engages the rocking lever in the guide of the connecting rod after the lever is reset. For Single-stroking the connecting rod is forced back at every revolution of the eccentric, so that the press is stopped after each stroke. For continuous operation the connecting rod is

held in its rear position by means of a locking

device, so that the rocking lever KH no longer

engages. In this way the stop A1 is retained at the

top and the machine strokes continuously.

Engaging: The flywheel runs continuously depending on the motor speed. The withdrawn stop A1 allows the cam (2) to turn 450 under the actions of the tensioned spring (7). With this movement the cam (2) releases the semi-circular key (4), which then turns on its axis under the action of the tension spring (1) and engages the first groove of the driving bush (8), i.e. the ram is enclutched.

Disengaging: The stop A1 is back in its starting

position, i.e. projecting, about 450 before the cam

(2) comes up against it, owing to the cam on bush

(9). During the remaining 450 movement by cam

(2) the springs (1 & 7) are tensioned, and the

semi-circular key (4) is forced back into the shaft

recess by the cam K. The flywheel runs free once

more and the ram is declutched.

Fig. Rolling Key clutch engaging mechanism

(diagram)

Page 12: Final Project Doc

3 Phase I

Alternative Solution

Pneumatic Clutch and Brake

Air actuation is the most common method for industrial equipment. Most industries have supply of compressed air that can serve the actuation of clutches and brakes. Pressures to 200 psi are used to inflate tubes or act on pistons to engage or disengage friction surfaces. Some are air-engaged and spring-disengaged; others are spring-engaged and air-disengaged. Some combination clutch-brakes use air-pressure to engage the clutch, and spring pressure to disengage the clutch while simultaneously engaging the brake. The greatest asset of an air-actuated clutch or brake is low heat generation in the actuator. Unlike an electric unit, there is no heat generation during a long period of engagement. Static pressure stays constant after the piston chamber is filled, so the power needed to sustain torque is almost nothing. As with the mechanical actuation, a degree of touch control or ‘feel’ can be gained with air clutches and brakes by channeling the pressure through hand or foot-operated throttles. Where remote control is desired, electrically actuated solenoid control valves may be used to pressurize a clutch or brake.

Supporting components To operate efficiently, air-actuated clutches and brakes need several supporting components:

Pressure regulators: Selected in accordance with their low capabilities, these valves set pressure ranges so that clutches and brakes deliver correct torque.

Filters: Installed ahead of the pressure regulator, a filter needs atleast 5 micron filtration capability.

Lubricators: Located between the pressure regulator and control valve, a lubricator injects oil into the air when pressure drops.

Control valves: Depending on the clutch or brake configuration, the control valve may be 3,4 or 5-way solenoid type. A 3-way valve controls either a clutch or brake. A 4-way valve controls a combination clutch-brake,

providing air to either component. A 5-way valve is used where the clutch and brake require different pressures. Generally, a control valve is located as close to its clutch or brake as possible to assure least lag-time.

Quick-exhaust valves: Installed at the clutch or brake inlet port and used where long lines are necessary, these valves improve response time because air need not travel back to the control to be exhausted. Instead, it exhausts at the quick –exhaust valve whenever supply pressure drops by, say, 3 to 5 psi.

Exhaust mufflers: To quite noisy valves, they typically reduce noise levels by up to 16 dB.

A disadvantage of air-actuated clutches and brakes is the support equipment needed the maintenance costs that go with it. The clutches and brakes themselves, however, use actuators that are typically no more complex than a cylinder and piston sealed with O-rings or U-cups. Thus, no special skills are needed to maintain them.

Fig: Pneumatic Circuit

Page 13: Final Project Doc

4 Phase I

ORTLINGHAUS CLUTCH/BRAKE UNIT

Introduction

Ortlinghaus pneumatically actuated clutch/brake combined units are designed based on the requirement given by the customer, to meet the ever increasing performance and safety requirements in presses. The series 0-420 offers the optimum in terms of maximum clutch brake torques with the smallest of dimensions, i.e. high performance compact design. These combined units represent the optimum drive component in stamping and forming presses and offer excellent adaptability in the following areas:

12-point suspension of the friction plates or two point suspension with lugs of the same or different lengths, giving flexibility for different applications.

Friction element selection, based on shape and material, to obtain the most effective service life with quiet operation under all conditions. The friction block version is to be recommended for machines with either high dynamic loading or load reversals under continuous operation.

Securing to the shaft or crank shaft can be with the aid of either keys or locking assemblies, these being fitted on the clutch side with series 0-420.

Friction combination: Cast iron/organic friction lining or cast iron/friction block of organic friction material.

Air intake: Via rotary inlet through shaft.

