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Documente Cultură
A PROJECT REPORT
Submitted by
Bhumin A. Patel
(110320119051)
Vishal K. Panchal
(120323119013)
Devarsh K. Patel
(110320119015)
Nishan K. Patel
(110320119016)
December, 2014
Guide
Vimal Salot
Mechanical Department
L.J.I.E.T.
Head of Department
Ms Prexa H Parikh
Mechanical Department
L.J.I.E.T.
Guide
Vimal Salot
Mechanical Department
L.J.I.E.T.
Head of Department
Ms Prexa H Parikh
Mechanical Department
L.J.I.E.T.
Guide
VImal Salot
Mechanical Department
L.J.I.E.T.
Head of Department
Ms Prexa H Parikh
Mechanical Department
L.J.I.E.T.
Guide
Vimal Salot
Mechanical Department
L.J.I.E.T.
Head of Department
Ms Prexa H Parikh
Mechanical Department
L.J.I.E.T.
(110320119051)
2. Vishal K. Patel
(120323119013)
3. Devarsh K. Patel
(110320119015)
4. Nishan K. Patel
(110320119016)
External Examiner(s):1. Name and Sign:2. Name and Sign:3. Name and Sign:-
ACKNOWLEDGEMENT
We would like to express the deepest appreciation to our team Guide, Asst.
Professor Mr.Vimal Salot, who has given us the idea about to make this type of
Project. He continuously conveyed us for further research regarding to this project
and without his guidance we dont know about that type of project which is very
useful in office works, household works, etc.
We would like to thank Mr. Paresh Patni (Production & Design Dept Head),
all the workers & operators of HASMUKH ENGINEERING WORKS(VATVA)
who had shared their technical knowledge, gained after a long experience of
working, with the student like us, for whom this was a totally new experience at
the shop-floor.
We express our deep gratitude to Head of Mechanical Engineering
Department, Ms. Prexa H Parikh, for encouraging us to prepare the project on
INCREASING THE EFFICINCY OF HORIZONTAL HONING MACHINE.
We take this opportunity to express our sincere gratitude to Dr. C. R. Maiti,
Director. L. J. Institute of Engineering and Technology for his valuable guidance,
motivation, co-operation with encouraging attitude at all the stages of this work.
We thank Almighty, our team guide, friends for their constant
encouragement without which this project work would not be possible.
BHUMIN A. PATEL
VISHAL K. PANCHAL
DEVARSH K. PATEL
NISHAN K. PATEL
ABSTRACT
Replacing hydraulic operated honing machine by servo mechanism which
helps in continuously checking the status of process and take action as per the need
automatically.
We will make the movement of hone tools with the use of servo motor.
The entire hone head will slide on the guiding rails through chain drive. The
rotation to the spindle of hone tool is given by motor through gear box.
Servo motor will aid to automatic hone tool movement with the help of
ball screw and nut mechanism. This will reduce human intervention in making
movements of hone tools.
CHAPTER 1:
a musical instrument or hand gun would require more precision during the honing
process and allows no room for errors in specification. Auto parts, such as brake
rotors, require a polished effect along with grooves and notches for the application
of other working parts. While honing metal surfaces of brake rotors, specification
is important but not near as delicate and precise as musical instruments or hand
guns. Precision in these types of examples is paramount.
Most manufacturers that create metal parts use some type of honing
process in the finishing of these parts. Some manufacturers have an in-house
machine shop or a honing machine on their assembly line. Smaller operations with
occasional honing jobs may choose to have this process outsourced to a local
machine shop that can hone their parts to specification. Either way, honing metal
parts will give that finished product the desired outcome to product specification.
Regarding texture, there are various amounts of desired metal textures
from rough to smooth. In some metal parts, a grooved texture may be desired.
Using a specific type of abrasive surface against the metal object or part will give
the desired outcome. When creating notches or grooves, also known as "keys", the
honing process may be used to create this specific shape and to give a smooth or
rough edge, whichever is required by the specification.
Basically, we have all been surrounded by a great many objects that
required the honing process. Hone metal parts are in our automobiles, machinery,
small engines and even delicate gears in musical instruments as well as our modern
weapons such as hand guns. Next time you are looking at a textured or tooled
metal object, just think of the precise work that was involved in "honing" the
grooves, notches, bores and keys to create desired surface textures.
