SYNOPSIS

The Fabrication of Dual purpose machine is a new innovative concept is

mainly used to save more power. In this concept we have designed a Grinding and
drilling in the one machine. Here we are using the low electric power energy for
Materials Grinding with drilling process.

This project is very useful in the industrial companies. In industrial companies

there is need to cut and drill the metals and woods to different shape. By using man
power it takes many times, and also accuracy may be low. By using this project
cutting operation is preformatted automatically. So it saves the time as well as
reduces the man power. The accuracy also achieved in this project.

1
 Chapter 1
INTRODUCTION

Industries are basically meant for Production of useful goods and services at
low production cost, machinery cost and low inventory cost. Today in this world
every task have been made quicker and fast due to technology advancement but
this advancement also demands huge investments and expenditure, every
industry desires to make high productivity rate maintaining the quality and
standard of the product at low average cost. In an industry a considerable portion
of investment is being made for machinery installation. So in this paper we have
a proposed a machine which can perform operations like drilling, sawing,
shaping, some lathe operations at different working centers simultaneously
which implies that industrial is thavenotto pay for machine performing above
tasks individually for operating operation simultaneously.

Economics of manufacturing: According to some economists, manufacturing

is a wealth-producing sector of an economy, where as a service sector tends to
be wealth-consuming. Emerging technologies have provided some new growth
in advanced manufacturing employment opportunities in the Manufacturing
Belt in the United States. Manufacturing provides important material support for
national infrastructure and for national defense.

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1.1 Literature Review

Before starting our work we have undergone through many research papers
which indicates that for a production based industries machine installation is a tricky
task as many factor being associated with it such as power consumption (electricity
bill per machine), maintenance cost, no of units produced per machine i.e. capacity
of machine, time consumption and many more….Some research papers which have
led us to approach to the idea of a machine which may give solution to all these factors
are as follows:

Heinrich Arnold 1 November 2001:

Rather long re-investment cycles of about 15years have created the notion
that innovation in the machine tool industry happens incrementally. But looking
at its recent history, the integration of digital controls technology and computers
into machine tools have hit the industry in three waves of technology shocks. Most
companies underestimated the impact of this new technology. This article gives an
overview of the history of the machine tool industry since numerical controls were
invented and introduced and analyzes the disruptive character of this new technology
on the market.About100 interviews were conducted with decision-makers and
industry experts who witnessed the development of the industry over the last forty
years. The study establishes a connection between radical technological change,
industry structure, and competitive environment. It reveals a number of important
occurrences and interrelations that have so far gone unnoticed.

3
Dr. Toshi michi Mori waki(2006):

Recent trends in the machine tool technologies are surveyed from the viewpoints of
high speed and high performance machine tools, combined multifunctional
machine tools, ultra precision machine tools and advanced and intelligent control
technologies.

Frankfurt-am Main, 10 January 2011 :

The crisis is over, but selling machinery remains a tough business. Machine tools
nowadays have to be veritable “jack of all trades”, able to handle all kinds of
materials, to manage without any process materials as far as possible, and be capable
of adapting tone job profiles with maximized flexibility. Two highly respected
experts on machining and forming from Dortmund and Chemnitz report on what’s
in store for machine tool manufacturers and users.

Multi-purposemachinesarethedeclarationsofindependence.Thetrendtowardsthekind
of multi-purpose machining centers that are able to cost efficiently handle abroad
portfolioofproductswithsmallbatchsizesacceleratedsignificantlyduringthecrisis.
“With a multi-purpose machine, you’re less dependent on particular products and
sectors”, explains Biermann.

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1.2 Proposed Methodology

In this project we will generally give the power supply to the shaft on which a bevel
gear is mounted on it, and a second bevel gear at a right angle to it has been mounted
on a drill shaft to which a drill b it is being attached. At one end of the shaft is
connected to power supply, other end is being joined to a circular disc, through this
circular disc scotch yoke mechanism is being performed (rotatory motion Is
converted to reciprocating motion) . Also in between these two helical gear is
mounted which transfer its motion to other Helical gear which is mounted on a shaft
consist of grinding wheel.

