FABRICATION OF PVC BALL MAKING MACHINE

Submitted in the partial fulfillment of the requirement for the award

“DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY)”

SUBMITTED BY:

1. S.SATHISH KUMAR 4. R.GOWRISHANKAR 2. V.VIGNESH 5.S.RANJITH KUMAR3. P.VIGNESH

Under guidance of

Mr V.K.RAJENDRAN, M.E.

OCTOBER 2015

DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY).

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGECHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGECHENNAI- BANGALORE ROAD

SEMBARAMBAKKAMCHENNAI 600123

BONAFIDE CERTIFICATE

This is to certify that this Project work on

“FABRICATION OF PVC BALL MAKING MACHNE ”

submitted by …………………… ……………. Reg. No. ……………

in partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING (FOUNDRY)

This is the bonafide record of work carried out by him under our supervision

during the year 2015

Submitted for the Viva-voce exam held on ……………..

H.O.D PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. R.J.KUMAR,M.E.F.I.E, M.I.S.T.E for encouragement and

valuable advice.

We thank our Esquired Head of Department Mr. S.N. SUNDAR, M..E.

for presenting his filiations on us.

We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E.

For guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the Mechanical

Department and Foundry Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.

CONTENTS

CONTENTS

CHAPTER NO. TITLE

1. INTRODUCTION

2. SYNOPSIS

3. SCOPE AND IMPORTANCE OF PROJECT WORK

4. OBJECTIVES

5. SELECTION OF PROJECT

6. CONSTRUCTION

7. WORKING PRINCIPLE

8. MAIN PARTS AND DESCRIPTION

9. DESCRIPTION OF THE COMPONENT

10. ADVANTAGES

11. PRINCIPLE OF DC MOTOR

12. TYPES OF DC MOTOR

13. FINISHING AND PAINTING

14. CONCLUSION

15. COST ESTIMATION

16. BIBLOGRAPHY

17. PHOTO VIEW

INTRODUCTION

INTRODUCTION

This project concentrates on providing descriptions of all the basic

operating principles and design of Plastic components.

In our technical education the project work plays a major role. Every

student is put in to simulate life particularly where the student required

bringing his knowledge, skill and experience of the project work.

It helps how to evolve specifications under given constrains by

systematic approach to the problem a construct a work device. Project work

thus integrates various skills and knowledge attainment during study and

gives orientation towards application.

As the students solve the various problems exposed by the project

work, the students get the confidence to overcome such problems in the

future life. It helps in expanding the thinking and alternatives for future

applications.

SYNOPSIS

SYNOPSIS

This project work “FABRICATION OF PVC BALL-MAKING

MACHINE” semi automatic is designed considering the need for

developing economic way of producing PVC balls with high production rate

and good surface finish.

The PVC balls are manufacturing by process of rotation moulding.

The die is rotated in horizontally by means of motor arrangements. The

development of our project work is a way to produce 15 balls per hour and

also is designed of the machine permits to ball produce different sizes of

dies.

The main advantage of our project work is less skilled labour is

sufficient and simple in design, cost is less. Our project work is productive

can be operated with comfort and require only less space. Our project work

can also be used in the development of entrepreneurship.

SCOPE AND IMPORTANCE OF PROJECT WORK

SCOPE AND IMPORTANCE OF PROJECT WORK

Enables to show the intrinsic knowledge of the individual.

Enables to develop the ability of the designing and developing factors and its applications.

Enables to induce the collection of technical data and other related standard data from the work.

Enables to apply the techniques of method study and time study.

Enables to have a complete knowledge of the particular work which they have designed and fabricated.

OBJECTIVES

OBJECTIVES

The following are the main objectives of our project

To provide higher accuracy and good surface finish ball

To manufacture various size of ball

Unskilled Labour is sufficient

To improve productivity

To improve entrepreneurial skills

SELECTION OF PROJECT

SELECTION OF PROJECT

Modern industries and business establishment has become very

complex and competitive in making up of machines based on their own

knowledge and skill.

