black book lift using water pumping updated

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INDEX

r. no.Name of the topic

PageNo.

1 Introduction 7

2 Components used 10

3 Design Consideration 12

4 Material selection 24

5 Manufacturing 27

6 Assembly 31

7 Cost Estimation 34

8 Advantages Disadvantages 38

9 !earning "ills 40

10 Conclusion 42

11 #eferences 44

I 1


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Chapter no$ %

IN'D(C&I'N

2


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INTRODUCTION

The energy is most important thing. The every work is done by using o energyThere are two type o energy

1. Renewab!e energy2. Non renewab!e energy

The non "renewab!e energy is most!y used but it is !imited in our wor!d so wewant to save that energy. so the #onservation o energy is most important . $y inspiring o energy #onservation we make a one energy saver ma#hine Our wor!d is automation wor!d in present a!so we have many bui!dings%more o them have !i t or transporting the peop!e up % down. or using o thismotion we #reate a ma#hine

In that ma#hine we use the motion o !i t is #ontro!!ed by pump meansthe downwards motion % it is transmitted to the re#ipro#ating pump % pumpdrive % water is pumped.

Factors in consideration of project &

1' Compatibi!ity with the ob(e#tive and p!an.2' )vai!abi!ity o needed s#ienti i# and engineering ski!!s in R % D.*' Criti#a! te#hni#a! prob!ems !ike!y to emerge.+' ,arket prospe#ts and potentia! o the proposed new produ#t.-' )vai!abi!ity o produ#tion ski!!s needed.

' /inan#ia! return e0pe#ted.' Cost and avai!abi!ity o #apita! re uired or investment.

3' 4stimate o #osts o deve!opment5 produ#tion and marketing. 6' 7rowth prospe#ts or the uture.

OBJECT !E*


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The ob(e#tive o our pro(e#t is to enab!e the human to have the abi!ity to move aroundthe p!a#e with abso!ute ease5 with the use o ) !i t with water pumping .

"a#ient feat$res of t%e project &

1. Contro! the motion o !i t using pump

2. Transportation the one p!a#e to another p!a#e

*. 4asy to use

+. Upto-8 kg !oad #arrying #apa#ity.

-. 9ater de!ivered upto-m

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Chapter no$ )

C'MP'NEN&SC'MP'NEN&S

(SED(SED

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&' s%ape co#$(n)

Dis#!osed herein is a bui!t:up type bo0:shaped stee! #o!umn or i!!ing#on#rete therein5 that #an be ormed easi!y and e#onomi#a!!y in a bui!t:up s#heme by using ;:beams and stee! p!ates5 and a method ormanu a#turing the same that in#!udes bonding a stee! p!ate at the inner sur a#e o a ;:shapes during a pro#ess o making a bui!t:up type bo0:shaped stee! #o!umn5 thereby having a good resistan#e against a!atera! pressure o #on#rete i!!ed in the stee! #o!umn and preventingthe bonded portion rom being e0posed to the outside to provide a better outer appearan#e. The bui!t:up type bo0:shaped stee! #o!umn

or i!!ing #on#rete therein5 in#!udes& a ;:shapes disposed at ea#h othe our #orners o a bo0:shaped stee! #o!umn to be ormed< and astee! p!ate disposed between the ;:shapes ad(a#ent to ea#h other /or #onne#ting ;: ea#h other.


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= uare bar

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pumps

) p$(p is a devi#e that moves !uids >!i uids or gases'5 or sometimess!urries5 by me#hani#a! a#tion. ?umps #an be #!assi ied into three ma(or groupsa##ording to the method they use to move the !uid&direct lift 5displacement 5and gravity pumps.@1A

?umps operate by some me#hanism >typi#a!!yre#ipro#ating or rotary'5 and#onsumeenergy to per ormme#hani#a! work by moving the !uid. ?umpsoperate via many energy sour#es5 in#!uding manua! operation5e!e#tri#ity5engines5 orwind power 5 #ome in many siBes5 rom mi#ros#opi# oruse in medi#a! app!i#ations to !arge industria! pumps.,e#hani#a! pumps serve in a wide range o app!i#ations su#h as pumping water

rom we!!s5a uarium i!tering5 pond i!tering andaeration5 in the#arindustry orwater:#oo!ing and ue! in(e#tion5 in theenergy industry or pumpingoi! andnatura! gas or or operating#oo!ing towers. In themedi#a! industry5 pumps are used or bio#hemi#a! pro#esses in deve!oping and manu a#turingmedi#ine5 and as arti i#ia! rep!a#ements or body parts5 in parti#u!ar thearti i#ia!heart and peni!e prosthesis.In bio!ogy5 many di erent types o #hemi#a! and bio:me#hani#a! pumps

haveevo!ved5 and biomimi#ry is sometimes used in deve!oping new types ome#hani#a! pumps.

• 1.1 ?ositive disp!a#ement pumpo 1.1.1 ?ositive disp!a#ement pump behavior and sa etyo 1.1.2 ?ositive disp!a#ement types

1.1.2.1 Rotary positive disp!a#ement pumps1.1.2.2 Re#ipro#ating positive disp!a#ement pumps1.1.2.* arious positive disp!a#ement pumps

1.1.2.*.1 7ear pump1.1.2.*.2 =#rew pump1.1.2.*.* ?rogressing #avity pump1.1.2.*.+ Roots:type pumps1.1.2.*.- ?erista!ti# pump1.1.2.*. ?!unger pumps1.1.2.*. Trip!e0:sty!e p!unger pumps

6

http://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Gashttp://en.wikipedia.org/wiki/Slurryhttp://en.wikipedia.org/wiki/Pump#cite_note-1http://en.wikipedia.org/wiki/Reciprocating_motionhttp://en.wikipedia.org/wiki/Rotationhttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Mechanical_workhttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Wind_powerhttp://en.wikipedia.org/wiki/Water_well_pumphttp://en.wikipedia.org/wiki/Water_well_pumphttp://en.wikipedia.org/wiki/Aquarium_filterhttp://en.wikipedia.org/wiki/Pondhttp://en.wikipedia.org/wiki/Aerationhttp://en.wikipedia.org/wiki/Car_industryhttp://en.wikipedia.org/wiki/Car_industryhttp://en.wikipedia.org/wiki/Water_coolinghttp://en.wikipedia.org/wiki/Fuel_injectionhttp://en.wikipedia.org/wiki/Energy_industryhttp://en.wikipedia.org/wiki/Pumping_(oil_well)http://en.wikipedia.org/wiki/Pumping_(oil_well)http://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Medical_industryhttp://en.wikipedia.org/wiki/Artificial_hearthttp://en.wikipedia.org/wiki/Artificial_hearthttp://en.wikipedia.org/wiki/Penile_prosthesishttp://en.wikipedia.org/wiki/Evolutionary_biologyhttp://en.wikipedia.org/wiki/Biomimicryhttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pump_behavior_and_safetyhttp://en.wikipedia.org/wiki/Pump#Positive_displacement_typeshttp://en.wikipedia.org/wiki/Pump#Rotary_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Reciprocating_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Various_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Gear_pumphttp://en.wikipedia.org/wiki/Pump#Screw_pumphttp://en.wikipedia.org/wiki/Pump#Progressing_cavity_pumphttp://en.wikipedia.org/wiki/Pump#Roots-type_pumpshttp://en.wikipedia.org/wiki/Pump#Peristaltic_pumphttp://en.wikipedia.org/wiki/Pump#Plunger_pumpshttp://en.wikipedia.org/wiki/Pump#Triplex-style_plunger_pumpshttp://en.wikipedia.org/wiki/Liquidhttp://en.wikipedia.org/wiki/Gashttp://en.wikipedia.org/wiki/Slurryhttp://en.wikipedia.org/wiki/Pump#cite_note-1http://en.wikipedia.org/wiki/Reciprocating_motionhttp://en.wikipedia.org/wiki/Rotationhttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Mechanical_workhttp://en.wikipedia.org/wiki/Engineshttp://en.wikipedia.org/wiki/Wind_powerhttp://en.wikipedia.org/wiki/Water_well_pumphttp://en.wikipedia.org/wiki/Water_well_pumphttp://en.wikipedia.org/wiki/Aquarium_filterhttp://en.wikipedia.org/wiki/Pondhttp://en.wikipedia.org/wiki/Aerationhttp://en.wikipedia.org/wiki/Car_industryhttp://en.wikipedia.org/wiki/Car_industryhttp://en.wikipedia.org/wiki/Water_coolinghttp://en.wikipedia.org/wiki/Fuel_injectionhttp://en.wikipedia.org/wiki/Energy_industryhttp://en.wikipedia.org/wiki/Pumping_(oil_well)http://en.wikipedia.org/wiki/Pumping_(oil_well)http://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Medical_industryhttp://en.wikipedia.org/wiki/Artificial_hearthttp://en.wikipedia.org/wiki/Artificial_hearthttp://en.wikipedia.org/wiki/Penile_prosthesishttp://en.wikipedia.org/wiki/Evolutionary_biologyhttp://en.wikipedia.org/wiki/Biomimicryhttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pumphttp://en.wikipedia.org/wiki/Pump#Positive_displacement_pump_behavior_and_safetyhttp://en.wikipedia.org/wiki/Pump#Positive_displacement_typeshttp://en.wikipedia.org/wiki/Pump#Rotary_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Reciprocating_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Various_positive_displacement_pumpshttp://en.wikipedia.org/wiki/Pump#Gear_pumphttp://en.wikipedia.org/wiki/Pump#Screw_pumphttp://en.wikipedia.org/wiki/Pump#Progressing_cavity_pumphttp://en.wikipedia.org/wiki/Pump#Roots-type_pumpshttp://en.wikipedia.org/wiki/Pump#Peristaltic_pumphttp://en.wikipedia.org/wiki/Pump#Plunger_pumpshttp://en.wikipedia.org/wiki/Pump#Triplex-style_plunger_pumps


