TA 201

INTRODUCTION TO MANUFACTURING
PROCESSES

ROTATING BRIDGE
PROJECT REPORT

GROUP 13
SECTION C10
Instructor: Dr. Anish Upadhyaya
Lab incharge : Mr. Anil Kumar Verma
Tutor: Mr. Rupesh Chafle
 GROUP MEMBERS

1. Abhinav Sharma- 14015

2. Kranti Prakash Yeole- 14324

3. Sahil Singh- 14581

4. Shivam Yadav- 14655

5. Shubham Swastik `Behera- 14685

6. Talla Aravind Reddy- 14746

ACKNOWLEDGEMENT

In this project we have got an opportunity to show our creativity. While

doing the project we faced a lot of difficulties. Even before starting the
project we didn’t even think of doing something like this. We were inspired
by our instructor Prof. Anish Upadhyaya , who actually gave us a chance in
the course TA201 to express ourselves .
We are thankful to tutor- Mr. Rupesh Chafle , teaching assistants- P Divya
Janani and Sayli S Jambhulkar , lab incharge- Mr. Anil Kumar Verma, and
lab assistants- Mr. G P Bajpai, Mr. Indra Pal Singh, Mr.Rakesh Kumar
Rajput, Mr. Gaurav Mishra, Mr. Sheelendra Kumar Agnihotri, and Mr.
Bharat Raj Singh who helped us to direct our project in a proper way with
nice mechanisms. Then came the final task of doing the projects, we are very
thankful to all the TAs, Lab Assistants, Helpers, who really helped us in
manufacturing our project.
We are making this project not only for marks but also to increase our
knowledge and experiencing the process to design and implement our ideas
on our own.
Thanks again to all who helped us.

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 PREFACE

It took us four weeks to design the project but during that period we needed
the background, study and experience of a whole lifetime.
We are the second year students of BSBE and CSE departments in IITK. We
always wanted to make our own metallurgical project and this opportunity
was provided to us by the college under the course TA201A which is
currently being taught by Prof. Anish Upadhyaya.
We have given every part’s detail and did our best to fulfil the purpose of
the design so that it can be manufactured in an organised and efficient
manner.

MOTIVATION

After going through lot of ideas, which included ideas on brake dance ride,
opera house, elliptical machine, moving trolley, etc. we settled for the
rotating bridge. It was said that there are credits to innovative ideas, so we
decided to do something new than those which have been done in the last
few years. We consulted with the tutors and came to know that it was not
done before (specially the gear system we have used to rotate the bridge) but
tutors said that the feasibility of the gear system which we decided to make
by casting is not good. Gears formed by casting might not be able to rotate
the bridge. We took it as a challenge and formed the good quality gears in
the first attempt.

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 APPLICATION

In its closed position, a rotating bridge carrying a road or railway over a

river or canal, for example, allows traffic to cross. When a water vessel
needs to pass the bridge, rod traffic is stopped, and then motors rotate the
bridge horizontally about its pivot point. The typical swing(rotating) bridge
will rotate approximately 90 degrees, one quarter turn, or may be built to
rotate only 45 degrees, in order to clear the channel.

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 The Rotating Bridge Section

Design

The Rotating Bridge Section is one of the most vital parts of the entire project.
It contains the roadway that is connected to a rotating pillar mechanism which makes it rotate when
required. The structure has triangular railing structure on its edges.
The structure serves by not only taking the weight of cars passing over it but it has also been made
of optimum width to allow ships of full size to pass under it when rotated

Part List with Materials

A. Roadway

Dimension: 30 cm X 10 cm X 2 mm
Material: Mild Steel Sheet 2 mm
Quantity: 1

B. Cylindrical Railings (short)

Dimension: 6 cm
Material: Mild Steel Rod Round 4 mm dia
Quantity: 28

C. Cylindrical Railings (long)

Dimension: 27 cm
Material: Mild Steel Rod Round 4 mm dia
Quantity: 2
 Manufacturing

Mild Steel Sheet

is cut into required
Dimensions

Mild Steel Rod round

is cut into 28
(5 cm) pieces and 2
(25 cm) pieces

The rods are joined

by brazing and finally
welded to the steel
plate

The edges of the

steel plate are laser-
cut to give a round
shape and then made
smooth by grinding
 Rotating Pillar Section