Superior Hone was founded in Elkhart, Indiana in the mid 1940's and was
a large contributor to the war effort with tool room production and precision
honing machines. Superior moved to Erwin, Tennessee and then on to the
Bradenton/Sarasota, Florida area in 1977. Today, with over 50 years of vitrified
and super finish abrasive know how to draw upon, the company can offer expert
product knowledge for all makes and suppliers of honing machines. Superior can
also provide honing machine consulting services for all your honing needs in our
plant or on site.
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Curvature
Conicity
lack of
roundness
Fig- 1.4 Surface uneveness
barrel form
waviness
taper
1.5 LIMITATION
All materials can be honed. However, the material removal rate is affected by the
hardness of the work material, the typical rates are
(i)soft material-1.5 mm/min on diameter
(ii)hard material-0.30 mm/min on diameter
The maximum bore size that can be conveniently honed is about 1500mm while
the minimum size is 1.5 mm in diameter. The honing allowance should be small to
be economical however, the amount also depends upon the previous error to be
corrected. The abrasive and grain size to be selected depend upon the work
material and the resultant finish desired.
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CHAPTER 2:
LITERATURE REVIEW
2.1 PATENTS REFERED
Honing tool
US 4566229 A
ABSTRACT
A tool for honing an axially facing annular surface surrounding an elongated shaft
includes an annulus which is placed around the shaft and supports honing stones
which are engage able with the sealing surface. Rods rigid with the annulus extend
longitudinally from the back of the surface and the outer ends of the rods extend
beyond the end of the shaft and are rigidly connected to a plate. The latter is
adapted to be turned by power about the longitudinal axis of the tool so that the
annulus is rotated about this axis and the honing stones polish the sealing surface.
Radially adjustable fingers project out beyond the periphery of the annulus and
engage a cylindrical wall surrounding the sealing surface to maintain the annulus
centered with the sealing surface.
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16
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Honing machine
US 3849940 A
ABSTRACT
A honing machine having a honing stone movable radially inwardly and outwardly
of a rotary shaft, in which constant pressure advance means and constant speed
advance means are provided for feeding said honing stone radially outwardly of
the rotary shaft and, in the honing operation, both of said means are actuated
concurrently and one of them which is higher in advance rate is automatically
selectively used for advancing the honing stone.
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Honing machine
US 4189871 A
ABSTRACT
A "beam stroker" type of honing machine which can, at the operator's option, be
power stroked by means of a double-acting pneumatic cylinder or manually
stroked. Both travel limits can be varied by the operator. A hydraulic double-acting
cylinder system functions to limit the stroking speed and has a needle valve
adjustment to vary the speed.
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US 4816731 A
ABSTRACT
A honing machine in which a micro-processor controls reciprocation with respect
to a work-piece of a spindle which carries honing stones, the micro-processor
being associated with a memory unit which holds an acceleration profile in terms
of position/time and being programmed to control reciprocation in accordance with
the required acceleration characteristics. Variable stroke parameters and required
mid-stroke speed are input from a console and the system ensures symmetrical
honing under controlled acceleration regardless of any conflict between selected
stroke length and mid-stroke speed.
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24
Honing Machine
Frame
Hone
Job
Hone
assembly
Drive
Clamping
Reciprocating
PLC&
Coolant
Electronics
Assembly
25
1. Frame Assembly
Main Frame: it is the outer case in which all components are placed.
2. Hone Drive
Gear Box: required to transmit Torque and Speed according to user
requirement
Motor: its the part that provide torque and power
Pulley Drive: required to achieve actual reduction
Ac Frequency Drive: required to vary speed and torque by varying
motor input frequency and voltage
3. Hone Reciprocating
Chain Conveyer: Required to provide motion to hone head
Gear Box: required to transmit Torque and Speed according to user
requirement
Drive Assembly: it is the total assembly containing Gear box, Motor,
Chain, sprocket
4. Job Clamping
Frame: it is the outer casing of various clamp drives
V-clamp: it is used to clamp any irregular section job
Chain Clamp: used to clamp the workpiece
5. Coolant Assembly
Coolant Tank: Reservoir having coolant
Pump: Required to pump the coolant to the target
Piping: that connect the coolant reservoir to the target
6. PLC & Electronics
Servo Motor& Drive: It has feed back circuit that helps to track the
position of machine tool etc..
PLC-HMI: it is required to program the whole unit
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3.3 Calculation
1. Calculation For Motor selection
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now we will select the Standard Helical Gear Box from the Catalog which is
having gear ratio near about 12.5
here we can select F720 or F820 Gear box having following specification:
Specification of F720:
Specification of F820 :
Now as per our requirement our output shaft should be having Diameter above
60mm.