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1.1.2.*.3 Compressed:air:powered doub!e:diaphragm pumps

1.1.2.*.6 Rope pumps1.1.2.*.18 /!e0ib!e impe!!er pump1.1.2.*.11 Roto!!ipti# pumps

• 1.2 Impu!se ?umpso 1.2.1 ydrau!i# ram pumps

• 1.* e!o#ity pumpso 1.*.1 Centri uga! pumpo 1.*.2 Radia!: !ow pumpso 1.*.* )0ia!: !ow pumpso

1.*.+ ,i0ed: !ow pumpso 1.*.- 4du#tor:(et pump• 1.+ 7ravity pumps• 1.- =team pumps• 1. a!ve!ess pumps

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http://en.wikipedia.org/wiki/Pump#Compressed-air-powered_double-diaphragm_pumpshttp://en.wikipedia.org/wiki/Pump#Compressed-air-powered_double-diaphragm_pumpshttp://en.wikipedia.org/wiki/Pump#Rope_pumpshttp://en.wikipedia.org/wiki/Pump#Flexible_impeller_pumphttp://en.wikipedia.org/wiki/Pump#Rotolliptic_pumpshttp://en.wikipedia.org/wiki/Pump#Impulse_Pumpshttp://en.wikipedia.org/wiki/Pump#Hydraulic_ram_pumpshttp://en.wikipedia.org/wiki/Pump#Velocity_pumpshttp://en.wikipedia.org/wiki/Pump#Centrifugal_pumphttp://en.wikipedia.org/wiki/Pump#Radial-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Axial-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Mixed-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Eductor-jet_pumphttp://en.wikipedia.org/wiki/Pump#Gravity_pumpshttp://en.wikipedia.org/wiki/Pump#Steam_pumpshttp://en.wikipedia.org/wiki/Pump#Valveless_pumpshttp://en.wikipedia.org/wiki/Pump#Compressed-air-powered_double-diaphragm_pumpshttp://en.wikipedia.org/wiki/Pump#Compressed-air-powered_double-diaphragm_pumpshttp://en.wikipedia.org/wiki/Pump#Rope_pumpshttp://en.wikipedia.org/wiki/Pump#Flexible_impeller_pumphttp://en.wikipedia.org/wiki/Pump#Rotolliptic_pumpshttp://en.wikipedia.org/wiki/Pump#Impulse_Pumpshttp://en.wikipedia.org/wiki/Pump#Hydraulic_ram_pumpshttp://en.wikipedia.org/wiki/Pump#Velocity_pumpshttp://en.wikipedia.org/wiki/Pump#Centrifugal_pumphttp://en.wikipedia.org/wiki/Pump#Radial-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Axial-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Mixed-flow_pumpshttp://en.wikipedia.org/wiki/Pump#Eductor-jet_pumphttp://en.wikipedia.org/wiki/Pump#Gravity_pumpshttp://en.wikipedia.org/wiki/Pump#Steam_pumpshttp://en.wikipedia.org/wiki/Pump#Valveless_pumps


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*eciprocatin+ positi,e disp#ace(ent p$(ps Main article: Reciprocating pump

=imp!e hand pump

and:operated5 re#ipro#ating5 positive disp!a#ement5 water pump inEoFi#e:Gahanov#e 5=!ovakia >wa!king beam pump'Re#ipro#ating pumps move the !uid using one or more os#i!!ating pistons5 p!ungers5 or membranes >diaphragms'5 whi!e va!ves restri#t !uid motion to thedesired dire#tion.?umps in this #ategory range rom simplex 5 with one #y!inder5 to in some#asesquad > our' #y!inders5 or more. ,any re#ipro#ating:type pumpsare duplex >two' ortriplex >three' #y!inder. They #an be either single-acting with su#tion during one dire#tion o piston motion and dis#harge on theother5 ordouble-acting with su#tion and dis#harge in both dire#tions. The

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http://en.wikipedia.org/wiki/Reciprocating_pumphttp://en.wikipedia.org/wiki/Ko%C5%A1icehttp://en.wikipedia.org/wiki/%C5%A4ahanovcehttp://en.wikipedia.org/wiki/Slovakiahttp://en.wikipedia.org/wiki/File:Pump-tah.jpghttp://en.wikipedia.org/wiki/File:Pump-tah.jpghttp://en.wikipedia.org/wiki/File:Hand_pump.pnghttp://en.wikipedia.org/wiki/File:Hand_pump.pnghttp://en.wikipedia.org/wiki/Reciprocating_pumphttp://en.wikipedia.org/wiki/Ko%C5%A1icehttp://en.wikipedia.org/wiki/%C5%A4ahanovcehttp://en.wikipedia.org/wiki/Slovakia


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pumps #an be powered manua!!y5 by air or steam5 or by a be!t driven by anengine. This type o pump was used e0tensive!y in the 16th #enturyHin theear!y days o steam propu!sionHas boi!er eed water pumps. Now re#ipro#ating

pumps typi#a!!y pump high!y vis#ous !uids !ike #on#rete and heavy oi!s5 andserve in spe#ia! app!i#ations that demand !ow !ow rates against high resistan#e.Re#ipro#ating hand pumps were wide!y used to pump water rom we!!s.Common bi#y#!e pumps and oot pumps orin !ation use re#ipro#ating a#tion.These positive disp!a#ement pumps have an e0panding #avity on the su#tionside and a de#reasing #avity on the dis#harge side. ;i uid !ows into the pumpsas the #avity on the su#tion side e0pands and the !i uid !ows out o thedis#harge as the #avity #o!!apses. The vo!ume is #onstant given ea#h #y#!e ooperation.

Typi#a! re#ipro#ating pumps are&• lunger pumps : a re#ipro#ating p!unger pushes the !uid through one or

two open va!ves5 #!osed by su#tion on the way ba#k.• Diap!ragm pumps : simi!ar to p!unger pumps5 where the p!unger

pressuriBes hydrau!i# oi! whi#h is used to !e0 a diaphragm in the pumping#y!inder. Diaphragm va!ves are used to pump haBardous and to0i# !uids.

• iston pumps disp!a#ement pumps- usually simple devices for pumping small amounts of liquid or gel manually" #!e common !and soap dispenser

is suc! a pump"• Radial piston pumps

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http://en.wikipedia.org/wiki/Bicycle_pumphttp://en.wikipedia.org/wiki/Inflatablehttp://en.wikipedia.org/wiki/Plunger_pumphttp://en.wikipedia.org/wiki/Diaphragm_pumphttp://en.wikipedia.org/wiki/Piston_pumphttp://en.wikipedia.org/wiki/Radial_piston_pumphttp://en.wikipedia.org/wiki/Bicycle_pumphttp://en.wikipedia.org/wiki/Inflatablehttp://en.wikipedia.org/wiki/Plunger_pumphttp://en.wikipedia.org/wiki/Diaphragm_pumphttp://en.wikipedia.org/wiki/Piston_pumphttp://en.wikipedia.org/wiki/Radial_piston_pump


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The air operated pump is genera!!y a !ow #ost work horse pump used ortrans erring any type o !i uid in#!uding s!udge. The in!et and out!et va!ves are

o ten !ow #ost easi!y rep!a#ed !ap or ba!! va!ves. The pump is #omprises two#ir#u!ar #hambers ea#h sp!it by a !arge e!astomeri# diaphragm. The twodiaphragm #enters are me#hani#a!!y #oup!ed together with a sha t. )ninter!o#ked va!ve admits air pressure to one side o one o the #hambers ande0haust the air rom the opposite side o the other #hamber. This #auses bothdiaphragms to move. One diaphragm pushing !uid out through a non returnva!ve. The other diaphragm drawing !uid in through a non return va!ve. On#omp!etion o a u!! stroke the va!ve reverses the air supp!y and e0haustdire#tions #ausing the diaphragms to move ba#k. The diaphragm whi#h was pushing !uid out o the pump now su#ks !uid and the diaphragm admitting

!uid now pushes !uid out. The system is there ore doub!e a#ting.

