A PROJECT REPORT

Submitted by BONY JACOB SAM DEEPAK PRADEEP GAUTHAM RAMDAS TARIQ AZEEZ M (0900808041) (0900808046) (0900808052) (0900808188)

Under the guidance of Prof.G.Ravikumar Solomon, M.E, (Ph.D.) in partial fulfillment for the award of the degree of

B.E (Bachelor of Engineering) IN MECHANICAL ENGINEERING

HINDUSTAN UNIVERSITY, CHENNAI - 603 103

MAY 2013

MODIFICATION ON Y-648 BORING MACHINE A PROJECT REPORT

Submitted by

BONY JACOB SAM DEEPAK PRADEEP GAUTHAM RAMDAS TARIQ AZEEZ M

(0900808041) (0900808046) (0900808052) (0900808188)

Under the guidance of Prof.G.Ravikumar Solomon, M.E, (Ph.D.) in partial fulfillment for the award of the degree of

B.E (Bachelor of Engineering) IN MECHANICAL ENGINEERING

HINDUSTAN UNIVERSITY, CHENNAI - 603 103

MAY 2013

HINDUSTAN INSTITUTE OF TECHNOLOGY & SCIENCE

BONAFIDE CERTIFICATE
Certified that this project report MODIFICATION ON Y-648 BORING MACHINE is the bonafide work of

BONY JACOB SAM (0900808041) DEEPAK PRADEEP (0900808046) GAUTHAM RAMDAS (0900808052) TARIQ AZEEZ M (0900808188)
who carried out the project work under my supervision during the academic year 2012-2013

SIGNATURE

SIGNATURE

HEAD OF THE DEPARTMENT

SUPERVISOR

INTERNAL EXAMINER Name: ________________________ Designation:_____________________

EXTERNAL EXAMINER Name: ________________________ Designation:_____________________ Institution Name:___________________

Project Viva - voce conducted on ___________

ACKNOWLEDGEMENT
We thank God; the great engineer, who presented to us, this wonderful opportunity and learning experience. We take this opportunity to express our profound gratitude and deep regards to Dr.T.S.Ravikumar, HOD, Department of Mechanical Engineering and Mr.K.Gnanasekaran, Assistant Professor, Hindustan University for giving us an opportunity to do this project. Our grateful thanks also go to Mr.Sajimon.P.C, Dy.Manager, Production Department, KAMCO for his exemplary guidance, monitoring and constant encouragement throughout the project. We extend our gratitude to Mr. Johnson Kallarackal, Assistant Engineer and Mr.Babulal.N.R, Assistant Engineer, Maintenance Department, KAMCO for their surpassing guidance and energetic cooperation which were instrumental in finishing the work successfully. We are obliged to staff members of KAMCO, for the valuable information provided by them in their respective fields. We are grateful for their cooperation during the period of our project. We thank the people who shared their insightful ideas and graced our project, moulding this idea into a reality. We thank our parents and friends for their efforts and support through the entire duration of the process.

PREFACE
This project aims at the design and development of a modified operation in a Special Purpose Boring Machine to bring about improvements in the quality of work done. As per the curriculum of Hindustan University for B.E. Degree, we, the students were required to do project work. This project on Modified Operations on special Purpose Boring Machine was done at KAMCO (Kerala Agro Machinery Corporation Ltd.). Aim of the project was to modify the boring operation as well as the time required on a Special Boring Machine that was available in the factory. The study was conducted within a period of two weeks from the date of 26 th December 2012. It was a valuable experience for us as we came face to face with the challenges of modifying a special purpose machine as well as in making sure the modifications would vastly improve the machining process happening in the plant. We were required to have firstly, the ability to understand and think of complicated phenomena scientifically and secondly, planning skills and practical skills.

ABSTRACT
The aim of our project is to improve the boring operation on a Special Purpose Boring Machine (Double Ended).This machine is necessary because by means of conventional boring machines, the work will not be economical. It is called a double ended boring machine because it has boring heads on both sides. The normal operation of this machine consists of two steps. In the first step, the rough boring of all work pieces is done. The finishing operation is done in the second step. These operations are controlled by a cam, limit switch, brake motor and other electrical accessories. For the normal operation, the work piece has to be mounted twice on the table because the rough and finish boring operations are done separately. The project explains a method to combine the rough and finish boring operations. This will enable the worker to complete the boring operation in a single step. The disadvantages and difficulties of the normal process can be overcome by this method.

CONTENTS
1. Introduction 2. Company Profile 2.1 Company 2.2 Objectives of company 2.3 Activities of company 2.4 Products 3. Boring 3.1 Machine tools used 3.2 Horizontal boring machine 3.3 Vertical boring machine 4. Machining 4.1 Various machining operations 5. Parts and Working 5.1 Headstock 5.2 Boring bar 5.3 Bed 5.4 Table 5.5 Brake motor 5.6 Electrical distributor cam 6. Double Ended Boring Machine 7. Factors affecting boring operations 8. Working Procedure 9. Operation on SPM Y648 boring machine 10.Operation table 11.Step boring methodology 11.1 Rough boring 11.2 Finish boring 12.Modification on tool spindle 13.Time and Cost Analysis 14.Processes in the assembly section 15.Conclusion 16.References 1 2 2 2 3 4 7 7 10 11 13 20 24 24 24 25 25 26 26 28 30 33 34 37 39 39 40 42 45 52 53 54

LIST OF FIGURES 3.1 Horizontal boring machine 3.2 Vertical boring machine 4.1 Effect of properties of metal being machined 4.2 Nature of wear of cutting tool 4.3 Resistance of cutting tool 5.1 Electrical distributor cam 5.2 General diagram of cam 6.1 Double ended boring 9.1 Layout of main gear case 11.1 Cam for rough boring 11.2 Cam for finish boring 11.3 Cam for combined operation 12.1 Tool for separate operation 12.2 Tool for combined operation 10 12 16 17 18 26 27 28 35 40 41 42 44 44