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But F720 gear box having output shaft Diameter is 50mm whereas F820 is having
64.5mm.
So we have selected F820 Gear box.
Comparison of Dimension can be made from catalog shown below:
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Less noise
Better power transmission efficiency
Ability to transmit power without slip
Now in our design as shown we are going to arrange that between the motor
output shaft and Gear Box input shaft. Now if we want spindle speed 120 RPM ,
the input speed can be found as following:
Gear box Gear ratio
11.52=
X = 1382RPM = Speed of shaft of gear box
So now motor shaft pulley is our Driving Pulley and input of gear box is our
Driven Pulley.
Now we are using timing belt for drive so we have to calculate pulley teeth.
So designations
Reduction Ratio= i
N1=RPM of Driving pulley=1500
T1=no of teeth on Driving Pulley=50
N2=RPM of Driven Pulley=1382
T2=no of teeth on Driven Pulley
Now equation is as followed:
i=
T2=55
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Load =500kg
Torque=Force*Radius
So we have to find the Diameter of the Chain
Sprocket :
Assume pitch(p)= 1inch
Teeth(Z) =25
Sprocket PCD=d=
=202mm
So Torque=(500*0.202)/2
=50kgcm =500Nm
Linear Velocity= *d*N
In our specification we have mention that linear velocity is 25m/min
25= *0.202*N
N=40 RPM
Now we have to find the Gear Box Reduction ratio, i
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(1.25=FOS)
=4Hp=3KW
so now from catalog we select the Gear Box having reduction ratio M720 which
has i=35.17 and output rpm is 40
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Here our selected gear ratio is near to our requirement so and with help of this
gear ratio we get the linear speed 27RPM so that could be step down to 25RPM
using AC Frequency Drive
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Chapter 4:
IMPLEMENTATION OF PROJECT
1.
Observation
of
existing
horizontal
honing
machine:
First we observed the routine available machine in industry then after we had a
brief knowledge about particular device from our guide.
2. List down the problems regarding to machine: By observing and analyzing
the information about the machine we listed out all the problems. So that after
listing out problems we got some idea how to solve it to make it better.
3. Finding Optimal Solution: After finding the problem in existing machine we
put our mind to solve it by critical thinking and using engineering concept. We also
tried to make it cost effective, size reduction, etc.
4. Calculations: Then we did the calculation of various assembly parts and
different drives required for the operation of the machine.
5. Analysis and Discussion: Then we analyzed and discussed the optimal solution
with our project guide. Various possible outcomes were been discussed
thoroughly.
6. Selection of best solution: After a thorough discussion we came to a best
solution which will really increase the efficiency of honing machine.
7. Preparation of Final Report: On each and every stage of our project we made
some suitable notes which are helpful to make our final project report.
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CHAPTER 5:
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So surface finish at the ends is more than the center portion .So improper finishing
is detected .This is due to variation of force occurring in cylinder as shown in
figure:
CHAPTER 6:
EXPECTED OUTCOME
- Surface finish of very high grade can be obtained at very less time:
In servomechanism forward and reverse stroke are sudden
and there is no time lag between that strokes so that proper finishing is
achieved.
- Maintenance cost is reduced:
There is no requirement of oil in servomechanism so system
remains less clumsy.
- Tool life increases:
Back pressure is reduced due to servomechanism so wear
and tear is reduced and tool life increase.
- Decrease overall machining time:
Servomechanism is faster than hydraulics. There is no time
lag between two stroke. Starting and completion of time is less
- Safety of workers is assured.
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CHAPTER 7:
CONCLUSION
We finally conclude that our effort of implementing this new technology will help
to increase the productivity as well as the high grade surface polishing.
Also it will reduce human intervention due to the automatic operation of
servomotor operated by PLC.
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CHAPTER 8:
REFERENCES
8.1 FIGURE REFERENCES
8.2 SITE REFERENCES
8.1 FIGURE REFERENCE
1.2.1
Honing mechanism
www.encyclopedia.com
1.4
Surface uneveness
www.googlepatent.com
Assembly Design
AutoCad
3.3.1
www.pbl.co.in
3.3.5
3.4
Honing Procedure
www.encyclopedia.com
Actual Machine
Industry
5.1
Bursted Pipeline
www.encyclopedia.com
5.2
Rough Finishing
www.encyclopedia.com
5.3
Oil Leakage
www.encyclopedia.com
45