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 Chapter 2

PROBLEM DEFINITION
2.1 Problem Statement

To design and development of MULTIPURPOSE MECHANICAL MACHINE, a

structured which is designed for the purpose of MULTI-OPERATIONS i.e.
DRILLING, CUTTING&SHAPING.

2.2 Problem Identification

This machine perform multipurpose operation at same time with required speed
&this machine is automatic which is controlled or operated by motor which is run
with the help of current. This machine is based on the mechanism of whit worth
return.

This model of the MULTIOPERATIONAL machine is maybe used in industries

and domestic OPERATION which can perform mechanical operation like
drilling, cutting &shaping of at hin metallic as well as wooden model or body.

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 Chapter 3

MECHANISM OFMACHINE
WHITWORTH’SQUICKRETURNMECHANISM

3.1 OBJECTIVE

The objective of this experiment is to investigate the performance of a whit

worth quick return motion and to verify that the motion does have a quick return
stroke and as low cutting or forward stroke.

3.2 THEORY

Definition of mechanism
Mechanism is a simplified model, usually in the form of a line diagram, which
is used to reproduce exactly the motion occurring in a machine. The purpose if this
reproduction is to enable the nature of the motion to be investigated without the
encumbrance of the various solid bodies which forms the machine elements.

3.3 WHIT WORTH QUICK RETURN MECHANISM

Fig : WHITWORTH MECHANISM

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The above diagrams how’s the mechanism as used on the apparatus. Link1 on the
top diagram is extended to point A. Attach to point A is another link with pivot. The
other end of this link terminated in a slider. In a machine tool where this mechanism
is used the cutting tool is attached to this slider.

The link POA rotates about a O. The mechanism is driven by crank PC which rotates
about C with constant velocity. The slider at P slides along POA as the crank is
turned. Its path is shown by the dashed circle, centered on C and through P. Clearly
when P is at P1 the slider S is at the outer extremely of its travel. When P is at P2
the slider S is at the inner extremely of its travel.

Now as P C rotates with constant velocity the time taken to go from P1 to P2 is less
than that taken to go from P2 to P1. However during both those time intervals the
slider as moving the same distance. Therefore the speed of S is different during the
different parts of cycle. During the shorter time intervals P1 to P2 the slider as has
the greater speed and during the interval P2 to P1it has slower speed. Thus P1 to P2
is quick return and P2 to P1.

When applied to metal cutting machine the other advantage is variable power
distribution during the cycle. When S is on the return stroke the slider at P is nearer
O and simple moment shows that the torque applied is low. Hence, the return stroke
uses less power as P=T.W. During the cutting stroke the slider at P is at greater
radius from O and thus more power is available toper form useful work in the cutting
metal.

Thus the overall performance is to provide high power forward cutting stroke
with a low power and higher speed quick return in preparation for the Next
cut.

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 Chapter 4

DESIGN OF MODEL

3D VIEW

9
ACTUALVIEW

10
 Chapter 5

MACHINE EQUIPMENTS

5.1 Component of machine

1)FRAME
2)BEVEL GEAR
3)WHITWORTH MECHANISM
4)MOTOR
5)PULLEY
6)BEARING (BALL&SLIDINGBEARING)
7)ROCKER ARM
8)HACKSAW BLADE
9)TOOL POST
10)DRILLING CHUCK
11)DRILL TOOL
12)SINGLE CUTTING TOOL
13)TABLE
14)NUT&BOLT
15)OTHER COMPONENTS

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The following components are the major components of the multi process machine:

5.2 Drilling
A drill is a tool fitted with a cutting tool attachment, usually a drill bit used for
drilling holes in various materials or fastening various materials together with the
use of fasteners. The attachment is gripped by a chuck a tone end of the drill and
rotated while Pressed against the target material. The tip of the cutting tool does the
work of cutting in to the target material. Drills are commonly used in wood working,
metal working and construction. Specially designed drills are also used in medicine,
space mission sand other applications. Drills are available with a wide variety of
performance characteristics, such as power and capacity.

