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
2. V.VIGNESH
KUMAR
3. P.VIGNESH

4. R.GOWRISHANKAR
5.S.RANJITH

Under guidance of
Mr V.K.RAJENDRAN, M.E.
OCTOBER 2015
DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY).
A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE
CHENNAI 600123

A.M.K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHENNAI- BANGALORE ROAD
SEMBARAMBAKKAM
CHENNAI 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

INTERNAL EXAMINER

PROJECT GUIDE

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 cooperation 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

operation is minimized and simplified.

fatigue

as

handling

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 INSTALLATION
Before 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 oillubricated,
kerosene.

remove

the

coating

with

benzene

or

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 COMPONENTS

When 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

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 BLOCKS

Once 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.
2.
3.
4.

Check appearance the of bearing for any irregularity.

Fouling of grease ,or contaminants in grease.
Loose adapter sleeve.
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 interferencefitted. 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 rustproofed.
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 BEARING

When 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 batterypowered 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)

Dont 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
5. plastic ore -----

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

800.00
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