DESIGN AND FABRICATION OF DUAL SHAPER

PROJECT REPORT 2018-2019

Submitted by:

COLLEGE LOGO

(Team name)

Guided by:

Submitted in partial fulfillment of the

requirement for the
Award of Diploma in
-----------------------------------------
By the State Board of Technical Education
Government of
Tamilnadu, Chennai.
Department:
College name:
Place:

COLLEGE NAME

COIMBATORE

DEPARTMENT

PROJECT REPORT-2008-2009

This Report is certified to be the Bonafide work done by

Selvan/Selvi ---------------- Reg.No. ------------ Of VI
Semester class of this college.

Guide Head of the Department

Submitter for the Practical Examinations of the board of

Examinations,State Board of Technical Education,Chennai,
TamilNadu.On -------------- (date) held at the ------------
(college name),Coimbatore

Internal Examiner External Examiner

DEDICATED TO OUR BELOVED

PARENTS
ACKNOWLEDGEMENT
 ACKNOWLEDGEMENT

At this pleasing movement of having successfully completed our

project, we wish to convey our sincere thanks and gratitude to the
management of our college and our beloved
chairman------------------------.who provided all the facilities to us.

We would like to express our sincere thanks to our principal

------------------for forwarding us to do our project and offering adequate
duration in completing our project.

We are also grateful to the Head of Department prof…………., for

her/him constructive suggestions &encouragement during our project.

With deep sense of gratitude, we extend our earnest &sincere

thanks to our guide --------------------, Department of Mechanical for
her/him kind guidance and encouragement during this project we also
express our indebt thanks to our TEACHING staff of MECHANICAL
ENGINEERING DEPARTMENT, ---------- (college Name).
DESIGN AND FABRICATION OF
DUAL SHAPER
CONTENTS
 CONTENTS

CHAPTER NO TITLE

SYNOPSIS
LIST OF FIGURES
NOMENCLATURE
1 Introduction
2 Literature review
3 Description of equipments
3.4 Shaft
3.5 Pump
3.6 Pulley
3.7 Belt
4 Drawing and general specification
4.2 Design calculation
5 Working principle
6 Merits & demerits
7 Applications
8 List of materials
9 Cost Estimation
10 Conclusion
Bibliography
photography
LIST OF FIGURES
 LIST OF FIGURES
Figure
Number Title

1 Cam
2 Fan pulley
3 Small pulley
4 Big pulley
5 Pump
6 Blades
7 Overall Diagram
SYNOPSIS
SYNOPSIS:

.
 CHAPTER-1

INTRODUCTION

CHAPTER – 1

INTRODUCTION
 CHAPTER-2

LITERATURE SURVEY

CHAPTER -2
 LITERATURE SURVEY

CHAPTER-3

DESCRIPTION OF EQUIPMENT
 CHAPTER-3

DESCRIPTION OF EQUIPMENTS

AC MOTOR
An AC motor is an electric motor driven by an alternating current
(AC). The AC motor commonly consists of two basic parts, an outside
stationary stator having coils supplied with alternating current to produce a
rotating magnetic field, and an inside (rotor attached to the output shaft
producing a second rotating magnetic field. The rotor magnetic field may be
produced by permanent magnets, reluctance saliency, or DC or AC electrical
windings.
Less commonly, linear AC motors operate on similar principles as rotating
motors but have their stationary and moving parts arranged in a straight line
configuration, producing linear motion instead of rotation.

Operating principles

AC motors operate with two rotating (or moving) magnetic fields on the
rotor and stator respectively. Pulling or pushing the poles of the two
magnetic fields along, the speed of the stator rotating magnetic field (Ws)
and the speed of the rotor rotating magnetic field (Wr), which is relative to
the speed of the mechanical shaft (Wm), must maintain synchronism for
average torque production by satisfying the synchronous speed relation (i.e.,
±Ws ±Wr = Wm). Otherwise, asynchronously rotating magnetic fields
would produce pulsating or non-average torque.

The two main types of AC motors are classified as induction or

synchronous. The induction motor (or asynchronous motor) always relies on
a small difference in speed between the stator rotating magnetic field and the
rotor shaft speed called slip to induce rotor current in the rotor AC winding.
As a result, the induction motor cannot produce torque about synchronous
speed where induction (or slip) is irrelevant or ceases to exist. In contrast,
the synchronous motor does not rely on slip-induction for operation and uses
either permanent magnets, salient poles, or an independently excited rotor
winding. The synchronous motor produces its rated torque at exactly
synchronous speed. The brushless wound-rotor doubly-fed synchronous
motor system has an independently excited rotor winding that does not rely
on the principles of slip-induction of current. The brushless wound-rotor
doubly-fed motor is a synchronous motor that can function exactly at the
supply frequency or sub to super multiple of the supply frequency.