Principle:

When a three-phase supply is connected across the stator windings, a rotating

magnetic field, constant in magnitude but rotating at synchronous speed, Ns, is
produced. The speed of the rotating field so produced depends upon the supply
frequency and the number of poles for which the winding is made. The direction of
the rotating magnetic field produced by the stator depends upon the supply phase
sequence. This field induces an electromotive force (emf) in the rotor conductors
which in turn produces the current flow. Thus magnetizing the rotor. Due to the
tendency of the rotor magnetic field to be aligned with the stator field, the rotor
develops the torque in the same direction and it starts rotating. The speed of the
rotor however is less than synchronous speed Ns (the speed of rotating magnetic
field developed by the stator). If the rotor runs exactly at the synchronous speed

12
induced emf in the rotor will be zero. Hence there will be no rotor current and rotor
torque.

The synchronous speed is a function of the no of poles of the motor and supply
frequency. This is given by:

Ns = 120 * frequency (f) / number of poles (P)

Hence the speed of an AC motor is a function of frequency and the number of motor
poles. The speed of the rotor relative to that of the stator-rotating field is called as
"SLIP". This slip is the difference between the synchronous speed, Ns and actual
speed N and is denoted by S. This is generally expressed as a fraction of the
synchronous speed. Thus slip is S = (Ns-N) / Ns where N- is actual rotor speed, Ns
- Synchronous speed The primary function of the motor is to provide torque, which
makes the shaft / loads to rotate at the required speed.

1) The "torque" of an induction motor depends upon the flux in the air gap.
2) Further, flux is directly proportional to V / f.... where V is supply voltage and
f is the supply frequency. It can therefore be said that, the torque T is directly
proportional to flux & flux is directly proportional to V / f.
3) Thus the torque producing capability of the motor at the rated / required
speeds can be retained constant, by maintaining the voltage v/s frequency ratio
constant.

Conclusively one can say that to vary the speed of an induction motor the frequency
of the supply going to the motor should be varied. In order to maintain the torque
producing capability the voltage applied to the motor needs to changed in the same
proportion as that of frequency.

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2.3 .Chuck&Spindle:

Drill chuck
A drill chuck is a specialized three-jaw chuck used to hold drill bits or related tools.
The image at right shows an assembled keyless chuck at the top. The tightening
action of this chuck style is performed by twisting the body using firm hand pressure
only.

The lower images show the traditional keyed style of drill chuck with its key. The
arbor is shown separately to the right. These chucks require a key to provide the
necessary torque to tighten and loosen the jaws. The rotary action of the key turns
the outer body which acts on an internal screw; this in turn moves the threaded jaws
in or out along a tapered surface. The taper allows the jaws to encompass various
sizes of drill shanks. The end view shows the three small jaws that slide within the
body.
Some high precision chucks use ball thrust bearings to reduce friction in the closing
mechanism and maximizing drilling torque. These chucks are sometimes referred to
as “super chucks”.

2.4. DRILL BIT MATERIAL

Characteristic: The characteristics of the ideal material are:

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1. Hot hardness. The material must remain harder than the work material at
elevated operating temperatures.

2. Wear resistance. The material must withstand excessive wear even though the
relative hardness of the tool-work materials changes.

3. Toughness. The term ‘toughness’ actually implies a combination of strength and

ductility. The material must have sufficient toughness to withstand shocks and
vibrations and to prevent breakage.

4. Cost and easiness in fabrication. The cost and easiness of fabrication should have
within reasonable limit. Drill bit:

Fig 2. Drill bits

Drill bits are cutting tools used to create cylindrical holes. Bits are held in a
tool called a drill, which rotates them and provides axial force to create the hole.
Specialized bits are also available for non-cylindrical-shaped holes.

The term drill can refer to a drilling machine, or can refer to a drill bit for use
in a drilling machine. In this article, for clarity, drill bit or bit is used throughout to

15
refer to a bit for use in a drilling machine, and drill refers always to a drilling
machine.

