Paper cutting & rewinding machine project report SREESANGH P GHOSH

1. 1. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13

ACKNOWLEDGEMENT I am very glad to represent project report on "PAPER CUTTING
ANDREWINDING MACHINE" fully designed, fabricated and tested in our polytechnicas part
of our curriculum is awarding the Diploma in Engineering. I have tried mylevel best to focus
upon each and every parameter. In concern with this topic thedetail, necessary figure,
definition, tabular analysis has been enumerated in veryeasy, simple, compact and lucid
manner. I have been able to achieve this task by the dynamic guidance ofhonorable
SIVARAMAN sir; I have no wards to express my gratitudetowards his kind, persistent
inspiration, parent advice and outstanding treatmentwhile clarifying my confusion. I also
extend my sincere thanks to our esteemed Head of MechanicalEngineering Department Mr.
M.R JAYACHANDRAN, whose guidance andconstant inspiration where a great use in
working of this project. We are alsograteful to our tutor MR. P.P. DEVADAS. I am also grateful
to our honorable work shop superintendentMr.N.M.SATHEESAN and members of staff of our
workshop for providingnumerous facilities and guidance due to which this difficult task turned
in aconvenient task. The permission granted to us by the honorable
principalMr.V.V.SADASIVAN, to do the project work in greatly acknowledged. Last but not
least, I am very thankful to my project partners without whosekind cooperation it was difficult
and impossible to go through the leaps andbounds while preparing this project. Also thanks
to them who directly or indirectlyco-operated and contributed during work. Page 1Department
of Mechanical Engg. S.R.G.P.T.C Triprayar
2. 2. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 ABSTRACT Paper
Cutting & Rewinding Machine is one of the simplest machine which cutsrolled paper in
needed amount and re-winded form. The conventional paper rewindingmachine has complex
mechanism and bulk size. We made some modification to theconventional machine and
eliminating its defects. The main peculiarity of machine is itssimplicity, reduced size, weight.
And also reduces floor space. This project can bedirectly implemented to paper cutting and
rewinding machines in Paper mills. Thismachine can also use in textile mills, plastic and
rubber sheets cutting and rewindingprocess in various industries by changing its cutting
components. By applying these modifications to the conventional machine
reducemaintenance and servicing cost, floor area and overhead expenditures. It is well
suitedfor small scale industries. Page 2Department of Mechanical Engg. S.R.G.P.T.C
Triprayar
3. 3. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 CONTENTSTOPIC
NO. TOPIC NAME PAGE-NO. 1. COMPONENTS OF MACHINE 4 2. MANUFACTURING
PROCESS 8 3. STRUCTURE FABRICATION PROCESS 8 4. ROLLER MACHING
PROCESS 10 5. CUTTER CLAMP MAKING PROCESS 12 6. DRIVING MECHANISM 13 7.
WORKING OF MACHINE 14 8. ADVANTAGES 15 9. SPECIFICATIONS OF MACHINE 15
10. MATERIAL REQUIREMENT & COST 16 11. BIBLIOGRAPHY 17 Page 3Department of
Mechanical Engg. S.R.G.P.T.C Triprayar
4. 4. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 COMPONENTS
OF PAPER CUTTING & REWINDING MACHINE The main components of Paper Cutting &
Rewinding Machine are listed below. 1) BASIC FRAME The entire unit is mounted on a rigid
frame. The frame is made of mild steel C- Channels (75X40 mm) connected in rectangular
form and weld at their joints. 2) ROLLERS The paper rotating element in this device is the
89 mm outer diameter rollers with 40 mm outer diameter journals, which made up of three
components. 1) G. I Hollow Pipe of 89 mm outer Diameter. 2) M.S Rod of 40 mm
Diameter. 3) M.S Circular Plate of 81 mm Diameter. The rotation of motor is transferred to
the one of the four rollers on which cut paper is mounting in operation. The rotating roll
makes all other three rollers to rotate. The roller is supported at its two ends by Plummer
block with ball bearing blocks. The main functions of roller are to favor the cutting operation
by moving paper and rewind it to rolls. Page 4Department of Mechanical Engg. S.R.G.P.T.C
Triprayar
5. 5. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 4) PLUMMER
BLOCK The roller is supported at the two ends with the help of Plummer block fitted with
40 mm diameter Ball bearings. The bearings are cleaned and greased for easy rotation of
roller. 5) BEARINGS Ball bearing is a type of rolling-element bearing that uses balls to
maintain the separation between the bearing races. The purpose of a ball bearing is to
reduce rotational friction and support radial and axial loads. It achieves this by using at least
two races to contain the balls and transmit the loads through the balls. In most applications,
one race is stationary in Plummer block and the other is attached to rollers journal. As one of
the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling
they have a much lower coefficient of friction than if two flat surfaces were sliding against
each other. Ball bearings tend to have lower load capacity for their size than other kinds of
rolling-element bearings due to the smaller contact area between the balls and races.