Application: On stamping and forming presses, on deep drawing presses, embossing presses and similar machines.

Functional description

Ortlinghaus 0-420 series is a clutch and brake mechanism combined in a single unit. The normal operating pressure of the unit is 5.5 bar and maximum permissible pressure is 6 bar.

Braking

Initially the pressure spring 4 press against piston 3 in the cylinder. This causes brake plate 2 to be pressed against the stop plate, thus bringing about the braking action in the unit.

Engaging the clutch

When the compressed air is applied to the piston via air intake 5, it causes brake plate 2 to be released and clutch plate 1 to engage. This causes clutch plate 1 to be pressed against the clutch body and transmit the motion from the flywheel to the shaft.

Fig.: Cross-sectional view of clutch/brake unit

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5

Fig.: Exploded view of clutch/brake unit

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6 Phase I

Table: Part list of Clutch/Brake Unit

Item Individual part

1 Hub

1.1 Hub

2 Ring

2.1 Ring

2.2 Dowel pin

2.3 Bolt

3 Springs 3.1 Spring mounting plate

3.2 Spring

3.3 Dowel pin

4 Clutch plate (12-point suspension)

4.1 Base element 4.2 Sleeve

4.3 Bolt

4.4 Strap

4.5 Circlip 4.6 Bolt

4.7 Tensioning sleeve

5 Piston

5.1 Piston 5.2 Grooved ring

5.3 Grooved ring

6 Brake plate (12-point suspension)

6.1 Base element 6.2 Sleeve

6.3 Bolt

12 Friction pad version

12.1 Housing plate section 12.2 Sleeve

12.3 Bolt

12.4 Friction pad

Page 16: Final Project Doc

7 Phase I

ASSEMBLY

Installation of Clutch

The Ortlinghaus 0-420 Clutch/Brake unit can be installed by two methods:

By 12-point plate suspension

By 2-point plate suspension In 12-point plate suspension method, the plates are mounted on the machine through 12 holes provided in them. In 2-point plate suspension method, the plates are mounted through 2 lugs at opposite ends of the plate. In EC 6 conversion 12-point plate suspension has been selected on the basis of the following criteria:

High frequency of operation (engaging and disengaging).

Heavy stresses generated on the clutch and the brake plates by the flywheel.

Ease of mounting on the machine base.

To distribute the load uniformly on the base.

Fig: 12-point suspension

Twelve-point suspension In 12-point suspension, the plates are

provided with 12 holes.

The brake plate halves are held by spring pressure and clutch halves by means of the securing straps.

The brake plate half will fall out if compressed air is applied to the clutch/brake unit, so it has to be tightened up using bolts.

Apply compressed air to the clutch/brake unit.

Insert sleeve 1. Tighten self-locking bolt 2 to the prescribed torque (refer table 4).

Turn flywheel until a securing hole is located opposite a recess in the brake plate. \

Insert one of the clutch plate halves if the clutch plate has been removed.

Insert sleeve 1. Tighten self-locking bolt 2 to the prescribed torque (refer table 4). Insert remaining five sleeves and tighten bolts.

Proceed in the same way with the other plate

half.

Table: Torque value for tightening bolts

Strength Class: 10.9

Locking agent: loctite 262

Design size

23 29 40 50 61 62 67 72

N-m 8.5 8.5 15 35 69 69 120 190

Design Size

77 80 83 87 91 91 92 93

N-m 190 295 580 1000 1000 1000 1500 2000

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8 Phase I

Installation conditions

Moving parts must be safeguarded by the customer against unintended contact, without significantly compromising the ventilation.

The installation area, with its connection faces, and the product must be free of grease, dust or other combination.

It must be ensured that the friction components are not contaminated by operating fluids such as oil or grease during installation or subsequent operation. If clamping rings are used for shaft connection then no oil must emerge from these after installation.

There must be no damage present at the joints of the machine.

Observe the fitting and position tolerances and the data on the product drawing. Otherwise small cracks or gaps from angular or radial misalignment of the shaft/machine are created.

Ensure that there is adequate space available in the installation area.

Development of design

The existing EC 6 Press Machine utilizes a Rolling key mechanism to transmit the power from the motor to the shaft assembly through the flywheel. But the spring that is used to engage the key for the power transmission was more prone to failure causing frequent breakdowns of the production line. To prevent the breakdown of the machine and to continue with the production without any glitches the rolling key mechanism is replaced by a Pneumatic Clutch (single plate). The preliminary aim of the project is to design the modified version of the Press Machine by the modification of the frame and its parts and introducing the pneumatic clutch in the assembly replacing the rolling-key clutch mechanism.