3.6 .SCREW ROD

There are various methods for generating screw threads. The method chosen for any
one application is chosen based on constraints—time; money; degree of precision
needed (or not needed); what equipment is already available; what equipment
purchases could be justified based on resulting unit price of the threaded part (which
depends on how many parts are planned); etc.

In general, certain thread-generating processes tend to fall along certain portions of

the spectrum from tool room-made parts to mass-produced parts, although there can
be considerable overlap. For example, thread lapping following thread grinding
would fall only on the extreme tool room end of the spectrum, while thread rolling
is a large and diverse area of practice that is used for everything from micro lathe
lead screws (somewhat pricey and very precise) to the cheapest deck screws (very
affordable and with precision to spare).

Threads of metal fasteners are usually created on a thread rolling machine. They
may also be cut with a lathe, tap or die. Rolled threads are stronger than cut
threads, with increases of 10% to 20% in tensile strength and possibly more in
fatigue resistance and wear resistance.

5.3 Shaping
Shaper operates by moving a hardened cutting tool backwards and forwards
across the work piece. On there turn stroke of the ram the tool is lifted clear of the
work piece, reducing the cutting action tone direction only. The work piece
mounts on a rigid, box shaped table in front of the machine. The height of the table

16
can be adjusted to suit this work piece, and the table can transverse side ways
underneath the reciprocating tool which is mounted on the ram, the table motion is
usually under the control of an automatic feed mechanism which acts on the feed
screw. The ram slides back and forth above the work, at the frontend of the ram is a
vertical tool slide that may be adjusted to either side of the vertical plane. This tool
slide holds the clapper box and tool post from where the tool can be positioned to
cut the straight, flat surface on the top of the work piece. The tool slide permits
feeding the tool downwards to put on acute or may be set away from the vertical
plane, as required. The ram is adjustable for stroke and due to the geometry of the
link age, it moves faster on there turn stroke than on the forward, cutting stroke.
This action is via as lotted link or whit worth link.

5.4 Cam arrangement

A cam is a rotating or sliding piece in a mechanical linkage used especially in
transforming rotary motion in to linear motion or vice-versa. It is often apart of a
rotating wheel (e.g. an eccentric wheel) or shaft (e.g. a cylinder with an irregular
shape) that strike salver a tone or more points on its circular path. The cam can be a
simple tooth, as is used to deliver pulses of power to a steam hammer, for example,
or an eccentric disc or other shape that produces a smooth reciprocating(back and
forth) motion in the follower, which is a lever making contact with the cam. The
cam can be seen as a device that rotates from circular to reciprocating (or sometimes
oscillating) motion. A common example is the cam shaft of an automobile, which
takes the rotary motion of the engine and translates it into the reciprocating motion
necessary to operate the intake and exhaust valves of the cylinders. Cams can also
be viewed as information-storing and transmitting devices. Examples are the cam-
drums that direct the notes of a musical box or the movements of a screw machine's
various tools and chucks. The information stored and transmitted by the cam.

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5.5 Bevel gear
A bevel gear is a type of mechanical gear. These gears where the axes of the two
shafts intersect and the tooth bearing faces of the gears themselves are conically
shaped. Bevel gears are most often mounted on shafts that are 90 degrees apart, but
can be designed to work at other angles as well. The pitch surface of bevel gears is a
cone.

5.6 Hydraulic bottle jack

Bottle jacks are hydraulic jacks that are placed in a horizontal position. These
jacks push against a lever, which lifts the main lift arm. Bottle jacks have a longer
handle than most hydraulic jacks, however, and it is possible to get more lift per
stroke with the increased leverage they provide when compared to regular models
of jacks. Bottle jacks are versatile because their horizontal position makes it possible
to place them in tight spots and provides good leverage. Recently bottle jacks have
proven useful in search and rescue missions following earthquake damage. As a
result, bottle jacks are standard equipment in fire houses and for search and rescue
teams. They are also used for lifting, spreading, bending, pushing, pressing, or
straightening requirements. The base and cylinders of bottle jacks are electrically
welded for strength, and all models are capable of working in upright, angled, or
horizontal positions.