We preferred to make the semi-automatic P.V.C. ball making

machine, which is simple in construction and design. It can be used in small

scale industries. For playing use, most items like small size balls and large

size balls are used for advertising purpose.

Most of them prefer for balls of less cost and more life. The P.V.C.

ball is made up of chemicals, which is harmless to people who makes them

and also who uses them.

CONSTRUCTION

CONSTRUCTION

This project consists of

1) M.S.Fabricated stand

2) D.C. Motor (24VDC)

3) BALL Die set

4) Plummer block bearings

5) 24VDC POWER SUPPLY

1)M.S.Fabricated stand;

The semiautomatic PVC ball- making machine consists of a M.S. Fabricated

stand of size 200 x 600 x 750 mm ( breath x length x height ) . This base

stand is made in 25 mm x 25 mm ´L “ angle of M.S. Material. A 24VDC

Shunt type DC electric motor is fixed on the novopan board which is

screwed on the top surface of the stand. The main shaft is fixed to the base

column by means of a sleeve bearing which allows the shaft to rotate freely.

The main shaft is connected to the die.

The power from the motor is transmitted to the shaft by means of the

coupling mechanism.

The mixing of chemical proportion are filled to the die which is

mounted on the main shaft. The blower is introduced over the die and a

timer is set to calculate the heating time required for the melting the ore.

2)D.C. Motor (24VDC);

This DC motor is shunt type 24V DC motor. It has high torque and low

speed capacity. A Separate electrical DC power supply is provided to the

24VDC motor.

MAIN SHAFT ;

The shaft must have sufficient thickness to avoid bending, due to

heavy load and vibrations. They supported over the base by means of the

sleeve. The coupler is fixed to the main shaft that transmits the power to the

shaft from the motor.

DIE

Die is made up of M.S. Plate which has less weight and good surface

finish in sphere with 30 mm inner diameter. Die sizes varies according to

sizes of the ball required. Die should withstand high temperature that is

required top melt the PVC powder inside the die. It is fixed to the main

shaft by means of fasteners.

BLOWER

Blower is an heating equipment used to heat the die to the required

temperature for the purpose of melting the PVC powder normally mostly gas

blowers are used for heating.

CHEMICAL

A proportionate mixture of PVC powder and COLOUR is used for

preparation of the ball.

PLUMMER BLOCK BEARINGS

WORKING PRINCIPLE

WORKING PRINCIPLE

The machine is seated without any vibration.

The chemical mixture proportion is taken in a required quantity

and it is filled into die.

The die is placed in the fixture, which is fixed to the fixture shaft

and tightened properly.

The blower is placed in position where the heating flames fall right

into the center of the die.

The machine is switched on.

The base shaft with the die arrangements rotates.

The timer is set from the start to end of the time required.

The time required for heating up of the die is 1 minute and 30

seconds.

The hot die plunged into the water for cooling.

The die is opened and the ball is removed.

The ball is compressed with air to the required size using syringe

arrangement

The placed is heated with a pin and closed where the air is inserted

into ball.

Thus using semi-automatic ball machine we can make ball of any

size.

MAIN PARTS AND

DESCRIPTION

MAIN PARTS AND DESCRIPTION

1. BASE STAND

2. ELECTRIC MOTOR

3. PLUMMER BLOCK BEARINGS

4. MAIN SHAFT

5. DIE

7. BLOWER

8. 24VDC POWER SUPPLY

9. CHEMICAL

DESCRIPTION OF THE

COMPONENT

DESCRIPTION OF THE COMPONENT

BASE STAND;

Base is the foundation of the machine, which withstands the vibration

of the machine and transmits it to the ground. It holds the machine parts. An

electric motor is fixed on the base.

ELECTRIC MOTOR

24V DC Motor

This DC motor is shunt type 24V DC motor. It has high torque and low

speed capacity. A Separate electrical DC power supply is provided to the

24VDC motor.