Page 18: Final Project Doc

9 Phase I

Part Designs

1. Bearing(Diameter- 85mm) It is designed to support the shaft from bending due the vertical component of the weight the parts assembled on it.

2. Bearing(Diameter- 100mm) It is designed to support the shaft from bending due the vertical component of the weight the parts assembled on it.

3. Bowl It serves the purpose of holding the coupling attached to the shaft assembly.

4. Brake plate mounting bracket It is designed to support the brake plate of the clutch/brake unit.

5. Brake plate pin It helps to attach the brake plate to the fabricated plate.

6. Centre plate clutch

It is the center plate of the clutch/brake unit used to transmit the torque during engagement of the clutch.

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10 Phase I

7. Clutch key It helps to transmit the power from the clutch to the shaft assembly.

8. Coupling

It acts a supporting element for the eccentric block.

9. Cover Plate

It separates the brake plate of the clutch/brake unit from the top base to reduce wearing of the unit.

10. Eccentric Block It is a part of the shaft assembly which acts a cam to convert the rotating motion of the shaft as a reciprocating motion and transmit it to the punch.

11. Fabricated Plate

The brake plate of the clutch/brake unit is mounted on this plate for permanent fixture.

12. Flywheel

Stores energy provided by the electric motor and supplies the same energy to the clutch plate which in turn supplies it to the shaft during engagement.

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11 Phase I

13. Guiderod

It helps the ram of the machine to reciprocate as the shaft rotates and the eccentric block makes it reciprocate.

14. Machine Base

It supports the entire mechanism and houses the various assemblies and sub –assemblies along with the electric motor and the belt drive to rotate the flywheel.

15. Round Pin

It is used to attach the flywheel to the clutch plate of the clutch/brake unit.

16. Sleeve

It supports the shaft and separates it from the top base to reduce wear.

17. Spacer It helps to keep an optimum space between the clutch/brake unit and the sleeve.

18. Top base

It supports the shaft assembly and houses the guiderod which makes the ram reciprocate.

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12 Phase I

ASSEMBLY DRAWINGS

Fig.: EC 6 assembly-Modified version

Fig.: Shaft assembly-Modified Version

Fig.: Top base assembly-Modified Version

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1 PHASE II

Design Analysis

This Phase of the project deals with simulating the various stresses developed in the machine.

The simulation is done on the major parts and sub-assemblies in the modified version of the

machine which are suspected to be more vulnerable to distortion or failure due to the generation

of stress.

The major parts and sub-assembly which have been put under stress analysis are:

1. Fabricated Plate

2. Eccentric Block

3. Shaft

4. Shaft-assembly

The simulations of the stress situations due to static as well as dynamic loading have been

considered and the design has been tested.

Suspected vulnerabilities in the mentioned parts

1. Fabricated plate: Wearing out of the thread holes due to the braking torque applied by

the brake plate of the clutch/brake unit.

2. Eccentric Block: Failure of the eccentric block due to the periodic shock load applied on

the on the block by the guiderod.

3 & 4. Shaft and Shaft assembly: Bending of the shaft due to weight of the clutch/brake unit

and the flywheel assembled on it. The tension of the belt is also considered to simulate the

load on the shaft.

The stress analysis reports of the parts of the above mentioned parts and sub-assemblies are

reports generated by the Autodesk Inventor Professional Suite 2011.

The reports include deflection of the parts and the sub-assembly in under static and dynamic load

situations. The bending and failure of the parts (if any) are also indicated.

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2 PHASE II

STRESS ANALYSIS- FABRICATED PLATE

Stress Analysis Report

Simulation: 1

General objective and settings:

Design Objective Single Point

Simulation Type Static Analysis

Last Modification Date 09-07-2012, 02:19

Detect and Eliminate Rigid Body Modes Yes

Advanced settings:

Avg. Element Size (fraction of model diameter) 0.1

Min. Element Size (fraction of avg. size) 0.2

Grading Factor 1.5

Max. Turn Angle 60 deg

Create Curved Mesh Elements Yes

Material(s)

Name Steel, High Strength Low Alloy

General

Mass Density 7.84 g/cm^3

Yield Strength 275.8 MPa

Ultimate Tensile Strength 448 MPa

Stress

Young's Modulus 200 GPa

Poisson's Ratio 0.287 ul

Shear Modulus 77.7001 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 47 W/( m K )

Specific Heat 420 J/( kg c )

Part Name(s) Fabricated plate.ipt

Analyzed File: Fabricated plate.ipt

Autodesk Inventor Version: 2011 (Build 150239000, 239)

Creation Date: 09-07-2012, 02:21

Simulation Author: Somnath Bhattacharjee

Summary:

Page 24: Final Project Doc

3 PHASE II

Operating conditions

Force: 1

Load Type Force

Vector X -16.021 N

Vector Y -11.972 N

Vector Z 0.000 N

Selected Face(s)

Force: 2

Load Type Force

Vector X -14.328 N

Vector Y -13.954 N

Vector Z 0.000 N

Selected Face(s)

Page 25: Final Project Doc

4 PHASE II

Force: 3

Load Type Force

Vector X -7.193 N

Vector Y -18.662 N

Vector Z 0.000 N

Selected Face(s)

Force: 4

Load Type Force

Vector X -1.198 N

Vector Y -19.964 N

Vector Z 0.000 N

Selected Face(s)

Page 26: Final Project Doc

5 PHASE II

Force: 5

Load Type Force

Vector X 8.654 N

Vector Y -18.031 N

Vector Z 0.000 N

Selected Face(s)

Force: 6

Load Type Force

Vector X 9.605 N

Vector Y -17.542 N

Vector Z 0.000 N

Selected Face(s)

Page 27: Final Project Doc

6 PHASE II

Force: 7

Load Type Force

Vector X 15.752 N

Vector Y -12.323 N

Vector Z 0.000 N

Selected Face(s)

Force: 8

Load Type Force

Vector X 19.239 N

Vector Y 5.464 N

Vector Z 0.000 N

Selected Face(s)

Page 28: Final Project Doc

7 PHASE II

Force: 9

Load Type Force

Vector X 17.974 N

Vector Y 8.770 N

Vector Z 0.000 N

Selected Face(s)

Force: 10

Load Type Force

Vector X -5.451 N

Vector Y 19.243 N

Vector Z 0.000 N

Selected Face(s)

Page 29: Final Project Doc

8 PHASE II

Force: 11

Load Type Force

Vector X -15.771 N

Vector Y 12.300 N

Vector Z 0.000 N

Selected Face(s)

Force: 12

Load Type Force

Vector X -10.801 N

Vector Y 16.833 N

Vector Z 0.000 N

Selected Face(s)

Page 30: Final Project Doc

9 PHASE II

Force: 13

Load Type Force

Vector X -14.701 N

Vector Y 13.561 N

Vector Z 0.000 N

Selected Face(s)

Fixed Constraint: 1

Constraint Type Fixed Constraint

Selected Face(s)

Page 31: Final Project Doc

10 PHASE II

Results

Reaction Force and Moment on Constraints

Constraint Name Reaction Force Reaction Moment

Magnitude Component (X,Y,Z) Magnitude Component (X,Y,Z)

Fixed Constraint:1 38.9716 N

14.2375 N

44.845 N m

0 N m

36.2777 N 0 N m

0 N -44.845 N m

Result Summary

Name Minimum Maximum

Volume 3173200 mm^3

Mass 24.8779 kg

Von Mises Stress 0.00000000504795 MPa 0.115715 MPa

1st Principal Stress -0.0238676 MPa 0.0937576 MPa

3rd Principal Stress -0.0834569 MPa 0.0250434 MPa

Displacement 0 mm 0.00000297303 mm

Safety Factor 15 ul 15 ul

Figures

Von Mises Stress

Page 32: Final Project Doc

11 PHASE II

1st Principal Stress

3rd Principal Stress

Page 33: Final Project Doc

12 PHASE II

Displacement

Safety Factor

Page 34: Final Project Doc

13 PHASE II

STRESS ANALYSIS- ECCENTRIC BLOCK

Stress Analysis Report

Analyzed File: Eccentric block.ipt

Autodesk Inventor Version: 2011 (Build 150239000, 239)

Creation Date: 09-07-2012, 16:34

Simulation Author: Somnath Bhattacharjee

Summary:

Simulation: 1

General objective and settings:

Design Objective Single Point

Simulation Type Modal Analysis

Last Modification Date 09-07-2012, 16:33

Number of Modes 8

Frequency Range 0 - 180

Compute Preloaded Modes No

Enhanced Accuracy No

Advanced settings:

Avg. Element Size (fraction of model diameter) 0.08

Min. Element Size (fraction of avg. size) 0.2

Grading Factor 1.5

Max. Turn Angle 60 deg

Create Curved Mesh Elements Yes

Material(s)

Name Steel, High Strength Low Alloy

General

Mass Density 7.84 g/cm^3

Yield Strength 275.8 MPa

Ultimate Tensile Strength 448 MPa

Stress

Young's Modulus 200 GPa

Poisson's Ratio 0.287 ul

Shear Modulus 77.7001 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 47 W/( m K )