The pump #apa#ity is !imited by the air pressure avai!ab!e >genera!!y bar' andthe design o the diaphragm. )n e!astomeri# diaphragm has a !imited !i e andwi!! on!y operate or a ew mi!!ion #y#!es. ) !ow rate o about +8 m* hr is areasonab!e ma0imum a#hievab!e !ow with a !arger pump.

/or any air operated diaphragm pump the higher the !ow the !ower thedis#harge head possib!e.

1*


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1+


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1-


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=pro#ket whee!&) sproc-et or sproc-et'.%ee# is a pro i!ed whee! with teeth5 #ogs5 or evenspro#kets that mesh with a #hain5 tra#k or other per orated or indentedmateria!. The name Jspro#ketJ app!ies genera!!y to any whee! upon whi#h areradia! pro(e#tions that engage a #hain passing over it. It is distinguished roma gear in that spro#kets are never meshed together dire#t!y5 and di ers roma pu!!ey in that spro#kets have teeth and pu!!eys are smooth.=pro#kets are used in bi#y#!es5 motor#y#!es5 #ars5 tra#ked vehi#!es5 andother ma#hinery either to transmit rotary motion between two sha ts wheregears are unsuitab!e or to impart !inear motion to a tra#k5 tape et#. ?erhaps themost #ommon orm o spro#ket may be ound in the bi#y#!e5 in whi#h the peda!sha t #arries a !arge spro#ket:whee!5 whi#h drives a #hain5 whi#h5 in turn5 drivesa sma!! spro#ket on the a0!e o the rear whee!. 4ar!y automobi!es were a!so!arge!y driven by spro#ket and #hain me#hanism5 a pra#ti#e !arge!y #opied rom bi#y#!es.=pro#kets are o various designs5 a ma0imum o e i#ien#y being #!aimed orea#h by its originator. =pro#kets typi#a!!y do not have a !ange. =ome spro#ketsused with timing be!ts have !anges to keep the timing be!t #entered. =pro#ketsand #hains are a!so used or power transmission rom one sha t to another wheres!ippage is not admissib!e5 spro#ket #hains being used instead o be!ts or ropesand spro#ket:whee!s instead o pu!!eys. They #an be run at high speed and some

orms o #hain are so #onstru#ted as to be noise!ess even at high speed.

1


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1

http://en.wikipedia.org/wiki/Wheelhttp://en.wikipedia.org/wiki/Roller_chainhttp://en.wikipedia.org/wiki/Caterpillar_trackhttp://en.wikipedia.org/wiki/Gearhttp://en.wikipedia.org/wiki/Pulleyhttp://en.wikipedia.org/wiki/Bicyclehttp://en.wikipedia.org/wiki/Motorcyclehttp://en.wikipedia.org/wiki/Automobilehttp://en.wikipedia.org/wiki/Continuous_trackhttp://en.wikipedia.org/wiki/Machinehttp://en.wikipedia.org/wiki/Flangehttp://en.wikipedia.org/wiki/Toothed_belt


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C%ain &

) c%ain is a ro!!er #hain that trans ers power rom the peda!s to thedrive:whee! o a bi#y#!e5 thus prope!!ing it. ,ost bi#y#!e #hains aremade rom p!ain #arbon or a!!oy stee!5 but some are ni#ke!:p!ated to prevent rust5 or simp!y or aestheti#s.

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/ipes)

ater pipes are pipes or tu bes5 re uent!ymade o po!yviny!

#h!oride >? C u? C'5 du#ti!e iron5 stee!5 #astiron5 po!ypro py!ene5 po!yethy!ene5 #opper5or > ormer!y' !ead5 that#arry pressuriBed and treated resh water to bui!dings >as part o a muni#ipa!water system'5 as we!! as inside the bui!ding.

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http://en.wikipedia.org/wiki/Roller_chainhttp://en.wikipedia.org/wiki/Power_(physics)http://en.wikipedia.org/wiki/Bicycle_wheelhttp://en.wikipedia.org/wiki/Bicyclehttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Alloy_steelhttp://en.wikipedia.org/wiki/Nickel-platedhttp://en.wikipedia.org/wiki/Roller_chainhttp://en.wikipedia.org/wiki/Power_(physics)http://en.wikipedia.org/wiki/Bicycle_pedalhttp://en.wikipedia.org/wiki/Bicycle_wheelhttp://en.wikipedia.org/wiki/Bicyclehttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Alloy_steelhttp://en.wikipedia.org/wiki/Nickel-plated


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Cran-)

KCran- K is a pe(orative term used or a person who ho!ds an unshakab!e be!iethatmost o his or her #ontemporar ies #onsider to be a!se.@1A ) #rank be!ie is sowi!d!y at varian#e with those #ommon!yhe!d as to be !udi#rous. Cranks#hara#teristi#a!!y dismiss a!! eviden#e or arguments whi#h #ontradi#t their ownun#onventiona! be!ie s5 making rationa! debate a uti!e task5 and rendering themimpervious to a#ts5 eviden#e5 and rationa! in eren#e.Common synonyms or K#rankK in#!udecrac-pot and -oo- . ) #rank di ers

rom a anati# in that the sub(e#t o the anati#Js obsession is either notne#essari!y wide!y regarded as wrong or not ne#essari!y a K ringeK be!ie .

=imi!ar!y5 the wordquac$ is reserved or someone who promotes a medi#a!remedy or pra#ti#e that is wide!y #onsidered to be ine e#tive< this term however does not imp!y any deep be!ie in the idea or produ#t they are attempting tose!!.%ran$ may a!so re er to an i!!:tempered individua! or one who is in a badmood5 but that usage is not the sub(e#t o this arti#!e.)!though a #rankJs be!ie s seem ridi#u!ous to e0perts in the ie!d5 #ranks aresometimes very su##ess u! in #onvin#ing non:e0perts o their views. ) amouse0amp!e is the Indiana ?i $i!! where a state !egis!ature near!y wrote into !aw a#rank resu!t in geometry.

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http://en.wikipedia.org/wiki/Polyvinyl_chloridehttp://en.wikipedia.org/wiki/Polyvinyl_chloridehttp://en.wikipedia.org/wiki/Ductile_ironhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Copperhttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Pressurehttp://en.wikipedia.org/wiki/Water_purificationhttp://en.wikipedia.org/wiki/Fresh_waterhttp://en.wikipedia.org/wiki/Municipal_water_systemhttp://en.wikipedia.org/wiki/Municipal_water_systemhttp://en.wikipedia.org/wiki/Pipe_(fluid_conveyance)http://en.wikipedia.org/wiki/Tube_(fluid_conveyance)http://en.wikipedia.org/wiki/Polyvinyl_chloridehttp://en.wikipedia.org/wiki/Polyvinyl_chloridehttp://en.wikipedia.org/wiki/Ductile_ironhttp://en.wikipedia.org/wiki/Steelhttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Cast_ironhttp://en.wikipedia.org/wiki/Polypropylenehttp://en.wikipedia.org/wiki/Polyethylenehttp://en.wikipedia.org/wiki/Copperhttp://en.wikipedia.org/wiki/Leadhttp://en.wikipedia.org/wiki/Pressurehttp://en.wikipedia.org/wiki/Water_purificationhttp://en.wikipedia.org/wiki/Fresh_waterhttp://en.wikipedia.org/wiki/Municipal_water_systemhttp://en.wikipedia.org/wiki/Municipal_water_system


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T'joint)

) fittin+ is used in pipe p!umbing systems to #onne#tstraight pipe or tubing se#tions5 to adapt to di erent siBes or shapes5 and orother purposes5 su#h as regu!ating or measuring !uid !ow. Theterm plumbing is genera!!y used to des#ribe #onveyan#e o water5 gas5 or !i uidwaste in ordinary domesti# or #ommer#ia! environments5 whereas piping iso ten used to des#ribe high:per orman#e >e.g. high pressure5 high !ow5 hightemper ature5 haBardous materia!s' #onveyan#e o !uids in spe#ia!iBedapp!i#ations. The termtubing is sometimes used or !ighter:weight piping5

espe#ia!!y types that are !e0ib!e enough to be supp!ied in #oi!ed orm./ittings >espe#ia!!y un#ommon types' re uire money5 time5 materia!s5 and too!sto insta!!5 so they are a non:trivia! part o piping and p!umbingsystems. a!ves are te#hni#a!!y ittings5 but are usua!!y dis#ussed separate!y.) tee is the most #ommon pipe itting. It is avai!ab!e with a!! ema!e threadso#kets5 a!! so!vent we!d so#kets5 or with opposed so!vent we!d so#kets and aside out!et with ema!e threads. It is used to either #ombine or sp!it a !uid !ow.It is a type o pipe itting whi#h is T:shaped having two out!ets5 at 68L to the#onne#tion to the main !ine. It is a short pie#e o pipe with a !atera! out!et. ) teeis used or #onne#ting pipes o di erent diameters or or #hanging the dire#tiono pipe runs. They are made o various materia!s and avai!ab!e in various siBesand inishes. They are e0tensive!y used in pipe!ine networks to transport two: phase !uid mi0tures. They are #ategoriBed as&

• 4 ua!• Une ua!

