design and fabrication of m10 hexagonal nut deburring
TRANSCRIPT
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LOW COST AUTOMATION OFM10 HEXAGONAL NUTDEBURRING MACHINE
Project GuideMr.P.Mohanavelu M.E
Lecturer
Mechanical engineering
Panimalar engg,coll
Project venue
TVS SFL
Padi
Project Members
Goutham. S
Gobinath. K
Karthikeyan.k Diwakaran. U
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CONTENTS
ABSTRACT
INTRODUCTION
NEED FOR DEBURRING OPERATION PHASES OF THE PROJECT
PHOTOS
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ABSTRACT Nut deburring is used to remove burrs in the work. When the job is machined
burrs are produced due to various reasons in the work and this may reduce theaesthetic value of the product.
The main objective of the operation is to get good surface finish. Machining at any
scale usually produces burrs on surfaces;
The deburring operation is performed by mounting the head of the machine withan inclination for the gravity feed of the work. The work is allowed through the
guide ways and the work is clamped and separated with the help of pneumatic
cylinders.
The expected benefits of the project are the low cost automation which is done
with the help of PLC which reduces the time involved and the fatigue. This will
also increase the production and decreases the amounts spend on the quality.
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INTRODUCTION
A burr is a raised edge or small pieces of material
remaining attached to a work piece after a modification
process. It may be present in the form of a fine wire on
the edge of a freshly sharpened tool or as a raised
portion on a surface, after being struck a blow from an
equally hard or heavy object. A normal burr from well-
maintained tools is usually less than 10% of material
thickness. If burrs are not acceptable (burr-freerequirement), then deburring needs to be done.
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NEED FOR DEBURRINGOPERATION
Deburring is important for quality, aesthetics,functionality and smooth operation of workingparts. It is also important for safety.
Even a small notch can cause moving parts to
catch, creating the potential for accident, injuryor unnecessary delay in production. Rough edges can also cause injury when
individuals are required to handle blanks. Each of these preventable problems can cost
companies a great deal of money.
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PHASES OF THE PROJECT
MECHANICAL
ELECTRICAL AND ELECTRONICS
PNEUMATICS
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MECHANICALThe mechanical part of our project actually consists of the following
steps. Setting up a suitable guide arrangement for the drill head. Arranging a work piece guiding setup. Fixing the two guide plates with the base.
Aligning the centre point of the tool with that of the work centre. Placing the cylinders to full fill the sequence. Making the guide ways according to the requirement.
OPERATIONS Milling the base plate . Brazing the end effecters of the cylinders. Grinding the extra metal in the end effecters. Drilling the plates for fastening.
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FABRICATION PROCESS The machine is made using a dismantled drill head attachment of a US
machine.
The head is given with an inclination of 35 degree for gravity feed;
The guide ways is bolted to the guide plate. The pneumatic cylinders are alsomounted to the guide plate.
Both the tool head and the guide plate are given some inclination and isattached to the base.
Two single acting and two double acting cylinders are used to fulfill theoperation.
The single acting cylinders are used for the tool feeding and for the stopping
action and is controlled by a 5/2 DCV.
The double acting cylinders are used for separating and clamping action andis controlled by a 3/2 DCV.
Pencil cylinder is used to control the mechanical actuator switch in the toolcylinder.
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ELECTRICAL ANDELECTRONICS
Selecting the appropriate motor for the spindle.
Fixing a DOL starter for the main spindle motor.
Wiring the solenoid coil for actuation
PLC.
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PNEUMATICS
The pneumatic section consists of the following steps.
Selecting the cylinder based upon the maximumpressure.
Selecting the directional control valve based upon
the cylinders used. Placing the FRL unit and silencers.
Fitting the tubes to the entire setup.
Clamping at the areas at which two tubes are
connected.
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PNEUMATICCOMPONENTS
The following are the pneumatic components used to satisfy thesequence.
Pneumatic cylinders 3 nos Clamping cylinder. Separating cylinder. Stopper cylinder.
5/2 directional control valves- 2 nos. 3/2 directional control valves- 2 nos. FRL unit. Air compressor. Silencers. Tubes.
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INSTALLATION OF FRLUNIT
The filter is installed upstream from other conditioning
components. This protects internal moving parts in theregulator from harmful contaminants and avoids foulingthe lubricator reservoir.
Large capacity filters are available to protect a pneumaticnetwork, but it is more common practice to install filter ineach branch. Likewise regulators are installed at eachbranch which requires a specified pressure setting.
Some pressure regulators are designed to be mounted onvalve manifolds.
Lubricators are installed at downstream end of the FRLunit. Just after the regulator and should be placed as closeto the equipment as possible.
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FUNCTIONAL DIAGRAM
CY-4
CY-3
CY-1
CY-2
VALVE-4
VALVE-1
VALVE-3
VALVE-2
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SEQUENCE
CYLINDERS FORWARD STROKE RETURN STROKE
CYLINDER-1 1
3
CYLINDER-2 2
7
CYLINDER-3 4
8
CYLINDER-4 5
6CYLINDER 1 SEPARATOR CYLINDERCYLINDER 2 CLAMPING CYLINDERCYLINDER 3 STOPPER CYLINDERCYLINDER 4 TOOL CYLINDER
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SELFEEDER DEBURRINGUNIT
MODEL SN4U
SPECIFICATIONS
STROKE MAX.: 3.15"
SPINDLE TAPER: JT1
THRUST: 310 LBS.
COLUMN DIAMETER: 2"
MOTOR: HORSEPOWER: 1/2
R.P.M.: 1100
VOLTS: 230/460
AMPS: 1.1/0.55
OVERALL DIMENSIONS: 10" X 5" X 22" TALL
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HYDRO SPEEDREGULATOR
The regulator will control the forward speed of the spindleto any desired rate.
The suitable feed can be set to the work piece. A constant smooth rate of travel is obtained.
The regulator prevents sudden forward surge breakthroughand thus prevents the drill damage. It is a compact and essential unit for precision and
maintenance of accuracy, clean finish and long life. It has also other application as like a shock absorber or a
linear speed regulator.
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PHOTOS AT ZEROTH REVIEW
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PHOTOS FOR THE FIRST
REVIEW
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ENTIRE SET-UP
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GUIDE WAYS FORM10 NUT
CYLINDER
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CYLINDERARRANGEMENT
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CONCLUSION
Thus we have designed the gatewaymechanism and the machine is operatedmanually. The PLC program are yet to be
done to make it perform automatically.
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THINGS TO BE DONE INTHE FUTURE
We are going to make this machinesuitable for components of various sizesby manufacturing a adjustable guide ways
and suitable standards for the tool.This machine is also to be manufactured in
many numbers for the use in productionarea and as a part of its qualityimprovement.
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