5.7 Vice
It is a device consisting of two parallel jaws for holding a work piece; one of the
jaws is fixed and the other movable by a screw, a lever, or a cam. When used for
holding a work piece during hand operations, such as filing, hammering, or sawing,
the vise maybe permanently bolted to a bench. In vises designed to hold metallic
18
work pieces, the active faces of the jaws are hardened steel plates, often removable,
with serrations that grip the work piece; to prevent damage to soft parts, the
permanent jaws can be covered with temporary jaws made from sheet copper or
leather. Pipe vises have double V-shaped jaws that grip in four places instead of only
two. Wood working vises have smooth jaws, often of wood, and rely on friction alone
rather than on serrations.

For holding work pieces on the tables of machine tools, vises with smooth hardened-
steel jaws and flat bases are used. These machine vises are portable but may be
clamped to the machine table when in use; means may also be provided for swiveling
the active part of the vises that the work piece can be held in a variety of positions
relative to the base. For holding parts that cannot be clamped with flat jaws, special
jaws can be provided.

5.8 Bearing
A bearing is a device to permit constrained relative motion between two parts,
typically rotation or linear movement. Bearings may be classified broadly according
to the motions they allow and according to their principle of operation. Low friction
bearings are often important for efficiency, to reduce wear and to facilitate high
speeds. Essentially, a bearing can reduce friction by virtue of its shape, by its
material, or by introducing and containing a fluid between surfaces. By shape, gains
advantage usually by using spheres or rollers. By material, exploits the nature of the
bearing material used. Sliding bearings, usually called bushes bushings journal
bearings sleeve bearings rifle bearings or plain bearings. rolling-element bearings
such as ball bearings and roller bearings. Jewel bearings, in which the load is carried
by rolling the axle slightly off-center.

19
 Fluid bearings, in which the load is carried by a gas or liquid magnetic bearings,
in which the load is carried by a magnetic field. Flexure bearings, in which the
motion is supported by a load element which bends. Bearings vary greatly over the
forces and speeds that they can support. Forces can be radial, axial(thrust
bearings)or moments perpendicular to the main axis. Bearings very typically involve
some degree of relative movement between surfaces, and different types have limits
as to the maximum relative surface speeds they can handle, and this can be specified
as a speed in ft/sorm/s. The moving parts there is considerable over lap between
capabilities, but plain bearings can generally handle the lowest speeds while rolling
element bearings are faster, hydrostatic bearings faster still, followed by gas bearings
and finally magnetic bearings which have no known upper speed limit.

5.9 Drillingtool
Drilling tool is a cylindrical end-cutting tool used to originate or enlarge
circular holes in solid material. Usually, drills are rotated by a drilling machine and
fed into stationary work, but on other types of machines a stationary drill may be
fed into rotating work or drill and work may rotate in opposite directions. To form
the two cutting edges and to permit head mission of a coolant and the ejection of
chips, two longitudinal or helical grooves or flutes are provided. The point or tip, of
a drill is usually conical in shape, and it has cutting edges where the flutes end. The
angle formed by the tapering sides of the point determines how large a chip is taken
off with each rotation of the drill. The degree of twist of the helical flutes also affects
the drill’s cutting and chip-removal properties. For general purpose twist drills the
helix angle is about 32°. The angle formed by the two sides of the tapering point is
118° for standard drills, while for drilling tough metals, a flatter point with a 135°
angle is recommended.