9hen the siBe o the bran#h is same as header pipes5 e ua! tee is used and when

the bran#h siBe is !ess than that o header siBe5 redu#ed tee wi!! be used. ,ost#ommon are tees with the same in!et and out!et siBes. =ome o the industria! teesare =traight Tee5 Redu#ing Tee5 Doub!e $ran#h Tee5 Doub!e $ran#h Redu#ingTee5 Coni#a! Tee5 Doub!e $ran#h Coni#a! Tee5 $u!!head Tee5 Coni#a! Redu#ingTee5 Doub!e $ran#h Coni#a! Redu#ing Tee5 Tangentia! Tee5 and Doub!e $ran#hTangentia! Tee.The above tees are #ategoriBed on the basis o their shapes and stru#ture. They#an a!so be #!assi ied on the basis o the app!i#ation they are re uired to per orm.@ urther e0p!anation neededA

21

http://en.wikipedia.org/wiki/Fanaticismhttp://en.wikipedia.org/wiki/Fixation_(psychology)http://en.wikipedia.org/wiki/Quackeryhttp://en.wikipedia.org/wiki/Indiana_Pi_Billhttp://en.wikipedia.org/wiki/Pejorativehttp://en.wikipedia.org/wiki/Crank_(person)#cite_note-1http://en.wikipedia.org/wiki/Fanaticismhttp://en.wikipedia.org/wiki/Fixation_(psychology)http://en.wikipedia.org/wiki/Quackeryhttp://en.wikipedia.org/wiki/Indiana_Pi_Bill


22/81

The three out!et siBes shou!d be named in order >e.g. !e t5 midd!e5 right<measuring 1-:22:1-'.@ furt!er explanation needed AThe three siBes o a tee are end 0 end 0 #enter. =o i you want a tee that is 1K on

both ends and * +K in the #enter it wou!d be 1K 0 1K 0 * +K.

T44.

22

http://en.wikipedia.org/wiki/Pipe_(fluid_conveyance)http://en.wikipedia.org/wiki/Tube_(fluid_conveyance)http://en.wikipedia.org/wiki/Fluidhttp://en.wikipedia.org/wiki/Pipinghttp://en.wikipedia.org/wiki/Plumbinghttp://en.wikipedia.org/wiki/Valvehttp://en.wikipedia.org/wiki/Wikipedia:Please_clarify


23/81

Nut % bo!t&

) n$t is a type o astener with a threaded ho!e. Nuts are a!most a!ways usedopposite a mating bo!t to asten a sta#k o parts together. The two partners arekept together by a #ombination o their threadsJ ri#tion5 a s!ight stret#h o the bo!t5 and #ompression o the parts. In app!i#ations where vibration or rotationmay work a nut !oose5 various !o#king me#hanisms may be emp!oyed&)dhesives5 sa ety pins or !o#kwire5 ny!on inserts5 or s!ight!y ova!:shapedthreads. The most #ommon shape is he0agona!5 or simi!ar reasons as the bo!thead : sides give a good granu!arity o ang!es or a too! to approa#h rom>good in tight spots'5 but more >and sma!!er' #orners wou!d be vu!nerab!e to

being rounded o . Other spe#ia!iBed shapes e0ist or #ertain needs5 su#h aswing nuts or inger ad(ustment and #aptive nuts or ina##essib!e areas. Nuts are graded with strength ratings #ompatib!e with their respe#tive bo!ts< ore0amp!e5 an I=O property #!ass 18 nut wi!! be ab!e to support the bo!tproostrength !oad o an I=O property #!ass 18.6 bo!t without stripping. ;ikewise5 an=)4 #!ass - nut #an support the proo !oad o an =)4 #!ass - bo!t5 and so on.) wide variety o nuts e0ists5 rom househo!d hardware versions to spe#ia!iBedindustry:spe#i i# designs that are engineered to meet various te#hni#a!standards.

2*

http://en.wikipedia.org/wiki/Wikipedia:Please_clarify


24/81

• s%aft)'

the sha t ismmadeup o ms .it is supported with two ro!!er bearings .onits one end rotating drum and on oter end is with driven pu!!ey .therotating drum through pu!!ey.

2+

http://en.wikipedia.org/wiki/Fastenerhttp://en.wikipedia.org/wiki/Screw_threadhttp://en.wikipedia.org/wiki/Screw#Bolthttp://en.wikipedia.org/wiki/Fastenerhttp://en.wikipedia.org/wiki/Screw_threadhttp://en.wikipedia.org/wiki/Screw#Bolthttp://en.wikipedia.org/wiki/Lockwirehttp://en.wikipedia.org/wiki/Hexagonhttp://en.wikipedia.org/wiki/Bolted_joint#Property_classhttp://en.wikipedia.org/wiki/Bolted_joint#Property_classhttp://en.wikipedia.org/wiki/Household_hardwarehttp://en.wikipedia.org/wiki/Engineeringhttp://en.wikipedia.org/wiki/Technical_standardhttp://en.wikipedia.org/wiki/Technical_standard


25/81


26/81

CO,?ON)NT )NTIT ?UR?OU=

;: shape #o!umn 3m To make a rame

= uare bar 2m To support the rame

=pro#ket whee! nos /or transmission

Chain +m /or drive to spro#ket whee!

Cir#u!ar shape rod 1 t 2nos /or arrangement o spro#ket whee!

pipe *m /or supp!y o water

9ood +P+ t 18mmthi#k

/or #ir#u!ar shape #rank

?iston %#y!inder 1.+P*8 /or pump the water

,otor 12v /or going to !i t up side

T:(oint 2nos /or pipe itting

Nut % bo!t 2- /or tightening o rame

2


27/81

Chapter no$ *

DESI+N

C'NSIDE#A&I'N

2


28/81

Introduction$

This #hapter des#ribes some o the design te#hni ue used by

designers o #omp!e0 stru#tures. ,athemati#a! mode!s and ana!ysis are brie !y des#ribe anddetai! des#ription is given o the inite " e!ement method o stru#tura! ana!ysis. =o!utionte#hni ues are presented or stati#5 dynami# % mode! ana!ysis prob!ems. )s part o the design pro#edure the designer must be ana!yses the entire stru#ture and some o its #omponents. To per orm this ana!ysis the designer wi!! deve!op mathemati#a! mode!s o stru#ture that areappro0imation o the rea! stru#ture5 these mode!s are used to determine the important parameters in the design. The type o stru#tura! mode! the designer uses depends on the

in ormation that is needed and the type o ana!ysis the designer #an per orm.

Three types o stru#tura! mode!s are :

1. *i+id e( ers) The entire stru#ture or parts o the stru#ture are #onsidered

to be rigid5 hen#e no de ormation #an o##ur in these members.

2. F#e i #e (e( ers & The entire stru#ture or parts o the stru#ture are mode!ed

by members that #an de orm5 but in !imited ways. 40amp!es o this members

trusses5 beams and p!ates.

*. Contin$$( & ) #ontinuum mode! o stru#ture is the most genera!5 sin#e ew i

any mathemati#a! assumptions about the behaviour o the stru#ture need

23


29/81

E E* & /*OCE:;*E C< E :E"

The genera! steps to be o!!owed in designing the ma#hine are as o!!owed.i' ?reparation o a statement o the prob!em indi#ating the purpose o

the ma#hine.

ii' =e!e#tion o groups o me#hanism or the desire motion.

iii' Ca!#u!ation o the or#e and energy on ea#h ma#hine member.

iv' =e!e#tion o materia!.

v' Determining the siBe o #omponent drawing and sending or

manu a#ture.

vi' ?reparation o #omponent drawing and sending or manu a#ture.

vii' ,anu a#turing and assemb!ing the ma#hine.

viii' Testing o the ma#hine and or un#tioning.

26


30/81

:E"

In this ma#hine o!!owing parts needs to design

• Fra(e co#$(n cripp#in+ =cr$s%in+

• "proc-et .%ee#

• Cran-

• C #inder = /iston

• < dra$#ic circ$it

*8


31/81

:E" OF F* E)' The #o!umn o rame is Q; se#tion

Dimension o se#tion isS 2.-+P2.-+P*;ength o #o!umn S1-88mm;e o #o!umn S2;S*888)rea o the se#tion isS 1+*.+#m*,oment o inertia S I00S668 .8*mm* IyyS **3.*2IminSIyyS **3.*2The standard materia! o ! #o!umn is #ast iron4 o #ast iron>modu!us o e!asti#ity'S P

/# o #ast iron >#rushing or#e'S--8 or #ast ironS

E$#er for($#a

$y this ormu!a the !oad S-+.1+kgS-*1.12N

*an-ine for($#a

Rankine s #ripp!ing !oadS 18.*+NS 2.+1kg$y #a!#u!ation this rame #an #arry sa e !oad uptoS+P-*1.12N S 212+.+3N

*1


32/81

Design o =ha t

Terms used&:

TS Twisting moment >or tor ue' a#ting on sha t.MS po!ar moment o inertia >po!ar ,I' o sha t about a0is o rotation.S Torsiona! shear stress N mm 2.

