Necessity and advantages of testing, repair and maintance:-

Maintenance testing uses system performance requirements as the basis for identifying the appropriate components for further inspection or repair.

A good testing program will maintain a record of test results and maintenance actions taken. These data will be evaluated for trends and serve as the basis for decisions on appropriate testing frequency, need to replace or upgrade equipment and performance improvement opportunities.

Types of maintenance for which testing can be used.

Maintenance falls into the following four categories:

Preventive maintenance — Changes to the existing system so as to reduce the risk of failure while operating.

Corrective maintenance — Correcting problems that arise while using the system. Perfective maintenance — Enhancements (modifications) to improve the safety, reliability,

efficiency or cost-effectiveness of operation.

Adaptive maintenance — Adaptations to address requirements that crop up due to changes in the environment or new regulations.

Performance; PerformanceRepair and Maintenance:-

The technical meaning of maintenance involves functional checks, servicing, repairing or replacing of necessary devices, equipment, machinery, building infrastructure, and supporting utilities in industrial, business, governmental, and residential installations.[1][2] Over time, this has come to include multiple wordings that describe various cost-effective practices to keep equipment operational; these activities take place either before[3] or after a failure.

1. Common instrument are required for testing:-

1Laboratory Grinders, Cutters and Polishers.2Materials Characterization Equipment.

2. Plastic and Rubber Testing Equipment.3. Portable Hardness Testers.4. Scratch Testers.5. Tensile Testing Machines.6. Torque Gages / Gauges.7. Tribometers - Friction and Wear Testers.

Significance of B-T curve in life span of machine tool.:-

* . Acceptance test for machine tools,Economic aspect:-

The basic function of a machine tool is to produce a workpiece of the required geometric form with an acceptable surface finish at, as a high rate of production as is economically possible. In order, therefore, to evaluate the relative merits of machine tools it is essential to perform the acceptance tests, i.e. to measure the geometric accuracy, the surface finish and the maximum metal removal rate (Dynamic performance test).

Experienced fitters and inspectors carry out the acceptance test of a new machine tool in the manufacture's works. These men know how to use measuring instruments and how to assemble the machine in such a manner that manufacturing tolerances of individual components have a compensating and a cumulative effect as far as the accuracy of the whole is concerned.

Machine tools, which satisfy the specified accuracies in the standards of machine tool acceptance tests, will produce components that will meet the requirements of modern production in accordance with standard limits and fits. However, if closer tolerances are needed, an expensive additional operations and tedious selective assembly have to be carried out. For the manufacture of components to medium or coarse tolerances, wide tolerances may be permissible.

When the machine tool is under load, deformations and vibrations are created in the frames and other parts of machine tool during machining operations. Tests that cover the vibration behavior of any machine tool are difficult.

With regard to vibrations, various investigations concerning the causing and elimination of chatter on different machine tools have carried out. Some of them serve for determining the conditions under which a machine tool can be used without the danger of chatter, others serve for the testing and improving of newly designed and prototype machines.

As far as acceptance tests for standard machines rather than prototypes are concerned, finishing cuts be still taken for determining the performance of the machine.

Manpower planning and materials management:-

ne of the goals of any organization or business enterprise is to satisfy a particular demand, and in doing so, the organization must have sufficient capacity. The capacity of any organization consists of machines, money, materials, and manpower (human resource). Human resources are valuable to all organizations, not only because of their ability to render services even in highly automated industries, but also because they are costly to acquire and develop and that substantial investments are required in order to build an effectively functioning human organization. As noted by Skulj et al. (2008), a crucial task of managing a large organizations such as industrial companies, state administration, military systems, and transportation is efficient manpower planning. Meyer (1967) emphasized the importance of human assets and their utilization as he opinene of the goals of any organization or business enterprise is to satisfy a particular demand, and in doing so, the organization must have sufficient capacity. The capacity of any organization consists of machines, money, materials, and manpower (human resource). Human resources are valuable to all organizations, not only because of their ability to render services even in highly automated industries, but also because