Specific Heat 420 J/( kg c )

Part Name(s) Eccentric block.ipt

Page 35: Final Project Doc

14 PHASE II

Operating conditions

Force: 1

Load Type Force

Vector X -25.363 N

Vector Y -493.348 N

Vector Z 0.000 N

Selected Face(s)

Page 36: Final Project Doc

15 PHASE II

Fixed Constraint: 1

Constraint Type Fixed Constraint

Selected Face(s)

Results

Result Summary

Name Result Value

Volume 164852 mm^3

Mass 1.29244 kg

Page 37: Final Project Doc

16 PHASE II

STRESS ANALYSIS- SHAFT ASSEMBLY

Stress Analysis Report

Analyzed File: Shaft assembly_new.iam

Autodesk Inventor Version: 2011 (Build 150239000, 239)

Creation Date: 09-07-2012, 23:45

Simulation Author: SomnathB

Summary:

Project Info (iProperties)

Physical

Mass 15.7584 kg

Area 868182 mm^2

Volume 8227410 mm^3

Center of Gravity x=-0.277797 mm y=-1.70027 mm z=-212.384 mm

Simulation: 1

General objective and settings:

Design Objective Single Point

Simulation Type Modal Analysis

Last Modification Date 09-07-2012, 23:35

Number of Modes 8

Frequency Range 0 - 700

Compute Preloaded Modes Yes

Enhanced Accuracy Yes

Advanced settings:

Avg. Element Size (fraction of model diameter) 0.08

Min. Element Size (fraction of avg. size) 0.2

Grading Factor 1.5

Max. Turn Angle 60 deg

Create Curved Mesh Elements No

Use part based measure for Assembly mesh Yes

Page 38: Final Project Doc

17 PHASE II

Material(s)

Name Steel, Mild

General

Mass Density 7.86 g/cm^3

Yield Strength 207 MPa

Ultimate Tensile Strength 345 MPa

Stress

Young's Modulus 220 GPa

Poisson's Ratio 0.275 ul

Shear Modulus 0 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 56 W/( m K )

Specific Heat 460 J/( kg c )

Part Name(s) Shaft1.ipt

Name Cast Iron

General

Mass Density 7.25 g/cm^3

Yield Strength 200 MPa

Ultimate Tensile Strength 276 MPa

Stress

Young's Modulus 120.5 GPa

Poisson's Ratio 0.3 ul

Shear Modulus 0 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 50 W/( m K )

Specific Heat 540 J/( kg c )

Part Name(s)

100dia plate.ipt 0420-129-61-332000_Clutch.ipt Flywheel.ipt coupling.ipt

Name Steel, High Strength Low Alloy

General

Mass Density 7.84 g/cm^3

Yield Strength 275.8 MPa

Ultimate Tensile Strength 448 MPa

Stress

Young's Modulus 200 GPa

Poisson's Ratio 0.287 ul

Shear Modulus 0 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 47 W/( m K )

Specific Heat 420 J/( kg c )

Part Name(s)

Eccentric block.ipt Clutch key.ipt Clutch key.ipt Sleeve.ipt

Name Cast Steel

General

Mass Density 7.85 g/cm^3

Yield Strength 250 MPa

Ultimate Tensile Strength 300 MPa

Stress

Young's Modulus 210 GPa

Poisson's Ratio 0.3 ul

Shear Modulus 0 GPa

Stress Thermal

Expansion Coefficient 0.000012 ul/c

Thermal Conductivity 50 W/( m K )

Specific Heat 460 J/( kg c )

Part Name(s) Spacer.ipt

Page 39: Final Project Doc

18 PHASE II

Operating conditions

Force: 1

Load Type Force

Vector X -80.283 N

Vector Y -487.433 N

Vector Z -0.000 N

Selected Face(s)

Page 40: Final Project Doc

19 PHASE II

Fixed Constraint: 1

Constraint Type Fixed Constraint

Selected Face(s)

Page 41: Final Project Doc

20 PHASE II

Fixed Constraint: 2

Constraint Type Fixed Constraint

Selected Face(s)

Page 42: Final Project Doc

21 PHASE II

Fixed Constraint: 3

Constraint Type Fixed Constraint

Selected Face(s)

Page 43: Final Project Doc

22 PHASE II

Fixed Constraint: 4

Constraint Type Fixed Constraint

Selected Face(s)

Page 44: Final Project Doc

23 PHASE II

Fixed Constraint: 5

Constraint Type Fixed Constraint

Selected Face(s)