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The peripheral portion of the drill body not cut away by the flutes is called the land,
and to reduce friction and prevent the land from rubbing against the sides of the hole,
most of the land is cut away, leaving an arrow ridge called the margin that follows
the edge of the side of the flute that forms the cutting edge. The fluted part, or body,
of a drill is either hardened high-carbon steel or high-speed steel; other drills have
inserts of cemented carbide to form cutting edges or are made from sintered-carbide
rods. The shanks of twist drills are either straight or tapered and when not integral
with the body are made from low-carbon steel and welded to the body. When a three-
phase supply is connected across the stator windings, a rotating magnetic field,
constant in magnitude but rotating at synchronous speed, Ns, is produced. The speed
of the rotating field so produced depends upon the supply frequency and the number
of poles for which the winding is made. The direction of the rotating magnetic field
produced by the stator depends upon the supply phase sequence. This field induces
an electromotive force (emf) in the rotor conductors which in turn produces the
current flow. Thus magnetizing the rotor. Due to the tendency of the rotor magnetic
field to be aligned with the stator field, the rotor develops the torque in the same
direction and it starts rotating. The speed of the rotor however is less than
synchronous speed Ns (the speed of rotating magnetic field developed by the stator).
If the rotor runs exactly at the synchronous speed induced emf in the rotor will be
zero. Hence there will be no rotor current and rotor torque.

The synchronous speed is a function of the no of poles of the motor and supply
frequency. This is given by:

Ns = 120 * frequency (f) / number of poles (P)

Hence the speed of an AC motor is a function of frequency and the number of motor
poles. The speed of the rotor relative to that of the stator-rotating field is called as

21
"SLIP". This slip is the difference between the synchronous speed, Ns and actual
speed N and is denoted by S. This is generally expressed as a fraction of the
synchronous speed. Thus slip is S = (Ns-N) / Ns where N- is actual rotor speed, Ns
- Synchronous speed The primary function of the motor is to provide torque, which
makes the shaft / loads to rotate at the required speed.

1) The "torque" of an induction motor depends upon the flux in the air gap.
2) Further, flux is directly proportional to V / f.... where V is supply voltage and
f is the supply frequency. It can therefore be said that, the torque T is directly
proportional to flux & flux is directly proportional to V / f.
3) Thus the torque producing capability of the motor at the rated / required
speeds can be retained constant, by maintaining the voltage v/s frequency ratio
constant.

Conclusively one can say that to vary the speed of an induction motor the frequency
of the supply going to the motor should be varied. In order to maintain the torque
producing capability the voltage applied to the motor needs to changed in the same
proportion as that of frequency.

22
Drill bit

23
Machine drawing

24
 Chapter 6
WORKINGPRINCIPLE

Here the bevel gear arrangement is used for carrying out the operations. Bevel gear
is used to perpendicular(90) power transmission. One of the bevel gear is connected
with the motor and another one with the drill chuck hence when the motor is rotated
the drill chuck also rotates. The motor pulley shaft is connected to a cam
arrangement on the other side. Cam arrangement converts rotary motion into
reciprocating motion and the reciprocating motion is used for the slotting and shaping
operation.

The slotting toll and shaping tool are guided by a horizontal guide bush. The up
down table is mounted on a hydraulic bottle jack piston rod hence when the bottle
jack handle is pumped the table height can be adjusted according to the requirement
when the after the process is completed the pressure should be released through
pressure relief valve to make the table comedown. A vice is mounted on the table to
hold the work piece.

List of materials factors determining the choice of materials:

The various factors which determine the choice of material are discussed
below.

6.1 Properties

The material selected must possess the necessary properties for the proposed
application. The various requirements to be satisfied that Can be weight, surface

25
finish, rigidity, ability to with stand environmental attack from chemicals, service life,
reliability etc.

The following four types of principle properties of materials decisively affect their
selection:

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal Conductivity,
specific heat, coefficient of thermal expansion, specific gravity, electrical
conductivity, magnetic purposes etc. The various Mechanical properties Concerned
are strength in tensile, Compressive hear, bending, torsional and buckling load,
fatigue resistance, impact resistance, elastic limit, endurance limit, and modulus of
elasticity, hardness, wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

a. Cast ability

b. Weld ability

c. Forge ability

d. Surface properties

e. Shrinkage

f. Deep drawing etc.

26
6.2 Manufacturing case

Sometimes the demand for lowest possible manufacturing cost or surface

qualities obtain able by the application of suitable coating substances may demand
the use of special materials.

6.3 Quality Required

This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by welding or hand
forging the steel.