Design

This structure consists of a dome shaped gear to which a hollow pillar is connected. At the top of
the pillar a cuboid is attached. The pillar and the gear have a common hole through which a rod
passes about which the entire structure shall rotate. The rod is connected to a cuboidal base on
which the entire structure rests.
 Part List with Materials

A. Gear

Dimension: Hemispherical (5 cm dia)

Material: Cast Iron
Quantity: 1

B. Hollow cuboidal pillar

Dimension: length 7 cm
Material: Mild Steel Square Pipe (15 mm X 15 mm)
Quantity: 1

C.Base

Dimension:10 cm X 10 cm X 2 cm
Material: Mild Steel sheet (1.5 mm)
Quantity: 1

D. Cuboidal Bridge Base

Dimension: 12 cm X 4 cmX 2 cm
Material: Cast Iron
Quantity: 1
 Manufacturing

The gear is cast into the

required shape using
proper dimensions and a
hole of 15 mm did is
drilled into it

Mild steel sheet is cut

into pieces of
required dimensions
and welded together
to make the base

The bridge base is

cast according the
dimensions and
welded to the top end
of the hollow pillar

A steel rod of length

12 cm is welded to
the base wile the
hollow pillar is welded
to the top of the gear
 Gears

Design

Two gears of different shapes have been designed for the entire gear mechanism.
The larger one is a hemispherical dome shaped that has been built via casting.
The bottom part is smooth and round while the top section contains all the gear grooves.
The second gear is a simple star shaped that has a shaft connected to it that facilitates in rotating
the mechanism.
 Part List with Materials

A. Main Gear

Dimension: Hemispherical of dis 5 cm (8 grooves)

Material: Cast Iron
Quantity: 1

B. Secondary Gear

Dimension: Circular of dia 4 cm (8 grooves)

Material: Cast Iron
Quantity: 1

C. Shaft

Dimension: 15 cm
Material: Mild Steel Rod Round 12 mm
Quantity: 1

Manufacturing

Both the gears are

carved into shape on A hole of 15mmm dia
thermocol and then is drilled into the the
cast into shape using main gear across its
cast iron entire height.

The two structures

are then welded to
the main base of the
project

The shaft is prepared Once out of the cast,

according to thee the gear and its
dimensions and grooves are polished
\ and smoothened.
attached to the
second gear
 Road extension and Project Base

Design

The road extension consists of the fixed part of the road that does not rotate with the bridge. It is
fixed to the base using 2 pillars on both sides. The project base is the main base on which the
entire project rest, in real life it represents the ground on which the bridge stands.

Right Section
Left Section

Parts with Materials List

A. Left & Right Extension

Dimension: 10 cm X 10 cm
Material: Mild Steel Sheet (2 mm)
Quantity: 2

B. Extension Pillar

Dimension: 9.5 cm X 16.5 cm

Material: Mild Steel Sheet (2 mm)
Quantity: 4 (2 drilled)

C. Main Base

Dimension: 60 cmX 60 cm
Material: Mild Steel Sheet (2 mm)
Quantity: 1
 Manufacturing

Sheet metal is cut

into proper
dimensions

The road extensions

are cut according to
the radius of the
rotating bridge
section

2 extension pillars are

drilled at a height of
10 cm from the base

The main base is cut

according to the
specified dimensions.

The extension Pillars

are finally welded to
the extension roads.
 Peripherals

Ship

A ship was created that has a height greater than the bridge itself to provide a demonstration of the
working of the entire project.
The ship is made using GI sheet and GI rod. It consists of a mast, hull and railings.

Dimensions:

length: 21cm
breadth: 7 cm
height: 25 cm (including mast)
railing height: 2 cm
 Full Body Analysis

Complete Assembly Design

The whole project consists of 4 parts. The gear mechanism, Rotating Pillar, Rotating Bridge section
and the Main base are finally welded together. The entire project is brushed and polished using
sand papers and then oiled to prevent further oxidation. The structure is weighed and then
analyses for any deformation etc.
 Weight Analysis:

Density of Mild Steel = 7.5 gm/cm3

Density of Galvanised Iron = 7.85 gm/cm3
Density of Cast Iron = 7.6 gm/cm3

Cast Iron:

1.5 Kg for Gears

0.8 Kg for Support

Mild Steel:

Sheet of 2mm Thickness Volume = 0.2 cm x 3055 sq.cm = 611 cm3

Rod of 4mm Thickness Volume = 3.14 x 0.4 cm x 0.4 x 222cm = 111.5 cm3

Rod of 12mm Thickness Volume = 3.14 x 1.2 x 1.2 x 28 cm3 =127 cm3

Total Volume of Mild Steel Used = 850 cm3

Weight of Mild Steel = Volume x Density = 850 x 7.5 = 6375gm = 6.4 Kg

Galvanised Iron:

Volume of 0.35mm Sheet used = 0.035 x 184 = 6.5 cm3

Volume of 0.5mm Sheet used = 636 x 0.05 = 31.8 cm3

Total Volume of Galvanised Iron Used = 38 cm3

Weight of Galvanised Iron Used = 38 x 7.85 gm = 300 gm = 0.3 Kg

Total Weight of Project = 2.3 Kg + 6.4Kg + 0.3Kg

= 9 Kg(Approximately)
 Cost Analysis:
Material Cost:

Cast Iron:

Weight = 2.3Kg, Price = 55/Kg

Cost of Cast Iron Used = Rs. 130

Mild Steel Sheet 2mm:

Bridge and Connecting Road: 50cm x 10cm = 500 sq.cm

Base of Project: 60cm x 30cm = 1800 sq.cm
Pillars: 4 x 9.5cm x 16.5cm = 627 sq.cm
Base Box : 128 sq.cm
Total: 3055 sq.cm
Price = Rs.107 per sq.ft
Total Cost of Mild Steel Sheet used = Rs. 350

Mild Steel Round Rod of 4mm diameter:

Total Length = 222 cm

Price = Rs.9 per ft
Total Cost of Mild Steel Round Rod of 4mm diameter = Rs.66

Mild Steel Round Rod of 12mm diameter:

Total Length = 28cm

Price = Rs.38 per ft
Total Cost of Mild Steel Round Rod of 12mm diameter = Rs. 35

Galvanised Iron Sheet:

Area of 0.35mm Sheet Used = 184 sq.cm

Price = Rs.20 per sq.ft
Cost of 0.35mm Sheet = Rs.4

Area of 0.5mm Sheet Used = 636 sq.cm

Price = Rs. 25 per sq.ft
Cost of 0.5mm Sheet Used = Rs.18
 Labour Cost

Unskilled Labour Cost = Rs.45 per hour

Unskilled Labour Hours = 6 x 6 x 3hours = 100 hours (including absent hours)
Total Cost of Unskilled Labour = Rs. 4500

Skilled Labour Cost = Rs. 60 per hour

Skilled Labour Hours = 6 x= 66 hours
hours = 36 hours
Total Cost of Skilled Labour = Rs.360
2160

Total Cost of Project = Rs.7,200

5,400 ( approximately)
 What we have learnt from the project -

Team work:

“Teamwork is the ability to work together toward a common vision. The

ability to direct individual accomplishments toward organizational
objectives. It is the fuel that allows common people to attain uncommon
results. “
We learned what team work is. How a piece of work is distributed among
team members, how the work becomes easy when each member works
efficiently to complete the job given. It generated a mutual understanding
among us. We come to know how different sets of ideas and different
approaches can be used to complete the task.

Planning:
We planned every aspect of our project beforehand. The day before the lab
turn was devoted to planning of what all had to be done in the upcoming lab.
We used to chart out a rough algorithm before making a part on any
machine. We divided our work for 7 labs and properly planned out the
complete project.

Time management:
The most useful aspect which made this project possible was dividing the
work among team members. It reduced our time over any job. All team
members reached lab at proper time, we learned punctuality, we learned how
so ever big the task is we can do it by branching it between the team
members and have that work done.

Dealing with last moment problems:

We learned how to work under critical conditions when there is a lot of
stress on our mind without losing our temperament. It gave us an overall
confidence of doing any sort of work in limited time.

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Dealing with real life situation:
We also learned how to give a shape to our ideas and how to implement
what we have in our minds.

The subject:
Needless to mention, the project has helped us in getting a better grasp over
the subject. Practicals are always useful, but when we do a project and
devote ourselves completely to it, we get a deeper knowledge and
understanding.

CONCLUSION

It was a nice experience to work with the most cooperative members of the
TA LAB (ME+MME). We realised that even small toys, small gadgets do
require a lot of mechanical knowledge, work, and precision.
We enjoyed the projects a lot and we would like to do such projects in our
academic curriculum.

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