TA 201

INTRODUCTION TO MANUFACTURING PROCESS

KRANE
PROJECT REPORT

GROUP 3: SECTION M1 Instructor: Dr. Anish Upadhyaya Tutor: Prof. H. Hatwal (ME) Ms. R. Mehta (MME)

GROUP MEMBERS
1. 2. 3. 4. Banda Girish Kumar Chandrika Prasad Rawat Deepak Kumar Gupta Deshmane Amit Ajit Y6136 Y6147 Y6154 Y6158 M1 M1 M1 M1

ACKNOWLEDGEMENT
In this project we have got an opportunity to show our creativity. While doing the project we faced a lot of difficulties. Even before starting the project we didnt even think of doing something like this. We were inspired by our instructor Prof. Anish Upadhyaya , who actually gave us a chance in the course TA201 to express ourselves . We are thankful to out tutor Prof. Hatwal and Ms. R. Mehta who helped us to direct our project in a proper way with nice mechanisms. Then came the final task of doing the projects, we are very thankful to all the TAs, Lab Assistants, Helpers, who really helped us in manufacturing our project. And we are specifically thankful to Mr. Nafe Singh ,who actually made us to overcome two major difficulties we faced during assembling the model.

MOTIVATION
It was said that there are credits to innovative ideas, so we decided to do something new than those which have been done in the last few years. Actually we were trying to do a simple system which can help people in their day to day life. So one of our colleagues came up with the idea of the packing system which is usually required in industries. We consulted with the tutors and came to know that it was not done before. So we were very happy but tutor said that it may take 3 to 4 semesters to complete. So we tried to minimize the Mechanisms of the system but again it was not that easy to be done in one semester. So what could a simple system be to done in one semester? Our another colleague said that I have seen cranes with too complicated mechanisms. So we took up a task to design a crane with a simple mechanism. One of our colleagues gave a full layout of the mechanism and we all agreed to proceed with this project and got confirmation remarks from tutors. In the meantime one our last colleagues searched a lot to get a simpler mechanism for the arm movement and he came up with the idea fixed arm with a rope lifting the loads. In this way we were through with our idea.

Introduction;
Ours is a 3-d model of a crane having 2 degrees of freedom. We have used worm gears to ensure that locking mechanism .The model is highly precise to the extent that it has accuracy of 6 degree. The model can be used to uplift heavy weights (up to the breaking point of the rope) to an elevated platform .Furthermore the project is a nice application of all the mechanical and metallurgical processes.

Description:
Angles 1.Hacksaw 2. Filing 3. Marking and Drilling Worm 1. Facing and Turning 2. Centre Drill 3. Worm Threading 4. 3.2 mm Drill Worm Gear (60T,40T) 1. Facing and Turning 2. Radius Turning 3. 5.2 Drill 4. 1/4inch taphole

5. Milling Base Support Shaft 1.Turning Handle 1.Filing 2. Welding 3. Sheet Metal 4. Drilling Reel 1.Casting 2. Machining (facing and Turning) 3. 5.2 Drill 4. 1/4 inch taphole Upper Circular Base 1. 6.5 mm drill 2. Grinding Arm Base 1. Cutting 2. Filing 3. Drilling (6.5 mm) Supports 1. Filing 2. Drilling (16, 12.7,6.5 mm) Hook 1. Hammering 2. Bending 3. Plier 4. Wise Sheet Metal 1. Bending 2. Shearing 3. Soldering 4.Drilling(6.5mm) 5. Hammering ( Mallet) Base 1.Drilling(6.5mm)

Base Support 1. Casting

2. Facing and turning 3. Drilling(16mm, 6.5mm) Arm Weights 1.Welding(MMAW) 1. Sheet Metal 2. Bending 3. Shearing 4. Soldering 5.Hook Fitting 6. Brazing

Cost Estimation:
Material cost: Total weight of the machine = 12.7 kgs Weight of nuts and bolts used =250 gm Material cost = Rs 35/kg Nuts & Bolts cost= Rs 60/kg Cost of the material used = Rs 444.50 Cost of Nuts & Bolts = Rs 15 Total Material cost= Rs 459.50

Machining charges:

Machine
Lathe

Rate/hr (Rs)
50

Hours used
10.5

Cost (Rs)
525.0

Milling

25

1.5

37.5

Drilling

40

11.5

442.0

Cutting

60

5.0

300.0

Total machining charges: Rs 1304.50

Labour Charges:
Unskilled Labour: Rate = Rs 95/day Number of hours used = Total unskilled labour charges = Rs Skilled Labour: Rate= 150/day Number of hours used = Total skilled labour charges = Rs