MAIN SHAFT

The shaft must have sufficient thickness to avoid bending, due to

heavy load and vibrations. They supported over the base by means of the

sleeve. The coupler is fixed to the main shaft that transmits the power to the

shaft from the motor.

DIE

Die is made up of M.S. Plate which has less weight and good surface

finish in sphere with 30 mm inner diameter. Die sizes varies according to

sizes of the ball required. Die should withstand high temperature that is

required top melt the PVC powder inside the die. It is fixed to the main

shaft by means of fasteners.

BLOWER

Blower is an heating equipment used to heat the die to the required

temperature for the purpose of melting the PVC powder normally mostly gas

blowers are used for heating.

CHEMICAL

A proportionate mixture of PVC powder and COLOUR is used for

preparation of the ball.

24VDC ELECTRICAL POWER SUPPLY ;

A 12 –0- 12 V AC step down transformer is used to step down 230V

AC to 24V AC .This 24V AC supply is converted to 24V DC using four

rectifier diodes .This voltage is used for supply for the stepper motor. From

12V DC .The power supply circuit is shown in fig.

ADVANTAGES

ADVANTAGES

Low investment

Production time is less

Unskilled labour can operate the machine

Low die cost

Maintenance cost is low

Number of part is less

Less floor space

Greater safety to the worker

Life span of the machine is high

To reduce the operator fatigue as handling

operation is minimized and simplified.

DETAILS OF

PLUMMER BLOCK

BEARING

PLUMMER BLOCK BEARING;

HANDLING THE PLUMMER BLOCK AND BEARING

Rolling bearings are precision components. To maintain accuracies, they must be handled very carefully. In particular, they must be kept clean, not be subjected to long impact, and be protected against possible rusting. Plummer blocks also need similar handling practices.

I. INSPECTION BEFORE INSTALLATIONBefore installation a bearing and a plummer block, the

blowing point must be thoroughly checked and inspected.

INSPECTION BEFORE INSTALLATION

Prepare installation tools, measured instruments, oil stone, lubricant and factory cloth. Before the installation work, remove dust and impurities from these tools

Make sure that the shaft is free from bends or other damages and that it has been dimensioned and formed as specified.

Remove dent marks even through very small from the mating faces with an oil stone or fine emery paper. Check that the contact face to the seal has specified surface roughness. Wipe dust away from the shaft with clean factory cloth.

Remove possible dust and metal chips from the inside of plumber block.

Check the flatness of the mounting face of the plummer block. When placed on a frame, the plummer block must be stably seated.

II. PREPARATION FOR INSTALLINT THE BEARING Unpack the bearing just before the installation work.

If the bearing is to be grease-lubricated, the rust-proof coating on it may remain unremoved. If it is to be oil-lubricated, remove the coating with benzene or kerosene.

Preparation for Installing the Bearing

For a bearing with an adapter, check its radial clearance before the installation work. To do so, place it on a flat work bench, and fit a thickness gage between the uppermost roller and the raceway surface on the outer ring to measure the clearance . Do not force the thickness gage in or turn the bearing. Otherwise, the resultant clearance measurement will be greater than the actual clearance.

III. INSTALLATION OF THE BEARING AND ASSOCIATED COMPONENTS

Once careful checking is complete, install the bearing and associated components. For the positional relationship.

INSTALLATION OF THE BEARING AND ASSOCIATED COMPONENTSWhen a bearing is installed onto a shaft or into a

housing. Do not directly hit its end face with a hammer. Otherwise, its design performance can be lost. Always evenly exert force around the entire bearing ring face. Also, do not apply force to one bearing ring.

o EXAMPLE; Outer ring

To convey the force via the rolling elements to the other bearing ring inner ring to install the latter. Otherwise, a dent mark or other damage can occur on either or both rings.

When installing a cylindrical bore bearing, whose interference is relatively small, its whole inner rings can be uniformly press-fitted at an ordinary temperature as illustrated .Usually, the inner ring is press-fitted by tapping the sleeve with a hammer. However, when many

bearings must be installed at a time, a mechanical or hydraulic press will be helpful.