Other types of motors include eddy current motors, and also AC/DC
mechanically commutated machines in which speed is dependent on voltage
and winding connection.
3.4. SHAFT:

A shaft is rotating the wheel or gear. The axle may be fixed in

position with a bearing or bushing sitting inside the hole in the wheel

or gear to allow the wheel or gear to rotate around the axle. In other

cases the wheel or gear may be fixed to the axle, with bearings or

bushings provided at the mounting points where the axle is

supported.

3.6 PULLEY:

A pulley is a wheel with a groove along its edge, also called a

sheave, for holding a rope or cable. Pulleys are usually used in sets

designed to reduce the amount of force needed to lift a load. The

same amount of work is necessary for the load to reach the same

height as it would without the pulleys. The magnitude of the force is

reduced, but it must act through a longer distance. The effort needed

to pull a load up is roughly the weight of the load divided by the

number of wheels. The more wheels there are, the less efficient a

system is, because of more friction between the rope and the wheels.

The pulleys and lines are weightless, and that there is no energy loss

due to friction. It is also assumed that the lines do not stretch. With

this assumption, it follows that, in equilibrium, the total force on the

pulley must be zero. This means that the force on the axle of the

pulley is shared equally by the two lines looping through the pulley.

The lines are not parallel, the tensions in each line are still equal, but

now the vector sum of all forces is zero.

A second basic equation for the pulley follows from the conservation

of energy the product of the weight lifted times the distance it is

moved is equal to the product of the lifting force times the distance

the lifting line is moved. The weight lifted divided by the lifting force is

defined as the advantage of the pulley system. It is important to

notice that the amount of work done in an ideal pulley is always the

same. The work is given by the effort times the distance moved. The

pulley simply allows trading effort for distance.

3.7 BELT:
Belts are used to mechanically link two or more rotating items. They

may be used as a source of motion, to transmit power at up to 98%

efficiency between two points, or to track relative movement.

As a source of motion, a conveyor belt is one application where the

belt is adapted to continually carry a load between two points. A belt

may also be looped between two points so that the direction of

rotation is reversed at the other point. Power transmission is achieved

by specially designed belts and pulleys. The demands on a belt drive

transmission system.

Belts normally transmit power only on the tension side of the loop.

Designs for continuously variable transmissions exist that use belts

that are a series of solid metal blocks, linked together as in a chain,

transmitting power on the compression side of the loop.

CHAPTER-4

DRAWING
 CHAPTER-IV

DESIGN OF EQUIPMENT AND DRAWING

4.1 COMPONENTS

e following components to full fill the requirements of complete

operation of the machine.

1. shaft

2. Pully

SHAFT:
 It’s made up of mild steel. It is straight rod having a step. It is

supported by two bearings in the cylinder. The diameter of rod is

15mm for a length of 150mm and 13.5mm diameter for 22mm length.

The fan is fitted on the shaft through flanges. The fan is fixed to

flanges and the flanges are fixed to the shaft through drilled holes.

shaft is a mechanical device for transferring power from the engine or

motor to the point where useful work is applied. Most engines or

motors deliver power as torque through rotary motion: this is extracted

from the linear motion of pistons in a reciprocating engine; water driving

a water wheel; or forced gas or water in a turbine. From the point of

delivery, the components of power transmission form the drive train.

Drive shafts are carriers of torque: they are subject to torsion and

shear stress, which represents the difference between the input force

and the load. They thus need to be strong enough to bear the stress,

without imposing too great an additional inertia by virtue of the weight

of the shaft.

FLY WHEEL:

A flywheel is a mechanical device with significant moment of inertia

used as a storage device for rotational energy. Flywheels resist

changes in their rotational speed, which helps steady the rotation of

the shaft when a fluctuating torque is exerted on it by its power

source such as a piston-based (reciprocating) engine, or when the

load placed on it is intermittent (such as a piston pump). Flywheels

can be used to produce very high power pulses as needed for some

experiments, where drawing the power from the public network would

produce unacceptable spikes. A small motor can accelerate the

flywheel between the pulses. Recently, flywheels have become the

subject of extensive research as power storage devices for uses in

vehicles;

Flywheels are not affected by temperature changes as are chemical

rechargeable batteries, nor do they suffer from memory effect. They are

also less potentially damaging to the environment, being made of

largely inert or benign materials. Another advantage of flywheels is

that by a simple measurement of the rotation speed it is possible to

know the exact amount of energy stored. However, use of flywheel

accumulators is currently hampered by the danger of explosive

shattering of the massive wheel due to overload.