Page 45: Final Project Doc

24 PHASE II

Results

Frequency Value

Result Summary

Name Result Value

Volume 8227430 mm^3

Mass 60.3516 kg

Figures

F1 20.54 Hz Displacement

F1 20.54 Hz

Page 46: Final Project Doc

25 PHASE II

F1 20.54 Hz X Displacement

Page 47: Final Project Doc

26 PHASE II

F1 20.54 Hz Y Displacement

Page 48: Final Project Doc

27 PHASE II

F1 20.54 Hz Z Displacement

Page 49: Final Project Doc

viii CONCLUSION

The CAD designs of the parts of the modified version of the EC6 Press Machine along with

their dimension specifications are:

1. Fabricated Plate

2. Spacer

3. Sleeve

4. Cover Plate

5. Flywheel

6. Shaft

7. Eccentric Block

8. 100 dia plate

9. Clutch key

10. Top Base

11. Machine base

12. Modified EC 6 Press Machine assembly

Page 50: Final Project Doc

A-A ( .4 )

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

ED B

Y A

N A

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DE

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OD

UC

T1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Fabricated plate

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:1

Approved

Of:SheetScale5

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

1

Dim. Linear

mm

Angular

±50 ±25"

A

A

n437,00

24,00

M10x1.5 - 6H12 nos @ PCD 408,00

N6

N6

n14

5,00

THRU

A

f 10 A

b 10 A

F:\E

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atic

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A1 A2

A3A4A5

A6

HOLE TABLEHOLE XDIM YDIM DESCRIPTION

A1 -105,00 40,00 n8,20 THRUv n15,00 x 9,00

A2 105,00 40,00 n8,20 THRUv n15,00 x 9,00

A3 144,00 92,00 n8,20 THRUv n15,00 x 9,00

A4 0,00 92,00 n8,20 THRUv n15,00 x 9,00

A5 -144,00 92,00 n8,20 THRUv n15,00 x 9,00

A6 0,00 167,00 n8,20 THRUv n15,00 x 9,00

0.4 : 1

HARDNESS: 550 HV - 600 HV

Page 51: Final Project Doc

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

ED B

Y A

N A

UTO

DE

SK E

DU

CAT

ION

AL P

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T1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Spacer

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:2

Approved

Of:SheetScale5

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

2

Dim. Linear

mm

Angular

±50 ±25"

4,00

n60,0

0

45,0

0 H

*

N6 N6

A

f 10 A

2.5 : 1

HARDNESS: 550 HV - 600 HV

NOTE: *Sliding fit with Shaft

Page 52: Final Project Doc

B ( 5 )

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

ED B

Y A

N A

UTO

DE

SK E

DU

CAT

ION

AL P

RO

DU

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DU

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DU

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UC

T1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Sleeve

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:3

Approved

Of:SheetScale5

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

3

Dim. Linear

mm

Angular

±50 ±25"

B

207,00 + 1050+

30,00147,0030,00

n60,00

45,0

0 H

7*

45,0

0 H

7*

n50

,00

N6

N6

Ab 5 A

b 5 A

N6N6

f 5 A

NOTE: *Sliding fit with Shaft Chamfer points: C1, C2, C3 & C4 0,20 X 45°

C1 C2 C3 C4

0,20 X 45,00°

1.25 : 1

HARDNESS: 550 HV - 600 HV

Page 53: Final Project Doc

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

ED B

Y A

N A

UTO

DE

SK E

DU

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ION

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DU

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T1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Cover plate

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:4

Approved

Of:SheetScale5

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

4

Dim. Linear

mm

Angular

±50 ±25"

1.5 : 1

n120,0

0

2,50

n5,50 THRUw n10,40 X 90,00°6 Nos @ PCD 100,00

80,0

N6 N6

60,00°

A

f 10 A

HARDNESS: 550 HV - 600 HV

Page 54: Final Project Doc

A-A ( .35 )

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

Cast Iron

Part Name

Remarks:

Flywheel

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1 no

:1

Approved

Of:SheetScale1

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

5

Dim. Linear

mm

Angular

±50 ±25"

A

A

70,00

5,00

80,0

0 H

#

27,00 + 010+

n80

,00

H7#

18,00 + 010+

n40,00

H7*

THRU

n408,00

PCD

15,00°

15,00°

15,00

°

M12x1.7518 nos

45,0

N6

N6

N6

N6

NOTE: # Sliding fit with Bearing outer race * Sliding fit with Shaft

F:\E

C6 c

onve

rsio

n\EC

6-P

neum

atic

clu

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raw

ing

files

\Fly

whe

el.id

w

U cut

U cut

Part to be given

.35 : 1

C

b 10 C b 10 C

f 10 C

f 10 C

Page 55: Final Project Doc

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

EN 45

Part Name

Remarks:

Round pin

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

18

:1

Approved

Of:SheetScale2

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

6

Dim. Linear

mm

Angular

±50 ±25"

n16,0

0

13,00A/F

M10x1

.5 -

6g

20,0022,50 + 020+

N6

N6

F:\E

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atic

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h pl

ate.

idw

0,50 X

45,00

°

U cutR 0,25M10

x1.5 -

6H

22,00

5 : 1

42,50

Page 56: Final Project Doc

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

EN 45

Part Name

Remarks:

Brake plate pin

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

18

:2

Approved

Of:SheetScale2

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

7

Dim. Linear

mm

Angular

±50 ±25"

0,50 X 45,00°

U cutR 0,25

M10x1.5 - 6g

50,5

0+

020+

24,0

0

N6

N6

15,0

0A/

F

n20,00

38,0

0

M10x1.5 - 6H

2.5 : 1

74,5

0

Page 57: Final Project Doc

A-A ( .6 )

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

---

Part Name

Remarks:

Shaft assembly

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1 set

:1

Approved

Of:SheetScale4

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

8

Dim. Linear

mm

Angular

±50 ±25"

A A

100dia plate

Eccentric block

F:\E

C6 c

onve

rsio

n\EC

6-P

neum

atic

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\Sha

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Page 58: Final Project Doc

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Shaft & Key

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1 & 2

:2

Approved

Of:SheetScale4

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

8a &8b

Dim. Linear

mm

Angular

±50 ±25"

174,00161,5047,5050,009,00

18,00

11,00

1,50

3 ,1 8°

M30x1.5 - 6g

n32

,00

2,00

n34

,00

40,0

0n

+510

+#

n45

,00

h6*

Ø44

,00

n45

,00

h6*

M45x1.5 - 6g

12,50

n40

,00

h6*28,00Ø

90,00

14,00Width Keyway

4,10Deep Keyway

N6

n38

,00

N6

61,00

n37

,30

CIRCLIP GROOVE

2,00

M24x1.5 - 6H

NOTE: * Sliding fit with bearing inner race # Intereference fit with Eccentric block & 100dia plate

87,00

F:\E

C6 c

onve

rsio

n\EC

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neum

atic

clu

tch

conv

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raw

ing

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\Sha

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.idw

15,0

15,00°

586,50

52,50

90,00

n14,00

7,95A

f 5 AHARDENED & GROUND

n8,00 THRU

36,00A/F

HARDNESS: 550 HV - 600 HV

#INTERFERENCE FIT WITH 100Dia PLATE

Page 59: Final Project Doc

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

OHNS

Part Name

Remarks:

Eccentric block

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:3

Approved

Of:SheetScale4

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

8c

Dim. Linear

mm

Angular

±50 ±25"

n80,00 h6

15,0

022

,50

n24,00

THRU

40,00

n

-100+

#

THRU

25,00

25,0

0

M6x1 - 6H

N6

50,00

N6 N6

NOTE: #Interference fit with shaft

F:\E

C6 c

onve

rsio

n\EC

6-P

neum

atic

clu

tch

conv

ersi

on\D

raw

ing

files

\Sha

ft a

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bly_

new

.idw

28,50 28,50

M4x

0.7

- 6H

DEEP

25,

00

HARDENED & GROUND

N6

HARDNESS: 550 HV - 600 HV

Page 60: Final Project Doc

B ( 10 )

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

SKS 3

Part Name

Remarks:

100 Dia plate

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:4

Approved

Of:SheetScale4

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

8d

Dim. Linear

mm

Angular

±50 ±25"

B

n62

,00

1,00

4,00

5,00

n100,00 h6

45,0

0- 1

00+

Ø

A

r 10 A

N6

N6

NOTE: #Interference fit with shaft

HARDENED & GROUND

HARDNESS: 550 HV - 600 HV

Page 61: Final Project Doc

A-A ( 1/3 )

1

1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

Qty.Material

Cast Iron

Part Name

Remarks:

Top base

Drawn CheckedSig.