;S ;ength o sha t in VmmW.?S power transmitted in E9.

>1'. =ha t sub(e#ted to twisting moment on!y5 T M S r /or so!id sha t5 TS d + T *2 d + S d 2 T S 1 d * X >1')!so5?ower >?' S 2 N T 81.+6P18 * S 2 *88 T 8T S + . 1 18 *N.mmTaking shear stress va!ue rom design data book5 S *2 N mm 2 OR ,?aUsing strength e uation rom e uation >1'5 T S 1 d *

*2


33/81

2*. 1 18 * S 1 d * +2 d S 22. -mm

2+mm >standard va!ue'

**


34/81

"/*OC>ET


35/81

F CTO* ,a#$e

*-


36/81

? 12. mm N 13Dr . > rom data sheet'

Ds . 3mmRs *.33mm) *3.**$ 1+.33)# .21, +.3T *.3-4 18.12B 8.6*

)b 1..39 18 .1213.33

/ 181. 3181.-3

= 2+.83?D *.1

*


37/81

/ "TO = C?& :E*

O$ter dia(eter of c #inder)' 1@43c(

nterna# dia(eter of c #inder)' 1@4c(

&en+t% of c #inder)' 30c("oA

(o$nt of .ater de#i,ered 2 c #inder ,o#$(e

!o#$(e of c #inder)'

!o#$(e of c #inder)' 172c(3

Tota# a(o$nt of .ater de#i,ered)' 2 172 369@45c(3

B$t1c(3 0@001#it

ater is de#i,ered at one stro-e)' 0@36#it

*


38/81

*3


39/81

C* >

C #inder #en+t%) 30c(

"tro-e #en+t% ) 28c(

T:C) 1((

B:C) 29((

:ia(eter of cran- sto-e #en+t% D distanceet.een T:C #o.er ed+e of cran-

:istance et.een T:C #o.er ed+e )'7@5c(

"o cran- dia(eter)' 35@5 c(

*6


40/81


41/81

Chapter no$ .

MA&E#IA!

SE!EC&I'N

+1


42/81

The proper se!e#tion o materia! or the di erent part o a ma#hine is the main

ob(e#tive in the abri#ation o ma#hine. /or a design engineer it is must that he be ami!iar with the e e#t. The Choi#e o materia! or engineering purposes depends upon the o!!owing

a#tors&1. )vai!abi!ity o the materia!s.2. =uitabi!ity o materia!s or the working #ondition in servi#e.*. The #ost o materia!s.+. ?hysi#a! and #hemi#a! properties o materia!.-. ,e#hani#a! properties o materia!.

The materia! se!e#ted shou!d with stand it. )nother #riteria or se!e#tion o meta!depend upon the type o !oad be#ause a ma#hine part resist !oad more easi!y than a !ive !oadand !ive !oad more easi!y than a sho#k !oad.=e!e#tion o the materia! depends upon a#tor o sa ety5 whi#h in turn depends upon the

o!!owing a#tors.1. Re!iabi!ities o properties2. Re!iabi!ity o app!ied !oad

*. The #ertainty as to e0a#t mode o ai!ure+. The e0tent o simp!i ying assumptions-. The e0tent o !o#a!iBed

. The e0tent o initia! stresses set up during manu a#turing

. The e0tent !oss o !i e i ai!ure o##urs3. The e0tent o !oss o property i ai!ure o##urs

+2


43/81

,)T4RI); U=4D

CO /O E T TE* &

/R),4 C)=T IRON

CR)NE 9OOD

?I?4 ?;)=TIC

C ;IND4R ,.=

NOYY;4 ?!asti#

Nut bo!t ,.=

CIRCU;)R ROD C)=T IRON

=?ROC4T ,.=

C )IN ,.=

T MOINT C)=T IRON

+*


44/81

• "e#ection of ateria#s)

To prepare any ma#hine part5 the type o materia! shou!d be proper!y

=e!e#ted by #onsidering design5 sa ety and o!!owing points&The se!e#tion o materia! or engineering app!i#ation is given by the o!!owing/a#tors&:

1' =uitabi!ity o the materia! or the re uired #omponents.

2' =uitabi!ity o the materia! or the desired working #onditions.

*')vai!abi!ity o materia!s.

+' Cost o the materia!s.

-' In addition to the above mentioned a#tors the other me#hani#a! % physi#a! prosperities shou!d be #onsidered whi!e se!e#ting materia! or abri#ation &

1' =trength&

It is the abi!ity o a materia! to resist the e0terna!!y app!ied or#es without$reaking or yie!ding.

2' =ti ness

It is the abi!ity o a materia! to resist de ormation under stress. The modu!uso e!asti#ity is the erasure o stu iness.

*' 4!asti#ity&

It is the property o materia! to regain its origina! shape a ter de ormation whene0terna! or#es are removed.+' ,);;4)$I;ITThe abi!ity o a materia! to be reshaped in a!! dire#tions without #ra#king

our te#hno!ogy te#hni#ian demonstrates the Qma!!eabi!ity o a materia! byheating a pie#e o mi!d stee! unti! it is red hot. e then beats it with a !arge

orging hammer to reshape it. $e#ause o the high temperature it rea#hes whi!eheating the stee! be#omes ma!!eab!e5 it #an be reshaped permanent!y.

++


45/81

4d o ten heats up stee!5 be#ause he !ikes the #o!or and it mat#hes his#omp!e0ion a ter he has run up the stairs.

-' TOU7 N4==) #hara#teristi# o a materia! that does not break or shatter when re#eiving a b!ow or under a sudden sho#k.

Our te#hno!ogy te#hni#ian demonstrates the Qtoughness o a materia! by hittinga pie#e or materia! to see i it wi!! break or shatter.

4d has been known to test authenti# Chinese ,ing Dynasty pottery with thesame te#hni ue. This is why he is o ten arrested in ,useums and has been banned rom the !o#a! )nti ue dea!ers.

' )RDN4==

The abi!ity o a materia! to resist s#rat#hing5 wear and tear and indentation.

Our te#hno!ogy te#hni#ian5 dressed in a ki!t5 s!ides a!ong the !oor to see i itwi!! s#rat#h. It wi!! be #onsidered to hard wearing i it resists s#rat#hing.

' /atigue ratio

The dimension!ess atigue ratio is the ratio o the stress re uired to #auseai!ure a ter a spe#i i# number o #y#!es to the yie!d stress o a materia!. /atigue

tests are genera!!y run through 18 or 183 #y#!es. ) high atigue ratio indi#atesmateria!s whi#h are more sus#eptib!e to #ra#k growth during #y#!i# !oading.

3' Creep

In materia!s s#ien#e5 #reep is the tenden#y o a so!id materia! to move s!ow!y or de orm permanent!y under the in !uen#e o stresses. It o##urs as a resu!t o !ong:term e0posure to high !eve!s o stress that are be!ow the yie!d strength o themateria!. Creep is more severe in materia!s that are sub(e#ted to heat or !ong periods5 and near their me!ting point. Creep a!ways in#reases with temperature.

+-


46/81

1' ,i!d stee!

Composition #arbon 8.28 Z : 8.2- Z

,anganese ma0 8.3Z

=u!phur5 ma0 8.8-Z

?hosphorus5 ma0 8.8-Z

=i!i#on5 ma0 8.2- Z

Iron Remainder

Tensi!e strength & ++-.+ N mm 2

ie!d stress & 238 N mm 2

ardness & 1 8 $ N

2' Cast iron

Composition

#arbon& 2.8 Z :+.8 Z

,anganese ma0& 8.+Z :1.8Z

=u!phur5 ma0& 8.8-Z :8.1Z

?hosphorus5 ma0 & 8.8 Z

+

http://en.wikipedia.org/wiki/Materials_sciencehttp://en.wikipedia.org/wiki/Yield_strengthhttp://en.wikipedia.org/wiki/Materials_sciencehttp://en.wikipedia.org/wiki/Stress_(physics)http://en.wikipedia.org/wiki/Yield_strengthhttp://en.wikipedia.org/wiki/Heat


47/81

=i!i#on5 ma0 &

8.1 Z : +Z

Iron & remainder

Tensi!e strength & 188 to 288 N mm 2

ie!d stress & 23 kg mm 2

Compressive strength& +88 TO 1888 N ,, 2

=hear stress & 128 N ,, 2

+


48/81

Chapter no$ /

MAN(0AC&(#IN+

+3


49/81

The pro#ess o #onversion o raw materia! in to inished produ#ts using thethree resour#es as ,an5 ma#hine and inished sub:#omponents.,anu a#turing is the term by whi#h we trans orm resour#e inputs to #reateUse u! goods and servi#es as outputs. ,anu a#turing #an a!so be said as anintentiona! a#t o produ#ing something use u! . The trans ormation pro#ess is=hown be!ow:

Input #onventiona! pro#ess out put

It s the phase a ter the design. en#e re erring to the those va!ues we wi!! p!anThe various pro#esses using the o!!owing ma#hines&:

i' Universa! !atheii' 7rinding ma#hineiii' ?ower sawiv' Dri!! ma#hinev' 4!e#tri# ar# we!ding ma#hine5 et#.