6.4 Availability of Material

Some materials may be scarce or in short supply it then becomes obligatory for
the designer to use some other material which though may not be a perfect substitute
for the material designed. The delivery of materials and the delivery date of product
should also be kept in mind.

6.5 Space consideration

Sometimes high strength materials have to be selected because the forces involve
dare high and space limitations are there.

27
6.6 Cost

A sin any other problem, in selection of material the cost of material plays an
important part and should not being no red. Sometimes factors likes capitalization,
appearance and non-maintenance of the designed part are involved in the selection of
proper materials.

6.7 Merits

a. Easy to operate.

b. Reduces time and increases production rate.

c. Low maintenance.

d. Easy to implement

6.8 Applications

a. Used in small scale industries to reduce machine cost.

b. In such places where frequent change in operation are required.

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6.9Advantages

 Multi machine are performed at one time.

 Our machine is used Return stroke(whit worth)mechanism.
 There turn stroke of shaper machine is utilized as cutting operation.
 All operation is performed by only one motor.
 Size is compact there fore it requires less space.
 Time saving.
 Less man power is required.
 Low manufacturing & maintenance cost.

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 Chapter 7

OPERATION OF MACHINE

Operations perform by machine:

1. DRILLING

2. SHAPING

3. CUTTING

7.1 DRILLING

Drilling is the operation of producing circular hole in the work-piece by using a

rotating cutter called DRILL.

 The machine used for drilling is called drilling machine.

 The drilling operation can also be accomplished in lathe, in which the drillis
held in tail stock and the work is held by the chuck.
 The most common drill used is twist drill.

Drilling Machine

 It is the simplest and accurate machine used in production shop.

 The work piece is held stationary i.e. champed in position and the drill
rotates to make a hole.

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Components of Drilling Machine:

1. Spindle
The spindle holds the drill or cutting tools and revolves in a fixed position in
a sleeve.

2. Sleeve
The sleeve or quill assembly does not revolve but may slide in its bearing in
a direction parallel to its axis. When the sleeve carrying the spindle with a cutting
tool is lowered, the cutting tool is fed in to the work and when its moved upward,
the cutting tool is with drawn from the work. Feed pressure applied to the sleeve by
hand or power causes the revolving drill to cut its way in to the work a fraction of an
mm per revolution.

3. Column
The column is cylindrical in shape and built rugged and solid. The column
supports the head and the sleeve or quill assembly.

4. Head
The head of the drilling machine is composed of the sleeve, a spindle, an
electric motor and feed mechanism. The head is bolted to the column.

5. Work table
The work table is supported on an arm mounted to the column. The work
table can be adjusted vertically to accommodate different heights of work or it can

31
be swung completely out of the way. It may be tilted up to 90degreein either
direction, to allow long pieces to be end or angle drilled.

6. Base

The base of the drilling machine supports the entire machined when bolted to
the floor, provides for vibration-free operation and best machining accuracy. The top
of the base is similar to the work table and may be equipped with-slot for mounting
work too large for the table.

7. Hand feed
The hand feed drilling machine are the simple stand most common type of
drilling machine in use today. These are light duty machine that are operated by the
operator, using a feed handled, so that the operator is able to “feel” the action of the
cutting tool as it cuts through the work piece. These drilling machines can be bench
or floor mounted.

8. Power feed

The power feed drilling machine are usually larger and heavier than the hand
feed ones they are equipped with the ability to feed the cutting tool in to the work
automatically duty work or the work that uses large drills that require power feed
larger work pieces are usually clamped directly to the table or base using t-bolts and
clamps by a small work places are held in a vice. A depth- stop mechanism is located
on the head, near the spindle, to aid in drilling to precise depth.

32
 Drilling machine

Specification:-

Drill size in mm Feed in mm/rev.

3.2 & less 0.025-0.050
3.2 to 6.4 0.050-0.10
6.4 to 12.7 0.10-0.18
12.7 to 25.4 0.18-0.38
25.4 &large 0.38-0.64

7.2 SHAPING

The shaping machine is used to machine flat metal surfaces especially where a large
a mount of metal has to be removed. Other machines such as milling machines are
much more expensive and more suited to removing smaller amounts of metal, very
accurately.