However, they can tolerate some misalignment of the inner and outer races. Page
5Department of Mechanical Engg. S.R.G.P.T.C Triprayar
6. 6. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 6) INDUCTION
MOTOR An induction or asynchronous motor is an AC motor in which all electromagnetic
energy is transferred by inductive coupling from a primary winding to a secondary winding,
the two windings being separated by an air gap. The machine is powered by 1 Hp motor with
1440 rpm. This makes one roll rotates and rotating roll makes other rollers to rotate and not
only wound the paper but also pull the paper to make the operation going. 7) SINGLE V-
BELT AND PULLEY SYSTEM Vee belts (also known as V-belt or wedge rope) solved the
slippage and alignment problem. It is now the basic belt for power transmission. They
provide the best combination of traction, speed of movement, load of the bearings, and long
service life. They are generally endless, and their general cross-section shape is trapezoidal
(hence the name "V"). The "V" shape of the belt tracks in a mating groove in the pulley (or
sheave), with the result that the belt cannot slip off. The belt also tends to wedge into the
groove as the load increases-the greater the load, the greater the wedging action, V-belts
may be homogeneously rubber or polymer. Belts are looped over pulleys. The belt drives the
pulleys in the same direction. As a source of motion, the belt is one application where the
 belt is adapted to continuously carry a load between the motor and pulley fitted on the roller.
Page 6Department of Mechanical Engg. S.R.G.P.T.C Triprayar
7. 7. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 8) CUTTER CLAMP
(C-CLAMP) WITH BOLTS c-clamp with the two bolts are used to clamp the cutter to the
frame and one extended piece of flat for mounting of cutter. 9) NUT AND BOLTS Bolt, is a
type of fastener characterized by a helical ridge, known as an external thread or just thread,
wrapped around a cylinder. A nut is a type of fastener with a threaded hole. Nuts are almost
always used opposite a mating bolt to fasten a stack of parts together. They are made up of
Mild Steel. Nuts and Bolts of different size is used for fixing the Plummer block to the main
frame and to install the cutter clamp. Page 7Department of Mechanical Engg. S.R.G.P.T.C
Triprayar
8. 8. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 MANUFACTURING
PROCESS I. STRUCTURE FABRICATING PROCESS :- For structure fabrication, the c-
channel of size 75 X 40 mm is used. Theapproximate wt. of it per meter is 6.8 kg. Steps in
fabrication of structure are givenbelow. Step One: First cut the c-channel in pieces of
length 71" (i.e. 6 feet [180 mm]- two pieces)and in 36" (i.e. 3 feet[91.5 mm] - three pieces).
Then Put the two lengths of 6 feetparallel to each other at a distance of 3 feet from each
other. Then put the lengths of 3feet on either end of two parallel lengths and weld them as
shown below. The twodiagonals must be same. Step Two: Then cut four pieces of c-
channel of length 24" (i.e. 2 feet[61 mm]) and weldtwo of them on one end of rectangular
structure vertically using engineers block. Thenweld remaining two pieces vertically at a
distance of 30" from previous pieces. Step Three: Then brought the two pieces of flat of
size 75 X 12 X 760 mm and weld them onthe top of four columns as shown. Page
8Department of Mechanical Engg. S.R.G.P.T.C Triprayar
9. 9. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 Step Four: Then
cut another two pieces oflength 48" (i.e. 4 feet[122 mm]) andweld them vertically at a
distance of16" from previously welded columns.Afterwards weld the previously cutpiece of
36"[41 mm] on top and inbetween the upper ends of thesecolumns. Step Five: Then cut
two pieces of C-channel of length 15". And four pieces of 4" length.Then at a distance of 4.5"
from nearest end weld them to form a frame as shown below. Page 9Department of
Mechanical Engg. S.R.G.P.T.C Triprayar
10. 10. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 II. ROLLER
MACHINING PROCESS Roll is mead up of hollow pipe, solid circular plates & solid shaft
journal. So we have to manufacture each part as per required size and then assemble it as a
roll. Steps in this task are:- Step one: First, brought the hollow pipe of required dimensions.
I.e. of required outer, inner and length. If it not available, then cut it on hacksaw machine.
Step two: Then brought two circular plates of 10 mm thickness, face them from bothsides by
holding them on lathe machine. And turn out to the diameter as equal toinner diameter of
hollow pipe so they can fit into pipe for welding purpose. Step three: Take solid bar of M.S.
of 50 mm diameter cut it to length 110 mm. Hold this bar on lathe chuck and turn it out up to
the diameter 38 mm so that it can be fit in pedestal self-aligning bearing block. Step four:
 Now, weld the turned solid bar to each of two s o l i d circular plates axially. Page
10Department of Mechanical Engg. S.R.G.P.T.C Triprayar
11. 11. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 GROOVE FOR
WELDING THE M.S ROD AT CENTRE- Step five: Now, weld these plates in the bore of
hollow pipe. Step six: The roll is completed, but because of welding different parts it need
to be turned again using lathe machine. Hold the journal on one side in chuck and turn the
other journal as well as hollow pipe part of roll. Do the same operation by holding other
journal in chuck so the roll will rotate along its axis accurately. Page 11Department of
Mechanical Engg. S.R.G.P.T.C Triprayar
12. 12. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13III. CUTTER
CLAMP MAKING PROCESS The c-clamp with the two bolts to clamp and one extended
piece of flat for mounting of cutter is welded. It is used to hold the cutter. Step One: First
take the flat of 25 X 10 and cut it by bend saw in size of 90 mm, 65mm, 60 mm and 40 mm.