they are costly to acquire and develop and that substantial investments are required in order to build an effectively functioning human organization. As noted by Skulj et al. (2008), a crucial task of managing a large organizations such as industrial companies, state administration, military systems, and transportation is efficient manpower planning. Meyer (1967) emphasized the importance of human assets and their utilization as he opinene of the goals of any organization or business enterprise is to satisfy a particular demand, and in doing so, the organization must have sufficient capacity. The capacity of any organization consists of machines, money, materials, and manpower (human resource). Human resources are valuable to all organizations, not only because of their ability to render services even in highly automated industries, but also because they are costly to acquire and develop and that substantial investments are required in order to build an effectively functioning human organization. As noted by Skulj et al. (2008), a crucial task of managing a large organizations such as industrial companies, state administration, military systems, and transportation is efficient manpower planning. Meyer (1967) emphasized the importance of human assets and their utilization as he opinene of the goals of any organization or business enterprise is to satisfy a particular demand, and in doing so, the organization must have sufficient capacity. The capacity of any organization consists of machines, money, materials, and manpower (human resource). Human resources are valuable to all organizations, not only because of their ability to render services even in highly automated industries, but also because they are costly to acquire and develop and that substantial investments are required in order to build an effectively functioning human organization. As noted by Skulj et al. (2008), a crucial task of managing a large organizations such as industrial companies, state administration, military systems, and

transportation is efficient manpower planning. Meyer (1967) emphasized the importance of human assets and their utilization as he opineManpower Planning is the development of strategies to match the supply of manpower to the availability of jobs at organizational, regional or national level. Manpower planning involves reviewing current manpower resources, forecasting future requirements and availability, and taking steps to ensure that the supply of people and skills meets demand.

. Fits and tolerances:-Two extreme permissible sizes of a part between which the actual size is contained are called limits. The relationship existing between two parts which are to be assembled with respect to the difference on their sizes before assembly is called a fit. Tolerance is defined as the total permissible variation of a size. It is the difference between maximum limit and minimum limit of size.

*Fits : When two parts are to be assembled the relation resulting from the difference between their sizes before assembly is called a fit. The fit signifies the range of tightness or looseness which may result from the application of a specific combination of allowances and tolerances in the design of mating parts.

1.2.1 Types of Fits

The three types of fits are shown in Fig. 1.1 The disposition of tolerance zones for the three classes of fit are shown in Fig. 1.2.

Fig. 1.1 Types of fits

Fig. 1.1 Types of fits

1. Clearance fit: A clearance fit is one having limits of size so prescribed that a clearance always results when mating parts are assembled.

2. Interference fit: An interference fit is one having limits of size so prescribed that an interference always results when mating parts are assembled.

3. Transition fit: A transition fit is one having limits of size so prescribed that either a clearance or interference may always result when mating parts are assembled.

1.3 Terminology The terminology used in fits and tolerances is shown in Fig. 1.3. The important terms are

 

Plant layout, location layout of machine in plant layout ,Principles of plant layout :-PLANT LAYOUT

DEFINITION

Plant Layout is defined as, “A technique of locating machines, processes and plant services within the factory in order to secure greater possible output of high quality at the lowest possible total cost of production.”

Plant layout provides a broad framework within which production and all other activities have

to take place. All facilities like equipment, raw-materials, machinery, tools, fixtures, finished goods, in-process inventories, workers and even scrap and waste etc., are given a proper place in the layout. The design of plant layout is a strategic decision and the analysis and planning of a sound plant layout is very important.

TYPES OF LAYOUTS

Plant Layouts can be classified as four basic types. But most of the practical layouts are a suitable combination of these basic types to match the requirements of activities and flow for a particular organization.The basic types are:1) Product or Line Layout.2) Process Layout or Functional Layout or Job Shop Layout.3) Cellular or Group Layout.4) Fixed Position Layout.

. Positioning of machine , grouping of machine:-

A machine (or mechanical device) is a mechanical structure that uses power to apply forces and control movement to perform an intended action. Machines can be driven by animals and people, by natural forces such as wind and water, and by chemical, thermal, or electrical power, and include a system of mechanisms that shape the actuator input to achieve a specific application of output forces and movement. They can also include computers and sensors that monitor performance and plan movement, often called mechanical systems.

Renaissance natural philosophers identified six simple machines which were the elementary devices that put a load into motion, and calculated the ratio of output force to input force, known today as mechanical advantage.[1]

Modern machines are complex systems that consist of structural elements, mechanisms and control components and include interfaces for convenient use. Examples include a wide range of vehicles, such as automobiles, boats and airplanes, appliances in the home and office, including computers, building air handling and water handling systems, as well as farm machinery, machine tools and factory automation systems and robots.

Foundation:- Machine foundations are special types of foundations required for machines, machine tools and heavy equipments which have wide range of speeds, loads

and operating conditions. These foundations are designed considering the shocks and vibrations (dynamic forces) resulting from operation of machines.