One of the primary limits to flywheel design is the tensile strength of

the material used for the rotor. Generally speaking, the stronger the

disc, the faster it may be spun, and the more energy the system can

store. When the tensile strength of a flywheel is exceeded the

flywheel will shatter, releasing all of its stored energy at once; this is

commonly referred to as "flywheel explosion" since wheel fragments

can reach kinetic energy comparable to that of a bullet.

Consequently, traditional flywheel systems require strong

containment vessels as a safety precaution, which increases the total

mass of the device. Fortunately, composite materials tend to

disintegrate quickly once broken, and so instead of large chunks of

high-velocity shrapnel one simply gets a containment vessel filled

with red-hot sand. Still, many customers of modern flywheel power

storage systems prefer to have them embedded in the ground to halt

any material that might escape the containment vessel.

When used in vehicles, flywheels also act as gyroscopes, since their

angular momentum is typically of a similar order of magnitude as the

forces acting on the moving vehicle. This property may be detrimental

to the vehicle's handling characteristics while turning. On the other

hand, this property could be utilised to keep the car balanced so as to

keep it from rolling over during sharp turns. Conversely, the effect can

be almost completely removed by mounting the flywheel within an

appropriately applied set of gimbals, where the angular momentum is

conserved without affecting the vehicle (see Properties of a

gyroscope). This doesn't avoid the complication of gimbal lock, and so

a compromise between the number of gimbals and the angular

freedom is needed. A single gimbal, for instance, could free a car for

the 360 degrees necessary for regular driving. However, for instance

driving up-hill would require a new gimbal mechanism with a new

degree of freedom. Two gimbals would theoretically solve this

problem and never lock unless your car rolls (something one carefully

placed gimbal would not let the car do). However, in reality these

gimbals would require (perhaps impossibly) clever regular

maintenance to stop the car from one day abruptly launching itself

into the air like a grasshopper.

An alternative solution to the problem is to have two joined flywheels

spinning synchronously in opposite directions. They would have a

total angular momentum of zero and no gyroscopic effect. A problem

with this solution is that when the difference between the momentum

of each flywheel is anything other than zero the housing of the two
flywheels would exhibit torque. You would, in effect, have two heavy

spinning gears. Both wheels must be maintained at the same speed

to keep the angular velocity at zero. Strictly speaking, the two

flywheels would exert a huge torqueing moment at the central point,

trying to bend the axle. However, if the axle were sufficiently strong,

no gyroscopic forces would have a net effect on the sealed container,

so no torque would be noticed.

2.2 DESIGN CALCULATION:

Data:

Pump

Dia of pump =77mm

Total length of pump =425mm

Stroke length =401mm

Rpm of pulley =50

Power transmit to the pump = w*Q*h

W =specific weight of water (1000) kg/m3

Q= discharge (m3/s)

h =245mm
Q= Discharge = a x v

a =3.14/4*(d)2

=0.785*(77)2

=0.785*(5929)

a =4654mm2

Discharge = a x v

= 4654x v

Dia of pulley =260mm (0.026m)

Rpm =50

V = 3.14*D*N/60

=3.14*0.026*50/60

V =0.06803m/sec

Q = 0.4654*0.06803=0.0317m3/sec

TO CALCULATE THE POWER TRANSIMIT TO THE PUMP:

Power transmit to the pump = w*Q*h

=1000*0.0317*0.245

P =7.7665kg-m/s
Torque

p = 2*3.14*N*T/60

7.7665 =2*3.14*50*T/60

T = 60*7.7665/2*3.14*50

T = 1.48 N-m

Pulley rim velocity:

Velocity of the rim = πdn/60

Where n = no of rim

D= diameter of the pulley

Velocity of the rim = πdn/60

= 3.14*260*4/60

= 53.8824 mm/s

SHAFT:

Speed N = 50rpm

Power transmits = 7.7665kg-m/s

 Diameter of the shaft d= 16 mm

Torque transmitted by the shaft,

T = p*60/2πN

= 7.7665 * 60 / 2*3.14* 50

= 1.48 N-m

BELT

Diameter of the large pulley = 260 mm

Diameter of the pulley = 50mm

Center distance of the pulley = 220mm

Length of the belt,

L= 2c +π/2(D+d) + (D-d) 2/4c

= 2*220+3.14(260+50) + (260-50)2 /4*220

= 977.060 mm

POWER TRANSMITTING CAPACITY:

Kw= (1.47s-0.09-506.7/de-2.34*10-4s2)s

de = equivalent pitch diameter = DP*Fb

 = 200*1.14

= 228mm

S = belt speed, m/s

= π dn/60

= 3.14*0.05 *50/60

= 0.131m/s

Kw= (1.47s-0.09-506.7/de-2.34*10-4s2)s

= (1.47*0.131-0.09-506.7/ 228-2.34*10-4 *0.1312)0.131

= 1.14kw

So we assume;

Wind force = 40km/s

Rotation of the pulley = 50rpm

Water sucking from the ground = 100ml

WATER PUMPING:

FOR EXAMPLE

Wind Mill Total Height = 3-m (10 ft)

Pump cylinder diameter = 75mm (3 in)

It produces about 760 liters of water per hour

Wind force = 16km (10 miles) per hour.