 The reciprocating motion of the mechanism inside the shaping machine can
be seen in the diagram. As the disc rotates the top of the machine moves
forwards and backwards, pushing a cutting tool. The cutting tool removes the
metal from work which is carefully bolted down.

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  The shaping machine is a simple and yet extremely effective machine. It is used
to remove material, usually metals such as steel or aluminum, to produce a flat
surface. However, it can also be used to manufacture gears such as rack and
pinion systems and other complex shapes. Inside its shell/casing is a crank and
slider mechanism that pushes the cutting tool forward and returns it to its original
position. This motion is continuous.

Shaping machine

7.3 CUTTING
A hacksaw is a fine tooth saw with a blade held under tension in a frame,
used for cutting materials such as metal or plastics, hand held hacksaws consist of a
metal arch with a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. A screw or other mechanism is used to put the thin blade under
tension. The blade can be mounted with a teeth facing toward or away from the
handle, resulting in cutting action one it her the push or pull stroke. On the push
stroke, the arch will flex slightly, decreasing the tension on the blade.

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 Blades are available in standardized lengths, usually 10 or 12 inches for a
standard hand hacksaw. “junior” hacksaws are half the size. Powered hacksaw may
use large blade in a range of sizes, or small machines may use the same hand blades.

Cutting machine

Specification of hacksaw
Size of hacksaw blade:-

Thickness = 1.27-

2.54mm Width= 25.40-

50.80mm Length=

304.80-609.60mm

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 Chapter 7

7.MATERIALS USED
Work piece material Cutting speed in m/s
Mild steel 0.75
Cast iron 0.50
Brass/aluminum 1.5
Bronze 1.25
Thin section(pipes & tubes) 1.5

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 LINE DIAGRAM

FABRICATION OF DUAL MACHINE USING BEVEL GEAR

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 COST ESTIMATION

S.NO COMPONENT QUANTITY MATERIAL COST(RS)

USED
1 MOTOR AC 1 M.S 2800
2 FRAME 1 - 750
3 DRILLING 1 - 450
MECHANISM
4 BEVEL GEAR 2 M.S 1450

TOTAL 5450

Total material cost =5450

Assembly cost =150
Total cost of the project=5600

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 MERITS AND DEMERITS

Merits:
It reduces the manual work
It reduces the production time
Uniform application of the load gives perfect fitting of the bearing.
Damages to the bearing due to the hammering is prevented
It occupies less floor space
Less skilled operator is sufficient

Demerits:
Initial cost is high
Cylinder stroke length is constant
Need a separate compressor

APPLICATIONS

Bending machine is used to forming operation is well suited for drop forging work
in foundry area. It is also used to shape the desired formation in structural work.

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 Chapter 8

FUTURE IMPLIMENTATION

 We can perform various operations like cutting, drilling or shaping

individually by introducing coupling (engagement & disengagement) between
them.
 We can perform grinding operation by introducing a grinding tool at them a
in shaft.
 We can perform boring operation by introducing a boring tool by
replacing drilling tool.
 We can change the speed of motor by regulator.

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 Chapter 9

CONCLUSION

 After completing the major project on “DESIGN AND FABRICATION OF

DUAL MACHINE USING BEVEL GEAR”. we are much happy and
would like to thank our teacher guides and the lectures of the concerned
department who have guided us.

 While making this project we have been also to learn a lot and understand the
various aspects of “DESIGN AND FABRICATION OF DUAL
MACHINE USING BEVEL GEAR” we can use our knowledge, which we
get during our study.

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 Chapter 10
REFERENCE

The websites:-
 www.technogystudent.com

 www.terry-eng27.blogspot.in

 www.wikipedia.org

 www.ask.refrence.com

 www.dictionary.refrence.com

 www.community.machinedesign.com

 www.google.com

 www.sciencedirect.com

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