Total labour charges =Rs

Total cost of the machine= Rs

Sr. No.
1 2 3 4 5

ME
Lathe Milling Drilling Hacksaw Machine Grinding

MME
Grinder Welding Shearing Bending Cutting

TOOLS/ACCESSORIES USED

Sr. No.
1 2 3 4 5 6 7 8 9 10 11 12 13

Tools Name
Turning Tool Radius Tool Worm Tool Module Milling cutter Wrench Drill (6.5,3.2,16,12.7,5.2) Tap Set(1/4 inch) Hammer Centre Punch Marker Vernier Height Gauge V Block Spanner Set

14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34

Pliers Scale Vernier Calliper Dog Carrier File(Rough, Smooth, Round) Revolving Centre Bench vise Centre Drill Hacksaw Tri Square T-Spanner Mallet Solder Gun Cutter Sand Paper Cope Drag Anvil Scissors Screw Driver Molasses Mould Thermocole

Difficulties faced :
Sr. no.
1

Difficulties faced
When our project was on the verge of completion, we encountered that the base support part made by casting had the drill slightly greater than 16mm, due to which our model was shaking. While assembling the model, we faced a serious problem when both handles were blocked by the upper base plate. While doing turning operation for the worm rod we wrongly reduced the diameter of the rod to 15mm instead of 16mm. Due to this our worm rod did not fit into the supports. After having done the assembly in the last lab, we found that the elevated platform made of the sheet metal was hindering the smooth movement of the upper circular base. While making boxes to be used as weights, we fell short of solder wire. It was unavailable for 2 consecutive labs. The drills in the lower worm were not in the exact position due to which the assembly was trembling.

Solutions
We consulted the TAs in the lab and they advised us to replace the base support by a new base support. We headed to his advice and the problem was well overcome.

We then fitted an extension into the handle collar (and in worm in the case of the second handle) so as to ensure its free movement. We then decided to reduce the diameter of the rod to the next standard value of 12.7mm and made new supports.

We then decided to reduce the diameter of the rod to the next standard value of 12.7mm and made new supports

So we finally decided to go for brazing rather than soldering.

To solve this problem, we added a washer in between that pin and the support, which ensured the perfect packing of the assembly.

Possible modifications / improvements :

1. Wheels can be attached to the circular base to make the model mobile. It can also be mounted on a vehicle to ensure its mobility. 2. Presently we are having only two degrees of freedom (circular direction, vertical direction) in our project. The arm of the crane can be made an extendable arm to make it move in the radial direction as well. 3. We could have mounted a pulley on the tip of the load arm to ensure frictionless movement of the rope over the tip, otherwise rope may wear out on continuous usage.

What we have learnt from the project

Team work : Teamwork is the ability to work together toward a common vision. The ability to direct individual accomplishments toward organizational objectives. It is the fuel that allows common people to attain uncommon results. We learned what team work is. How a piece of work is distributed among team members, how the work becomes easy when each member works efficiently to complete the job given. It generated a mutual understanding among us. We come to know how different sets of ideas and different approaches can be used to complete the task. Planning: We planned every aspect of our project beforehand. The day before the lab turn was devoted to planning of what all had to be done in the upcoming lab. We used to chart out a rough algorithm before making a part on any machine. We divided our work for 7 labs and properly planned out the complete project.

Time management: The most useful aspect which made this project possible was dividing the work among team members. It reduced our time over any job. All team members reached lab at proper time, we learned punctuality, we learned how so ever big the task is we can do it by branching it between the team members and have that work done.

Dealing with last moment problems: We learned how to work under critical conditions when there is a lot of stress on our mind without losing our temperament It gave us an overall confidence of doing any sort of work in limited time.

Dealing with real life situation: We also learned how to give a shape to our ideas and how to implement what we have in our minds.

The subject: Needless to mention, the project has helped us in getting a better grasp over the subject. Practicals are always useful, but when we do a project and devote ourselves completely to it, we get a deeper knowledge and understanding.

CONCLUSION
It was a nice experience to work with the most cooperative members of the TA LAB (ME+MME). We realised that even small toys, small gadgets do require a lot of mechanical knowledge, work, and precision. We enjoyed the projects a lot and we would like to do such projects in our academic curriculum.

Thank you