DRAWING
DRAWING FOR DESIGN AND FABRICATION OF DUAL SHAPER

Chapter -5

WORKING PRINCIPLE
 Chapter -V

WORKING PRINCIPLE:
Shaper is the metal cutting machine tool designed for cutting flat work
piece by a tool. Shaping is used to machine thin and soft plates. The operation of
machine is simplified to few simple operations involving a motor and tool head
arrangement. When the crank is driven by a motor or by handle, the crank rotates
about the axis, so the crankpin slides inside the slot of the slotted plate. As the
crank rotates, the slotted bar reciprocates due to the sliding of crank pin. The
connecting rod attached with the slotted plate on both sides, reciprocates as the
crank rotates.
The cutting tool is attached at the both sides of connecting rod, to carry out
the cutting operation. Since the cutting tool is placed on both sides, operation can
be done at both the sides of the machine i.e. the return stroke at one end is
converted into cutting stroke at the other end, thereby it reduces the production
time and increases the Metal removal rate (MRR).

CHAPTER -6

MERITS AND DEMERITS

 CHAPTER -VI

MERITS AND DEMERITS

MERITS:
Low cost automation
Easy maintenance
Less cost
Mass production

DEMERITS:

 Suitable for only simple application

 Chapter-7

APPLICATIONS
 CHAPTER-VII

APPLICATIONS

 For Industries uses

 CHAPTER-8

LIST OF MATERIALS
 CHAPTER-VIII

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS

The various factors which determine the choice of material are

discussed below.
1. Properties:

The material selected must posses the necessary properties for

the proposed application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand

environmental attack from chemicals, service life, reliability etc.

 The following four types of principle properties of materials

decisively affect their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific

gravity, electrical conductivity, magnetic purposes etc.

The various Mechanical properties Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue

resistance, impact resistance, eleastic limit, endurance limit, and

modulus of elasticity, hardness, wear resistance and sliding

properties.

The various properties concerned from the manufacturing point

of view are,

 Cast ability

 Weld ability

 Surface properties

 Shrinkage
  Deep drawing etc.

2. Manufacturing case:

Sometimes the demand for lowest possible manufacturing cost or

surface qualities obtainable by the application of suitable coating

substances may demand the use of special materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately

the material. For example, it would never be desirable to go casting of

a less number of components which can be fabricated much more

economically by welding or hand forging the steel.

4. Availability of Material:

Some materials may be scarce or in short supply. It then

becomes obligatory for the designer to use some other material which

though may not be a perfect substitute for the material designed. the
delivery of materials and the delivery date of product should also be

kept in mind.

5. Space consideration:

Sometimes high strength materials have to be selected because the

forces involved are high and space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of

material plays an important part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-

maintenance of the designed part are involved in the selection of

proper materials.
 Chapter-9

COST ESTIMATION
 Chapter-IX

COST ESTIMATION

1. LABOUR COST:

Lathe, drilling, welding, grinding, power hacksaw, gas cutting cost

2. OVERGHEAD CHARGES:

The overhead charges are arrived by” manufacturing cost”

Manufacturing Cost =Material Cost +Labour Cost

Overhead Charges =20%of the manufacturing cost

 =

3. TOTAL COST:

Total cost = Material Cost +Labour Cost +Overhead Charges

Total cost for this project =

Chapter-10

CONCLUSION
 CHAPTER-X

CONCLUSION

The project carried out by us made an impressing task in the

field of electricity department. It is used for to produce the current in

windmill unit.

This project has also reduced the cost involved in the concern.

Project has been designed to perform the entire requirement task

which has also been provided.

BIBLIOGRAPHY
 BIBLIOGRAPHY

1. Design data book -P.S.G.Tech.

2. Machine tool design handbook –Central machine tool

Institute, Bangalore.

3. Strength of Materials -R.S.Kurmi

4. Manufaturing Technology -M.Haslehurst.

5. Design of machine elements- R.s.Kurumi

PHOTOGRAPHY