TITA

N IN

DU

STR

IES

LTD

.(M

OD

ULE

MA

INTE

NA

NC

E)

1

:1

Approved

Of:SheetScale1

DatePROJECT NAME:

Item

WATCH DIVISION

EC 6 Pneumatic clutch conversion

Tol.

mm

General Tol.Unit

9

Dim. Linear

mm

Angular

±100 ±25"

A

A

F:\E

C6 c

onve

rsio

n\EC

6-P

neum

atic

clu

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bas

e1.id

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48,00

f 10 A

42,00

b 10 A

N6

A

3,00 + 020+

19,00

n91

,50

f 10 A

Milling finish

A1 A2

A3A4A5

A6

B1B2B3

C1

C2

C3

C4

C5

C6

HOLE TABLEHOLE XDIM YDIM DESCRIPTION

A1 -105,00 40,00 M8x1.25 - 6HA2 105,00 40,00 M8x1.25 - 6HA3 144,00 92,00 M8x1.25 - 6HA4 0,00 92,00 M8x1.25 - 6HA5 -144,00 92,00 M8x1.25 - 6HA6 0,00 167,00 M8x1.25 - 6H

B1 165,00 120,00Dowel hole

n8,00 - 100+ -15,00 DEEP

B2 0,00 120,00Dowel hole

n8,00 - 100+ -15,00 DEEP

B3 -165,00120,00Dowel hole

n8,00 - 100+ -15,00 DEEP

C1 0,00 50,00 M5x0.8 - 6HC2 43,30 25,00 M5x0.8 - 6HC3 43,30 -25,00 M5x0.8 - 6HC4 0,00 -50,00 M5x0.8 - 6HC5 -43,30 -25,00 M5x0.8 - 6HC6 -43,30 25,00 M5x0.8 - 6H

Circlip groove

b 10 A

n85

,00

Page 62: Final Project Doc

A-A ( .2 )

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

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2

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3

3

4

4

5

5

6

6

A A

B B

C C

D D

±25"

Angular

±100

General Tol.

Linear

Datemm

Tol.

mm

EC 6 Pneumatic clutch conversion

Dim.

X

Unit

ItemEC 6 Machine

assembly---

Part Name Material

Remarks:

Drawn Checked

---

Approved

WATCH DIVISION

PROJECT NAME: Scale

Sig.

1 3 Sheet :

:Of

TITA

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Qty.

50,00

108,

00

Machine base

Top base assembly

Brake plate pin

Round pin

Flywheel

Shaft assembly_new

DIN 471 - 40x1.75

Spacer

Sleeve

100dia bearing

85dia bearing

80dia bearing

NOTE: Clutch not visible Top base moves 40mm (from its Original mounting position)

FRONT SIDE

F:\E

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atic

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Page 63: Final Project Doc

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

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Y A

N A

UTO

DE

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1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

±25"

Angular

±100

General Tol.

Linear

Datemm

Tol.

mm

EC 6 Pneumatic clutch conversion

Dim.

X

Unit

ItemEC 6 Machine

assembly---

Part Name Material

Remarks:

Drawn Checked

---

Approved

WATCH DIVISION

PROJECT NAME: Scale

Sig.

2 3 Sheet :

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TITA

N IN

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NOTE: Clutch not visible Top base moves 40mm (from its Original mounting position)

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Page 64: Final Project Doc

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT

PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCTPR

OD

UC

ED B

Y A

N A

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DE

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1

2

2

3

3

4

4

5

5

6

6

A A

B B

C C

D D

±25"

Angular

±100

General Tol.

Linear

Datemm

Tol.

mm

EC 6 Pneumatic clutch conversion

Dim.

10a &10b

Unit

ItemMachine base &Projected piece

---

Part Name Material

Remarks:

Drawn Checked

---

Approved

WATCH DIVISION

PROJECT NAME: Scale

Sig.

3 3 Sheet :

:Of

TITA

N IN

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Qty.

156,

0014

0,00

155,00

24,8

4° 50,9

0

96,0

0

R107,8

6 552,00

560,00

n40,00

THRU5,00

Plate thick

R50,00

Weldment

Weldment

Weldment

100,

00

64,00 6,00

100,

00

8,00

50,0

0

14,00

Material: OHNSHardness: 550 HV - 600 HV

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100,

00

150,00

400,

00

19,00

26,00

n11,00 THRU

25,0

0

19,0035

,00 n11,00 THRU

3 nos

25,0

0

19,0026,00

Page 65: Final Project Doc

ix BIBLIOGRAPHY

Papers and Journal:

1. Mechanical Press Types and Nomenclature© 1993-2005, David Alkire Smith, pg 10-13.

2. Manufacturing process-III, pg 38-40.

3. Pneumatically actuated clutches and brakes- Ortlinghaus.

4. Metal Forming Practise, Heinz Tschaetsch, pg 300-303.

5. Rolling key clutch- service manual, Bliss clearing.

6. Power transmission design 1997, pg 129, 140-141.

Websites:

1. www.mullermachines.com/es/pdf/machine/15011

2. www.merriam-webster.com/dictionary/rolling%20key%20clutch

3. www.ortlinghaus.at/pdf/tpi/en/TPI_0750_EN.pdf

4. http://books.google.co.in/books?id=W-6SFIX2qp4C