When installing a non-separable bearing to the shaft and housing at a time, apply a press-fitting force to both the inner and outer rings by using a pressure distribution pad.

IV.ASSEMBLING THE PLUMMER BLOCKS

When installing two or more plummer blocks on a shaft, use one block to locate the outer ring of a bearing in the axial direction, and arrange the other block (s) so that the outer ring (s) of bearing (s) in the latter block (s) can more freely in the axial direction.

ASSEMBLING THE PLUMMER BLOCKSOnce the bearing has been installed to the shaft and

the associated components have been inserted over the shaft, assemble the plummer blocks according to the following procedure.

\

V. MAINTENANCE AND INSPECTION

To be able to use a bearing to its design life and avoid by accident, check the following points at regular servals.1. Running sound on bearing. 2. Temperature on bearing or plummer block.3. Vibration on shaft.4. Leaking grease or worn oil seal.5. Loose tightening and mounting bolts.6. Trouble- free operation of the lubrication system, and

loosening or leakage with piping. The bearing arrangement must be inspected while it is a

standstill, check it for the following points:

1. Check appearance the of bearing for any irregularity.2. Fouling of grease ,or contaminants in grease.3. Loose adapter sleeve.4. Worn or damage seal.

VI.BEARING DISASSEMBLY

Straighten the bent tab on the washer, and loosen the nut by two or three turns. Place a drift to a face of the nut. Sightly tap the drift to turn the sleeve. Once be sleeve is shifted in the axial can be direction, the bearing easily removed.

Note,however,when the nut as been excessively loosened and only a few ridges remain engaged,and if the nut is further tapped,the threading on the sleeve or nut may be stripped.

VII.CYLINDRICAL BORE BEARING

Usually, a cylindrical bore bearing is interference-fitted. Thus, the bearing is simply drawn out by placing a jig to yhr face of the inner ring and exerting a forces illustied with a hand press. However,be careful not to apply a force to the outer ring. When using this tool, make sure that the jig is fully engaged with the face of the inner ring.

VIII.CLEANING THE BEARING

Clean the removed bearing with diesel oil or kerosene. USE TWO VESSELS.

One for rough cleaning and the other for finish cleaning. Prepare a cleaning station that has a metal screen as illustrated. So that the bearing does not directly contact the fouling on the bottom of vessel. In rough cleaning, virtually all oil and foreign matters should be removed from the bearing which should be immediately transferred to the finish vessel. The finish vessel must be provide with a filter unit to maintain the cleaning agent clean.

Once cleaned, the bearing must be immediately rust-proofed.

The bearings (which have been carefully removed) must be checked whether they can be reused. The judging criterion for reuse should be determined considering the following criteria through a trial-and-error basis.

1. Scheduled operating duration to next regular inspection.

2. Importance of the machine that uses the bearing in question

3. Operating conditions such as loading and bearing speed.

4. Severity of damage on the rolling contact surface.5. Tendency of increasing bearing clearance and wear on

the cage.6. Loss in accuracy, etc.,

IX. STORING THE BEARINGWhen storing a bearing, pay particular attention to rust

prevention. Note that the rust-proofing grease in the bearing will run away at a temperature of 50 to 60 C. Therefore, store a bearing in a dry, cool location at a height at least 30cm above the floor. Remember that wooden crate attracts moisture. Thus, immediately unpack the delivered bearings, and store them on shelves.

PRINCIPLE OF DC MOTOR

PRINCIPLE OF DC MOTOR

A DC motor is a dc machine working as a motor to convert dc

electrical energy into mechanical energy ( DC ) motor are very commonly

used in cars, trucks, aircrafts, etc. They are also used in large ratings, where

wide range of speed control is necessary.

When a conductor is carried a current and in lying in magnetic filed.

Force acting on the conductor. This is the principle of a Dc motor. The

conductor is housed in armature slots and current is applied from the DC

source through brushes and commutator. The field poles provide the

magnetic field.