+6


50/81

1 CO /O E T) FRAMETE* &)' M.S. V - ANGLE

=R. NO

D4=CRI?TIONO/

O?4R)TION,)C IN4

U=4D CUTTIN7 ,4)=UR4,4NT

1Cutting theang!e in to!ength as perdwg

7as#utting

ma#hine7as

#utter =tee! ru!e

2

Cutting theang!e in tonumber o pie#e as perdwg

7as#utting

ma#hine7as

#utter =tee! ru!e

*

/i!ingoperation #an be per ormedon #uttingside and bringit in perpendi#u!arC.=.

$en#hvi#e /i!e Try s uare

-8


51/81

+

9e!d theang!es to there uired siBe

as per thedrawing

4!e#tri#ar#

we!dingma#hine

::::::: Try s uare

- Dri!!ing therame at

re uired points as perthe drawing.

Radia!dri!!

ma#hine

Twistdri!!

ernier #a!iper

)1 C'MP'NEN&$ = )/T O/ =?ROCE4T MA&E#IA!$2 M.S. CIRCULAR ROD

3(AN&I&, $ 2

*1 Component$ Connecting pin

Material$ M.S

3uantity$ 2

=r no:escription of

t%e

opration, CUse Migs andi0ture Too# ;sed ,easuringInst. TimeRe ured

1 Turning Lathe Chuck =ing!e pointtoo! Varnier 1- min

2 Facing Lathe ChuckSingle point

toolVarnier 10 in

! C"a pe#ing Lathe Chuck C"a pe#ing $ % in

-1

=r :escription of , C Use Migs and Too# ;sed ,easuring Time

No the operation /i0tures Inst Re uired

1 /a#ing ;athe Chu#k =ing!e pt. ernier *8 ,in

#utting too! Ca!!iper

2 =tep turnig ;athe Chu#k Dri!!s ernier *8 ,inCa!!iper

* Threading ;athe $en#h i#e Enur!ing :::::::::::: 18 ,in

Too!


52/81

tool

-2


53/81

Chapter no$ 4

ASSEM5!,

-*


54/81

""E B&? OF "E ?

-+


55/81

• Fi#&t o' all (e a)e ain '#a e o' li't *+ c,tting & ,a#e #o)& *+

ga& c,tting (el)ing p#oce&&e&.

•

/"en oint t"e ci#c,la# #o) to t"e &p#oc et ("eel• /"en t"e &p#oc et ("eel &"a't attac"e) to t"e '#a e

• /"en t"e ot"e# &p#oc et al&o attac"e) to it& place

• /"en t"e c"ain i& appl+ to t"e all &p#oc et&.

• /"en c#an attac"e) to t"e '#a e eac" c#an i& eccent#ic at

110)eg#ee

• On t"e e)ge o' c#an t"e #o) o' pi&ton attac"e).

• /"e c+lin)e# i& 'i3e) on a '#a e

• /"e en) o' c"ain i& attac"e) to t"e ,p&i)e o' li't anot"e# en) i&

attac"e) to *otto o' li't

• /"e lo(e# &i)e o' li't t"e one &p#ing i& attac"e) to #e&i&t t"e loa)

•

On t"e )i&c"a#ge o' t"e c+lin)e# non #et,#n 4al4e i& attac"e) &o(ate# #e4e#&e 'lo( i& a4oi)e)

• /"e *ot" c+lin)e#& )i&c"a#ge i& a))e) toget"e# *+ appl+ing / oint

--


56/81

F B* C T O

/o!!owing di erent #omponent we have abri#ated in our #o!!ege9orkshop using avai!ab!e resour#es&:

• /rame &:

The three dimensiona! view o rame o body is shown in ig. This is the/rame in to whi#h a!! the #omponents or parts o ma#hine are itted. This rameis itted with the he!p o we!ding. Raw materia! or the rame& : ,.=. )ng!e

• ?u!!ey&:,ain un#tion o pu!!ey is to trans er the motion or power avai!ab!e rom onesha t to another sha t with the he!p o !eather be!t. The ve!o#ity ratio is in thereverse ratio o the diameter o driving and driven pu!!eys. ?u!!eys must be per e#t a!ignment in order to a!!ow the be!t to be trave!ed in a !ine norma! to the pu!!ey a#e. The pu!!ey is made o #ast iron be#ause the #ast materia! has a good

ri#tion and wear #hara#teristi#s. The pu!!ey is having key s!ot and : groove to

a#i!itate it or i0ing on the sha t and to insta!! the v: be!t. The v: groove o pu!!ey is :type

• =ha t&:=ha t is a rotating ma#hine e!ement whi#h is used or transmitting power

rom one p!a#e to another p!a#e. In order to transmit power rom one p!a#e to)nother p!a#e various members !ike pu!!eys 5 gears et#.5 are mounted on thesha t.,ateria! used or sha t is mi!d stee!

• $earing&:) bearing is a ma#hine e!ement whi#h supports another moving ma#hine4!ement >known as (ourna!'. It permits re!ative motion between the #onta#tsur a#es o members5 whi!e #arrying the !oad. In order to redu#e ri#tiona!resistan#e and wear and in some[ #ases to #arry the heat generated5 !ayer o a

!uid >known as !ubri#ant' may be provided. The !ubri#ant used to separate the (ourna! and bearing is usua!!y a minera! oi! re ined rom petro!eum 5 butvegetab!e oi!s 5 si!i#on oi!s 5 grease et#. may be used.

-


57/81

/*OCE"" /&

?ro#ess p!anning is an important un#tion5 whi#h takes p!a#e dire#t!y a ter the design o produ#t. It takes the in ormation re#eived and #reates a p!an or manu a#ture. The pro#ess p!anning invo!ves an app!i#ation o systemati# pro#edures whi#h invo!ves o!!owing steps.

)' ?R4;I,IN)R ?)RT ?RINT )N); =I=

1' =iBe #on iguration2' ,ateria!*' Dimensiona! re!ationships and identi i#ation o various re eren#e sur a#es+' Imp!i#it and e0p!i#it remarks regarding rom error and inish.

$' D4T4R,IN)TION ;O7IC); =4 U4NC4 O/O?4R)TION

1' Identi i#ation o sur a#e to be ma#hined5 se!e#tion o ma#hine too!.2' =upporting a##essories5 pi#tures5 gauges et#.

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Chapter no$ 6

C'S&

ES&IMA&I'N

-3


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Co&t e&ti ation a+ *e )e'ine) a& t"e p#oce&& o' 'o#eca&ting t"e e3pen&e& t"at

,&t *e inc,##e) to an,'act,#e a p#o),ct. /"e&e e3pen&e& ta e into a

con&i)e#ation all e3pen)it,#e in4ol4e) in a )e&ign an) an,'act,#ing (it" all #elate)

&e#4ice& 'acilitie& &,c" a& patte#n a ing tool a ing a& (ell a& a po#tion o' t"e

gene#al a) ini&t#ati4e an) &elling co&t&.

PURPOSE OF COST ESTIMATING 5

1. /o )ete# ine t"e &elling p#ice o' a p#o),ct 'o# a ,otation o# cont#act &o a& to

en&,#e a #ea&ona*le p#o'it to t"e co pan+.

2. C"ec t"e ,otation &,pplie) *+ 4en)o#&.

!. Dete# ine o&t econo ical p#oce&& 6 ate#ial to an,'act,#e t"e p#o),ct.

7. /o )ete# ine &tan)a#)& o' p#o),ction pe#'o# ance t"at a+ *e ,&e) to cont#ol t"e

co&t.

BASICALLY THE BUDGET ESTIMATION IS OF TYPES:

1. Mate#ial co&t

2. Mac"ining co&t

!. La*o,# co&t

7. O4e#"ea) co&t

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Cost of project= A! "#ter$#% cost& B! M#c'$($() cost& C! L#*o+r cost

& D! O,er'e#- cost

CO"T E"T T O

Cost estimation may be de ined as the pro#ess o #asting the e0pensesthat must be in#urred to manu a#ture a produ#t. These e0penses take into a#onsideration a!! e0penditure invo!ved in design and manu a#turing with a!!re!ated servi#es a#i!ities su#h as pattern making 5 too! 5 making as Vwe!! as a portion o the genera! administrative and se!!ing #ost.