Different Types of Machine Foundations and their Uses

Machine foundations are special types of foundations required for machines, machine tools and heavy equipments which have wide range of speeds, loads and operating conditions. These foundations are designed considering the shocks and vibrations (dynamic forces) resulting from operation of machines.Following are the types of machine foundations generally used:1. Block Type Machine Foundation:Following figure shows block type machine foundation. This type of foundation consists of a pedestal resting on a footing have has large mass and a small natural frequency

2. Box or Caisson Type Machine Foundation:Box type foundation consists of a hollow concrete block as shown in figure below. The mass of this foundation is less than block type machine foundation as it is hollow. The natural frequency of the box type machine foundation is increased.

3. Wall Type Machine Foundation:

This type of machine foundation consists of a pair of walls with a slab resting on top. This type of foundation is constructed of homogeneous materials. It is used for small machines and the machine is rested on the top slab.

4. Framed Type Machine Foundation:This type of machine foundation consists of vertical columns with horizontal frame at their tops. It is used for larger machines. The machines are rested on the top of frames. The vertical and horizontal members of this foundation can be constructed by different materials.

5. Non-Rigid or Flexible type of Machine FoundationFollowing figure shows the non-rigid or flexible foundation.

FOUNDATION PLAN , TYPE OF FOUNDATION BOLTS,ERECTION AND LEVELING , GROUTING:-

Foundation bolts are mostly used to set machines on concrete floorings. Here is how the process goes:Initially, the position of the bolts is marked on the ground. Then, dimensionally accurate holes are dug in their exact positions. The bolts are then suspended on their respective holes and the concrete is poured around it. Once the concrete sets, the suspensions are removed and the machine is installed.TYPES OF FOUNDATION BOLTSEYE FOUNDATION BOLT:The eye foundation bolt has one end of it forged to bend and look like an eye. The eye-end also has a cross piece fixed in it for the setting of the machine. These bolts are used to securely hold industrial grade cables which need to be able to withstand strong movements, winds and pressure.

L/J FOUNDATION BOLT:These foundation bolts are used to hold together significantly heavy support structures. They mostly find their application in electrical and cell phone towers. Depending on the required tensile strength, these bolts can be manufactured in various grades of stainless steel.

BENT FOUNDATION BOLTThese bolts feature a signature bend on one end and can be set in either concrete or stone beds. The bolts are initially set in lead and then the whole assembly is set in concrete for improved hold. To secure the base of the machines in place, an industry-grade screw is used. The bend on the lower end results in a firmer grip.

RAG FOUNDATION BOLT:-This unique foundation bolt has a tapered body which comes with grooves on all sides of its body and a square or rectangular cross-section. Similar to the bent foundation bolt, it is mandatory to first allow the rag bolts to set in lead before allowing the whole assembly to set in concrete.

LEWIS FOUNDATION BOLT:These bolts are unique in design as well as usage. Lewis foundation bolts are tapered in width on one side and come with keys which allow it to be removed with ease. Therefore, these bolts are used predominantly for lifting and moving huge blocks of stones instead of fastening machines to a foundation. To use this bolt, a foundation block is used to create a pit in cement concrete. Once the concrete sets in, the Lewis foundation bolt is placed inside it with the tapered side of the bolt facing the tapered face of the pit. On the straight faces of the bolt and the pit, a key is inserted to enable the removing of the bolt. Like we mentioned before, this bolt is used mainly to lift and shift heavy stones. Therefore, the other end of the bolt can be forged into a loop to allow for its easy lifting.COTTER FOUNDATION BOLT:-These bolts are used specifically for installing heavy machinery in place. The bolt has a rectangular slot in the bottom to facilitate the insertion of the cotters. Please note that a washer has to be used to act as the bearing surface for the cotter.PLATE TYPE FOUNDATION BOLTA very popular bolts types of foundation bolts, the plate type foundation bolt comes with a housing plate on one end and heavy-duty threadings on the other end. This is popularly used in the construction industry.

Vibration damping, vibration isolation- method of isolation, anti vibrantion mount:-

Vibration damping is a term that's used in industrial, electronic and ergonomic applications when there is a need to reduce the amount of energy that's produced by the system. Normally engineers try to address and reduce this energy at its source so the disturbing force is not at or near a natural frequency

* Vibration isolation:-Vibration isolation is the process of isolating an object, such as a piece of equipment, from the source of vibrations. Vibration is undesirable in many domains, primarily engineered systems and habitable spaces, and methods have been developed to prevent the transfer of vibration to such systems.