The construction of dc motor and generator are similar. However

their external appearance may be somewhat different. A motor has a rather

closed frame because it is may be operating in dusty environment and

unskilled workers may be working in its vicinity.

TYPES OF DC MOTOR

TYPES OF DC MOTOR

DC Shunt Motor:

This motor has medium starting torque, a speed regulation of 5 – 10 %

and excellent adaptability to adjustable speed service. It can be used for

constant speed drives like pumps, fans blowers, etc,. However for all these

applications, a 3 phase induction motor is preferable, because it ;is cheaper,

more rugged and requires lesser maintenance than dc motor. However a dc

shunt motor is cheaper for low speed drives. Moreover, whenever a wide

range of speed control is required, dc shunt motor is used. The main

application of dc shunt motor is in steel and aluminium, rolling mills and

ward – Leonard speed control system.

Dc Series Motor:

This motor has a very high starting torque. Moreover it speed

decreases with increase in load torque. So that its power input remains more

or less constant. It is best suited for hoist cranes and traction. Speed control

is generally obtained through armature control. They are used for battery-

powered vehicles.

Compound Motor:

A differential compound is rarely used. The characteristics of a

cumulative compounds motor depend on the relative strength of series and

shunt fields. It has good starting torque and dropping speed – load

characteristic. They can be used for pulsating loads needing flywheel action,

viz. shears, conveyors, crushers, hoists, plunger pumps, etc., Whenever the

supply voltage is likely to vary considerably, a compound motor is preferred.

Because its induction and contribution to back emf, the series field helps in

reducing the fluctuations of current drawn from mains.

FINISHING AND PAINTING

FINISHING AND PAINTING

JOB PREPARATION;

Before welding, remove any bend in the L angle with the sludge

hammer on the anvil block. Then it is cut to the required length

with the hacksaw blade and fabricated to required dimensional

shape with arc welding.

FINISHING OPERATION BEFORE PAINTING;

After welding, any slag on the welded area is removed with the

chipping hammer and cleaned with the metal wire brush. Then all

the surfaces are rubbed with the emery sheet.

Metal primer is applied on the surfaces with the brush .After

drying the metal primer, the second coating is applied with the

paint.

FEATURES OF THIS PROJECT

It is compact in size

It can be move

Low electrical power consumption

It can be utilized at our work shop

It is simple in construction

Low cost

Less weight and easy to handle

It reduces the man power

It is simple in operation..

SAFETY,CARE AND MAINTENANCE

Before starting the machine, some of the points to be noted for safety purpose,

1. Before starting the operation, check the following items

(1) Check the mechanism for proper operation .

(2) Check the alignment of DIE SET in the machine

(3) Don’t insert the any material or object between the during

operation of machine

(4) Check the bearing alignment and fitment of die set in the

machine

(5) Wear gloves and shoe for proper handling .

CONCLUSION

CONCLUSION

With the amount of materials we wish to conclude our project report of

semi automatic PVC Ball making machine. The design of our project is

simple and cost is low and well sufficient for manufacturing PVC balls.

All details necessary for the project are mentioned in the project report.

The machine can be used for long duration of the period if proper

maintenance is carried out.

We hope that our effort in the fabrication of the project and in

preparation of the project will be appreciated.

We once again convey our sincere thanks to every one who helped in

bringing out this project work a successful one.

COST ESTIMATION

COST ESTIMATION

1. D C MOTOR with built in gear box 2200.00

2. Sleeve bearing and its support 2 Nos 1600.00

3. Die set 800.00

4. M.S .Stand ------------------------ 800.00

5. plastic ore ----- 200.00

----------------- 6000.00

---------------------

BIBLIOGRAPHY

BIBLIOGRAPHY

Machine Design by

R.S. Khurmi

J.K. Gupta

Production Technology by

R.K. Jain

Tool Design and Engineering by

Cyrll Donaldson

P. Rajagopal

Estimating & Costing by

Banga & Sharma

PHOTO VIEW