/;*/O"E OF CO"T E"T T1' To determine the se!!ing pri#e o a produ#t or a uotation or #ontra#t=o as to ensure a reasonab!e pro it to #ompany.

2' Che#k the uotation supp!ied by venders.

*' Determine the most e#onomi#a! pro#ess or materia! to manu a#ture the?rodu#t.

+' to determine standards o produ#tion per orman#e that may be used to#ontro! the #ost.

$)=IC);; T 4 CO=T 4=TI,)TION O/ T9OT ?4=.

1. ,ateria! #ost.2. ,a#hining #ost.

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• TE* & CO"T E"T T O )

Mate#ial co&t e&ti ation gi4e& t"e total a o,nt #e ,i#e) to collect ate#ial ("ic" t"e

#a( "a& to *e p#oce&&e) o# 'a*#icate) to )e&i#e) &i8e an) ',nctioning o' t"eco ponent&./"e&e ate#ial& a#e )i4i)e) into t(o catego#ie&.

1. ,ateria! or abri#ation &

In t"i& ate#ial i& o*taine) in #a( con)ition an) i& an,'act,#e) o# p#oce&&e) to'ini&"e) &i8e 'o# p#ope# ',nctioning o' the co ponent& .

2. =tandard pur#hased parts.

This in#!udes the part whi#h was readi!y avai!ab!e in the market !ike)!!en s#rews et#. ) !ist in or #hard by the estimation stating the ua!ity 5siBe and standard parts 5 the weight o raw materia! and #ost per kg or the abri#ated parts

• CO"T E"T T O B? "E&ECT O OF /*O/E*

C< E /*OCE"")

/I$ROU= =TRUCTUR4 O/ /OR7IN7=& 7R)IN " /;O9&:

In orging5 meta! !ows simi!ar to the !ow o sand:#ement mortar whi!e$eing s ueeBed. /orging #auses the grains !ow and random!y dispersed=ma!! in#!usions and segregations ound in #ast meta! to be#ome e!ongatedin the same dire#tion as the meta! is #aused to !ow. I a orged part is #ut ina p!ane a!igned with the dire#tion and the sur a#e is ground smooth andThen immersed in an a#id so!ution the e0posed meta! wi!! appear to naked4ye to have a iber:!ike stru#ture. ) se#tion o an upset gear b!ank a ter Deep et#hing is shown in /ig. a. These ibers are non:meta!!i# in#!usionsor segregated phases that are e!ongated or K !owedK in the dire#tion o 9orking. 7rain !ow iber stru#ture5 !ow !ines and orging ibers are termsUse to des#ribe this e e#t. The grain: !ow o orged part resemb!es in,any ways the grain o wood. ;ike wood5 the strength and toughness o

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This meta! is greatest in the dire#tion o the iber. In the dire#tions at right)ng!es to these ibers5 the strength is norma!!y no greater than that ound inDense5 sound #asting.

/ig 1I 5 on orging5 the grain: !ow is in a dire#tion para!!e! to the?rin#ipa! grain: !ow it is said to !ow in its #orre#t iber dire#tion5 and i Otherwise5 it is said to !ow in its in#orre#t iber dire#tion.The e e#t o these !ow:!ines is to produ#e marked dire#tiona! properties in stee!. /or stati# !oad5 the dire#tions b these !ow:!ines are not

=o important5 but these are important on parts where sho#k and atigue are4n#ountered. The du#ti!ity and resistan#e to impa#t o the meta! are !ess in aDire#tion at right ang!es to the !ow:!ines than para!!e! with them. =pe#ia!Care is5 there ore5 taken in the ranking o orgings or gears5 #ranksha ts o otherhigh!y stressed parts to have the meta! !ow in the most avorab!e dire#tion in a!! portions o the orgings. It is #ommon ?ra#ti#e: or pur#hasers o orgings tospe#i y the desired dire#tions or the iber: !ow !ines to meet the stressese0pe#ted under a#tua! =ervi#e #onditions.

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/ig a!so shows the iber:!ines in a orged #ranksha t where it .#an be seen that the dire#tiona! ua!ities othe iber5 toughness to the web and where they (oin the round parts o the sha t.

4//4CT= O/ /OR7IN7& : /OR74D ?)RT= =. C)=T?)RT=.

/orging re ines the stru#ture o 5 meta! by smashing up !arge grain/ormations and #!osing up any #avities that may be present. In addition toThe re inement o grain siBe other e e#ts a!so resu!t rom suitab!e orging.?ie#es ormed by orging e0hibit dire#tiona! properties indi#ated by the/!ow !ines. The origina! #rysta!s typi#a! o the #ast stru#ture are destroyed5

ard i!ms o britt!e #onstituents or impurities ar# broker up or ro!!ed into/ibers and uni ormity is estab!ished. In additions to those e e#ts #ertain,e#hani#a! properties5 padi#u!ar!y e!ongation per#entage5 redu#tion o area?er#entage5 and resistan#e to sho#k and vibration5 are improved5 and in/avorab!e #ases #ra#ks and b!ow ho!es are we!ded up.) #ast iron5 on the other hand5 is very hard and britt!e5 and may be4asi!y broken when Qsub(e#ted To sho#k and vibration. It is very poor inTensi!e strength. =o ma#hine parts whi#h are !iab!e !o tension #annot be,ade o britt!e materia!s. It may a!so #ontain during #asting5 #ra#ks any$!ow ho!es and other de e#ts5 whi#h make the #a! iron very weak a5Unsuitab!e or use in many #ases.

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D4/4CT= IN /OR7IN7

De e#ts in meta! part o er a serious a#tor in the produ#tion o the orged ?arts

and thereby it be#omes very #ost!y. De e#t most #ommon!y ound in meta!s thathave been sub(e#ted to more or !ess p!asti# shaping may be.

C!assi ied as o!!ows&

!. De e#ts. Resu!ting rom the me!ting pra#ti#e su#h as dirt or s!agJ$!ow ho!es. 4t#.

2. Ingot de e#ts su#h as seams5 pipingJ #ra#ksJ s#a!es or bad

=ur a#e and segregation.*. De e#ts resu!ting rom improper heating and #oo!ing o the/orging su#h as burnt meta!J de#arburiBationJ and !akesJ

+. De e#t resu!ting rom improper orging su#h as seamJ #ra#ksJ;aps. 4t#.

-. /au!ty orging design.

. /au!ty die design.

. Improper p!a#ement o the meta! in the die #ausing mismat#hed/orging.:efects in for+in+ can e re(o,ed as fo##o.s &1. =ha!!ow #ra#ks and #avities #an be removed by #hipping out o The #o!d

orging with pneumati# #hise! or with hot sets during The orging pro#esses.2. =ur a#e #ra#ks and de#arburiBed areas are removed rom Important orgings by grinding on spe#ia! ma#hines. Care =hou!d a!so be taken to see that the work pie#e is not underheate+ de#a!burise+ overheated and burnt.*. Die design shou!d be proper!y made taking into #onsideration )!! re!evantand important aspe#ts that may impair orging % ens and u!timate spoi!age.+.the parting !ine o a orging shou!d !ie in one p!ane to avoid mismat#hing.-. Destroyed orgings are straightened in presses i possib!e.

. The me#hani#a!:properties o the meta! #an be improved by /orging to#orre#t iber !ine and ina!!y interna! stresses deve!oped due to heating and#oo!ing o the work pie#e are Removed by annea!ing and or norma!iBing

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4)T TR4)T,4NT O/ /OR74D ?)RT=

40#ept or ma#hining operations stee! orgings are sometimes used in theK)s orgedK #ondition without additiona! heat:treatment other than whatThey re#eive during the orging operation. owever5 i ma0imum servi#e is40pe#ted o a stee! orging it be#omes ne#essary to give the orging one or ,ore heat:treatment be ore it goes into servi#e.

=tee! orgings are heat:treated or the a!!owing purpose &

1 To remove stresses arising in the stee! during orging and

Coo!ing.25 to e ua!iBe the stru#ture o 5 the meta! o the orging.

* to give the steer that degree o hardness whi#h makes it most4asy to ma#hine.

+. To improve some o the me#hani#a! properties o the stee!.

Usua!!y orged parts are annea!ed and norma!iBe to obtain desired resu!ts

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)NN4);IN7

)nnea!ing is a orm o heat:treatment whi#h is app!ied to remove stresses5)nd improve the me#hani#a! properties and ma#hinabi!ity o orgings.The annea!ing pro#ess #onsists in heating the orgings urna#eTo a temperature o about -8 to 6888#5 depending on the #arbon #ontent o The stee! >to a temperature o about *8 to -8o# above the higher #riti#a!?oint' with subse uent s!ow #oo!ing.