Mounts :- Ideally the vibration mounts should be placed symmetrically around the centre of gravity and following the same layout. If the load placed on the vibration mountings is unequal, isolators should be selected so that the deflection remains the same at all points. In a purely practical sense, it can be difficult to position the vibration mountings on the same horizontal level as the centre of gravity. If that is the case, the distance between the vibration mountings needs to be greater than the horizontal distance between the vibration mountings and the centre of gravity

Testing equipments- dial gauge, mandrel:-

 Dial gauge:-. Dial gauges are used for checking flatness of surfaces; parallelism of bar and rods; and detecting small differences if any in linear measurement of identical objects. A dial gauge is also used for measuring concentricity of round objects.

“*A mandrel also mandril or arbor) is one of the following:,a round object against which material can be forged or shaped; a flanged or tapered or threaded bar that grips a workpiece to be machined in a lathe. A flanged mandrel is a parallel bar of a specific diameter with an integral flange towards one end, and threaded at the opposite end. Work gripped between the flange and a nut on the thread. A tapered mandrel (often called a plain mandrel) has a taper of approximately 0.005 inches per foot and is designed to hold work by being driven into an accurate hole on the work, gripping the work by friction. A threaded mandrel may have a male or female thread, and work which has an identical thread is screwed onto the mandrel.

On a lathe, mandrels are commonly mounted between centres and driven by a lathe dog (typically the flanged or tapered mandrels), but may also be gripped in a chuck (typically the threaded mandrels, where the outer face of work is to be machined. Threaded mandrels may also be mounted between centres.

In addition to lathes, arbors are used to hold buffing wheels, circular saws, and sanding discs. Typically, these mandrels consist of a cylinder that is threaded on one end. There are many different types of mandrels for specialized applications. Examples include live chuck mandrels, live bull ring mandrels, and dead bull ring mandrels.

a shaped bar of metal which is placed inside a workpiece to be formed, e.g. arbors used to bend the exhaust pipes for automobiles and in the production of molten glass, metal rings, threaded rods, and furniture legs.

Spirit level, straight edge:- An engineer's spirit level (or machinist's level) is generally used to level machines, although

they may also be used to level large workpieces on machines such as planers. Using gravity as a reference and checking a machine's axis of travel at several points, the level is used to ensure the machine's axis is straight. A perfectly level machine does not actually need to be achieved, unless the particular manufacturing process requires it. Spirit levels are also used in building construction by carpenters and masons.

A straightedge or straight edge is a tool used for drawing straight lines, or checking their straightness. If it has equally spaced markings along its length, it is usually called a ruler.

Straightedges are used in the automotive service and machining industry to check the flatness of machined mating surfaces.

True straightness can in some cases be checked by using a laser line level as an optical straightedge: it can illuminate an accurately straight line on a flat surface such as the edge of a plank or shelf.

Run test, vibration, noise:-

RUN TEST- Pump Mechanical Run Test. Pump mechanical run test is performed for 4 hours to proves pump work in stable condition and all variables are within acceptance range. The mechanical run test is performed after successful completion of the pump performance test and net positive suction head test.. Noise and Vibration:-Noise and Vibration Laboratory, caters to the measurement of parameters like Force, Displacement, stress and strain in machine tools and components. The

laboratory is equipped with qualified, trained and experienced Technical Staff and state of the art facility for measurement and analysis of various parameters such as Noise, Vibration, Force, Pressure, Strain, Torque, Speed, Temparature, etc

maintenance: corrective, preventive, adaptive, and perfective:Corrective maintenance can be either unscheduled (emergency) or scheduled. ..Preventive maintenance is scheduled. ...Adaptive maintenance is less common and occurs when EIT changes one system to adapt to changes in another system.

Breakdown /corrective:- It is not possible to determine that a particular machine, the type of maintenance to be ... Corrective maintenance: The set of tasks is destined to correct the defects to ... inspections and lubrication mentioned previously, the arising breakdowns ...

Iso standard for maintenance documentation:- Technical documentation is a very broad domain.

For mechanical industries it may include quality reports, design reports, production and planning reports, forecasting data or even ISO reports.Documentation is an art and it is indeed an important one. For engineers, all the results research and other data is the essence of their job. This requires proper documentation. It may seem boring, but for the long term it is as valuable as any other things for an organization.

Reasons of failure:- Some types of mechanical failure mechanisms are: excessive deflection, buckling, ductile fracture, brittle fracture, impact, creep, relaxation, thermal shock, wear, corrosion, stress corrosion cracking, and various types of fatigue.

Compressors and boilers:- A compressor is a mechanical device that increases the pressure of a gas by reducing its volume. An air compressor is a specific type of gas compressor. Compressors are similar to pumps: both increase the pressure on a fluid and both can transport the fluid through a pipe.