This annea!ing wi!! resu!t in

1' Re inement o the grain ormed in stee! on the #omp!etion o the orgingat high temperature.

2' Remova! o interna! stresses resu!ting rom the hot 9orking o the meta!.

*' Comparative so tening o the stee!.


67/81

NOR,);IYIN7

It #onsists o heating the orged parts in urna#es as in annea!ing5 andsubse uent #oo!ing in the air. The o!!owing resu!ts are a#hieved due tonorma!iBing

1' a ine:grained stru#ture5 the grain stru#ture5 the grain being re ined to agrate degree than by annea!ing.

2' Improved me#hani#a! properties in#reased tensi!e strength 5 du#ti!ity .*' Remova! o interna! stresses.

• C< CO"T E"T T O :This #ost estimation is an attempt to ore#ast the tota! e0penses that may in#!udemanu a#turing part rom materia! #ost. Cost estimation o manu a#turing parts#an be #onsidered as (udgment on and a ter #are u! #onsideration whi#hin#!udes !abor5 materia! and a#tory servi#es re uired to produ#e the re uired

parts.

?ROC4DU4R /OR C);CU;)TION O/ ,)T4RI); CO=T

/"egene#al

p#oce),#e'o# calc,lation o' ate#ial

co&te&ti ation

i&

1. A'te# )e&igning a p#o ect a *ill o' ate#ial i&)i4i)e) into t(o Catego#ie&

a. Fa*#icate) co ponent& b. Stan)a#) p,#c"a&e co ponent&.

2. /"e #ate& o' all &tan)a#) ite & a#e ta en an) a))e) ,p.!. Co&t o' #a( ate#ial p,#c"a&e ta en an) a))e) up


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,ateria! #ost&

=r no ?art name materia! #ost 1 ang!e rame ,.= 22-8 : 2 ?!ate> -P28P8. ' ,.= 1--8 : * ?!ate or drum ,.= 11-8 : + i!ter =tain!ess stee! 1888 :- /orging materia! C.I 2888 :

Ro!!er bearing =tain!ess stee! *18 :?u!!ey C.I 1388 :

3 Oi! sea! : 1-8 :

6 v:be!t rubber *88 :18 ,otor >2 .?' : *-88 :11 sha t ,.= 1888 :

12 strips ,.= *88 :1* other : 1888 :

TOT); 2**18 :

,a#hining #ost

ere we have to work on the di erent m # or operation. =o the ma#hine is being hired /or that mu#h period o time. Considering the depre#iation andthe e!e#tri# !ight bi!! a!ong with the rent o work shop or the initia!investment5 the ma#hining #ost is #a!#u!ated as the #ost in Rs hr

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=r no.

operation rupees

1 $oring +88 :2 /inishing or orging materia! 1888 :* painting 88 :+ we!ding 1888 :- ro!!ing +8 :

dri!!ing 1888 :#utting -88 :

Tota!+ +8 :

La*o,# co&t

the ;abour #ost #onsists o the amount in#reased on the wages paid to theoperators. The #ost is #a!#u!ated based on the #a!#u!ation o the hour!y wages5 paid to the operators. ere the operators are #onsidered as the ski!!ed operator.

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Chapter no$ 6

AD-AN&A+ES DISAD-AN&A+ES

8


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AD-AN&A+ES

• It $s #+to"#t$c.

• E#s/ to oper#te.

• It 0or1s o( GRA2ITATIONAL ENEGRY.

• Pro,$-es "#3$"+" co"fort $( %$ft.

• E(er)/ -e"#(- $s -ecre#ses .

• .

• A%% t'e s/ste" '#,e 'e#,/ -+t/ .

• Co"p#ct $( s$4e #(- e#s/ $( 0or1$().

• It '#s #*$%$t/ to "o,e $( %$"$te- sp#ce.

DISAD-AN&A+ES

• It $s re5+$re- "ore sp#ce

• Not perfect$o( $( %$ft

• Mo(t#(#(s of %$ft $(cre#ses.

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C7AP&E# 8 &ES&IN+ '0 MAC7INE

PA#&S

Testing o ,a#hine ?arts2


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1' Testing o $ody or rame

The testing o who!e body or rame o the ma#hine whi#h the who!e weight o ma#hine with respe#t to ground is essentia!. $e#ause the ang!es o the bodyshou!d be at right ang!e to ground and !ywhee!5 sha ts and other parts areinsta!!ed on the body. )!ignment o rame must be a##urate whi#h in turndepends on perpendi#u!arity o verti#a! % horiBonta! ang!es. $ush mountingsshou!d be put on the mounting p!ate para!!e! to ground and sha t wi!! be passingthrough it. /or padd!e and #ontro! !ever shou!d be mounted by proper ad(ustment on body. Distan#e o #entre o sha t with ground shou!d be maintain#onstant and shou!d avoid b!o#king o motion o sha t.

2' Testing o #entre distan#e o motor and pu!!ey

The distan#e between motor whi#h is used to drive the ma#hine and pu!!ey\=hou!d be maintaining #onta#t as spe#i ied in drawing in running #ondition. The

i0ed distan#e between motor and pu!!ey prevent e0tra !oad on the be!t whi#his used to transmit power rom motor to sha t via pu!!ey.

*' Roundness o sha t

The sha t whi#h is used as the main power transmission member in the ma#hineshou!d be in per e#t round #ondition. The roundness o the sha t shou!d be#he#ked proper!y by using b!o#k and height gauge and a!so by mi#rometer sothat the standard deviation shou!d not more than ]8.8- mm. The pre#isionshou!d maintain a!! over the sur a#e o the sha t and outer a#e o the sha tshou!d be harden to the RC*8 to RC+- so that it shou!d not wear out easi!y andnot to !ose its #ir#u!arity.

+'4rror in a!ignment 5The testing o a!ignment o sha t with the !ywhee! and a!! the other parts withea#h other shou!d be #he#ked proper!y so that the me#hanism shou!d work proper!y. ,isa!ignment may give rise to the #y#!i# atigue set up in re!ated partsand parts may undergoes severe atigue whi#h resu!ts in sudden ai!ure o thema#hine parts without any pre symptoms.

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To avoid this a!! parts shou!d be #he#ked to ^ 8.8- mm standard deviationwhi#h is mu#h more in some #asesJ =o mu#h #are shou!d be taken in assemb!yo a!! members o the me#hanism.

-' Che#king o bearing so#kets.

The spa#e where we it bearing is #a!!ed bearing so#ket. This bearing so#ketis we!t ma#hined and given proper p!us to!eran#es so that bearing shou!d betight

itted in the so#ket. The #entre misa!ignment o the sha t and bearing shou!d notmore than that spe#i ied by the manu a#turer. 9hi#h get indi#ated in thestandard

Cata!ogue avai!ab!e to the se!!er.' Noise

The noise !eve! in the working mode! shou!d not more so that to disturbothers. ,ore noise means more ri#tion being taken p!a#e in the me#hanismwhi#h#ou!d be minimiBe by proper oi!ing and greasing and proper a!ignment o a!! parts

where noise generation taken p!a#e.

+


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Chapter no$ %9

!earning E:periences

-


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&E * OBJECT !E)

19 /o get e3pe#ience (o# (it" ot"e# people get no(le)ge '#o ot"e# g#o,p

e *e#& a*o,t (o# ing & ill&

29 (e lea#n a*o,t elect#o ec"anical &+&te ("ic" ,&e) in o ent& o' li't . eg.

!9 (e ,n)e#&tan) t"at i po#tant t"ing t"at ("ic" ate#ial o# &peci'ic pa#t (e #e ,i#e)

("ic" i& a4aila*le in a# et *,t not in p#ope# )i en&ion& (e #e ,i#e).&o t"at &,c"

t+pe& o' pa#t& an,'act,#e *+ &el'.

79 :e lea#n a*o,t co&ting .(e ta e a*o,t co&t o' p#o ect ini , a& po&&i*le

&t#engt" al&o o#e.

%9 /o no( a*o,t anage ent o' (o# ing. :e )i&c,&& a*o,t ("at (ill (o# )o

to o##o(.

;9 I p#o4e o,# (o# ing intellect,al & ill ("ic" #e ,i#e) in in),&t#ie&.


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Chapter no$ %%

C'NC!( I'N


78/81

CO C&;" O

B/ +s$() t'$s co(cept 0e co(ser,e t'e e(er)/

As (ot +se- f+e%6 $t -$rect%/ #ffect t'e $"p#ct of )%o*#% 0#r"$().

T'e o(e t$"e t0o 0or1 $s '#ppe(e-

Us$() t'e )r#,$t#t$o(#% e(er)/

3


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Chapter no$ %)

#E0E#ANCE

6


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R4/4R4NC4=

• ,a#hine design by R.=.E UR,I• )dvan#ed manu a#turing by aBara % Chaudhari• Design data by ?=7• www.segway.#om• www.wikipidea.#om

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