Boilers - The boiler system comprises a feed-water system, steam system, and fuel system. The feed-water system supplies treated water to the boiler and regulate it automatically to meet the steam demand. Various valves and controls are provided to access for maintenance and monitoring

*.Lubricant conditioning and disposal:- Across industry, great emphasis is placed on the handling and application of lubricants from the moment they arrive at a facility to the time they are introduced into service. However, proper handling techniques do not end when the oil has been put into service.

Once the life of the oil has been exceeded, you must ensure the lubricant is captured and disposed of both safely and in an environmentally friendly way.

*.Basic principles of material handling:-Planning Principle: It establishes a plan which includes basic requirements, desirable alternates and planning for contingency. ... Unit

Load Principle: Handle product in a unit load as large as possible. Space Utilization Principle: Encourage effective utilization of all the space available.

*Type of material handling:- The four main categories of material handling equipment include storage, engineered systems, industrial trucks, and bulk material handling.

* Forklift trucks:- A forklift is a powered industrial truck used to lift and move materials over short distances. ... Commonly referred to as Pyroban trucks in Europe, they must meet the ... Snow plough – a mechanical attachment that allows the forklift operator to easily and ... and they have established joint statistical and engineering programs.

*Conveyor models,AGV System:-

Conveyor Systems are mechanical devices or assemblies that transport material with minimal effort. While there are many different kinds of conveyor systems, they usually consist of a frame that supports either rollers, wheels, or a belt, upon which materials move from one place to another.

AGV Systems:- An automatic guided vehicle system (AGVS) consists of one or more computer-controlled, wheel-based load carriers (normally battery powered) that runs on the plant or warehouse floor (or if outdoors on a paved area) without the need for an onboard operator or driver.

Automated storage &Retrivel system(ASRS):-  automated storage and retrieval system (ASRS or AS/RS) consists of a variety of computer-controlled systems for automatically placing and retrieving loads from defined storage locations.[1] Automated storage and retrieval systems (AS/RS) are typically used in applications where:

There is a very high volume of loads being moved into and out of storage Storage density is important because of space constraints No value is added in this process (no processing, only storage and transport) Accuracy is critical because of potential expensive damages to the load

An AS/RS can be used with standard loads as well as nonstandard loads,[2] meaning that each standard load can fit in a uniformly-sized volume; for example the film canisters in the image of the Defense Visual Information Center are each stored as part of the contents of the uniformly sized metal boxes, which are shown in the image. Standard loads simplify the handling of a request of an item. In addition, audits of the accuracy of the inventory of contents can be restricted to the contents

of an individual metal box, rather than undergoing a top-to-bottom search of the entire facility, for a single item.

The inside of an ASRS at the Defense Visual Information Center, used for the storage of media items such as film canisters..

*CAROUSELS:- The carousel conveyor (which is sometimes referred to as only a carousel) can be thought of as a set of “moving shelves" for industrial storage applications.

It is characterized by its “horse track" shaped conveyor belt arrangement – the total path of the conveyor belt looks like a horse track. The shelves or the bins are hinged with the conveyor belt in such a way that the bins can move with the belt without dropping the objects in them.

Some applications (like baggage handling systems at airports) don’t require separate shelves or bins to be attached to the conveyor belt as the belt itself carries the materials.

Two common configurations of carousel conveyors used across industry are the horizontal and vertical types.

The horizontal carousel has two conveyor belts run by a motor pulley and a conveyor belt idler, one running at the top and another at the bottom. The bins are placed in between the two belts by hinge joints.

In vertical carousels, the two belts run side by side and the shelves are placed in between the belts, again with the hinges.

In both the types, the bin with the specific part is moved to the picking station, where the part is picked up by an operator.

When Should a Carousel Conveyor be Used?

Typically a carousel moves at a speed of around 1 MPH and a person can walk at a speed of around 3 MPH.

So you may think that rather than moving the conveyor, the operator herself can go and pick up the desired parts from the bins in a much faster way. Your calculation is right, provided there is only one conveyor used and that you ignore human fatigue.

In a more practical situation, multiple numbers of such conveyors are placed side-by-side and coordinating software is used for optimally moving the carousels.

Say, you need to collect five components from the five different conveyors. As the operator is collecting the first component, the required bin of the second conveyor is already moving toward the pick-up station and so on. As a result the overall efficiency increases.

Manual storage systems require larger areas and are less ergonomic. When using manual storage, the entire storage location needs to be illuminated and ventilated, but for carousel systems, ventilation and the illumination are required only at the pick-up stations.

Provision for advanced access control is made possible, especially through using the vertical system.