Step Two: Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of 40
mmin length and weld it on the 65 mm side of clamp. Step Three: By using drilling
machine, make three holes of 10 mm at the points shown below in the complete assembly of
cutter. Afterwards perform the tapping operations using tap of inch. Page 12Department of
Mechanical Engg. S.R.G.P.T.C Triprayar
13. 13. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13IV. DRIVING
MECHANISM As our project as a demo and also designed for small weight we use the 1 Hp
A.C. motor. It is having the 1440 rpm speed. We use two pulleys of three [7.62 mm] & eight
[20.32] inch diameter respectively on motor and roller. One on the motor shaft and another is
on the shaft of roll. The numbers of belts required for given application is one. V-belt is used
for this purpose. Page 13Department of Mechanical Engg. S.R.G.P.T.C Triprayar
14. 14. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13V. WORKING OF
MACHINE As we give number of modifications it is necessary to briefly explain working
procedure of machine. When the paper being manufactured in paper mill it is not of standard
size an also get torn out at the edges. And here is the need of re-winding machine. The roll
of paper manufactured is mounted on the roll (A). In our machine we have given the self-
aligning bearing with inner extended ring for ease in mounting and urn- mounting. Then
paper is passed around roll (B) to ensure that paper remain straight and tight. Then it passed
through the cutter and grooved roll on top of machine, where it is cut. Because of our
modification to this cutter roll the wt. of machine is decreased. Then the paper which is cut is
come to the roll at bottom, The roll is powered by 1 Hp motor with 1440 rpm. This rotating roll
makes other roll (C) to rotate and not only wound the paper but also pull the paper to make
the operation going. Page 14Department of Mechanical Engg. S.R.G.P.T.C Triprayar
15. 15. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 Advantages 1) It
is more compact as compared with conventional one. 2) Operation is simple Because of
eliminating complex mechanisms. 3) Saving of floor space as motor is adjusted inside the
structure. 4) New cutter clamping assembly given will eliminate the biggest disadvantage of
machine i.e. high weight. SPECIFICATIONS OF MACHINE 6 feet ( 152.4") Length =
387.096 mm Width 0.914 feet ( 36") = 91.44 mm Height 4 feet ( 48" ) = 121.92 mm 4 Hollow
 rolls, 8 Plummer Components blocks,8 bearings 1 Hp, 3 phase, induction Motor motor Page
15Department of Mechanical Engg. S.R.G.P.T.C Triprayar
16. 16. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 MATERIAL
REQUIREMENTS & COST SL DESCRIPTION QTY. RATE AMOUNT No. 760 X 89 mm
G.I 1 25 Kg. Rs. 81 per Kg. Rs. 2025.00 Pipe(4 Nos ) M.S. Rod 2 135 mm X 50 mm 24
Kg. Rs. 58 per Kg. Rs. 1392.00 M.S Circular Plate 3 12mm X 90 mm 7 Kg. Rs.58 per Kg.
Rs. 406.00 (8 No.) M. S. Flat 12 X 75 X 4 760 11 Kg. Rs. 58per kg. Rs. 638.00 (2 No C-
channel 5 76 Kg. Rs. 58 per kg. Rs.4400.00 75 X 40 ( 12.2 meter ) Plummer Blocks 6 8 No.
Rs.200 per block Rs.1600.00 No 208 i.e. 40 mm Bearings 40 mm 8 No. Rs.30 per
Bearing Rs. 240.00 7 Inner Pulleys 3" 1 No. Rs. 240 per Pulley Rs. 150.00 8 Pulley 8" 1 No.
Rs. 540 per Pulley Rs. 540.00 9 V- Belt of B-type 1 No. Rs.180 per Belt Rs.180.00 10 Paper
4.1 kg Rs. 35 per kg. Rs.131.00 Motor 1 Hp Induction 11 1 No. Rs. 2500 Rs. 2500 Motor
(2nd Hand) 12 Travelling Charge --- ------ Rs.1,160.00 Total Rs.14,962.00 Page
16Department of Mechanical Engg. S.R.G.P.T.C Triprayar
17. 17. PAPER CUTTING & REWINDING MACHINE Project Report 2012-13 BIBLIOGRAPHY
Forbes Marshall- Engineering Data Book Workshop Technology- B.S. Raghuwanshi (Vol. I
& II) Production Management- ICFAI University Elements of machine design- V. B.
Bhandari Strength of materials- R. K. Bansal Page 17Department of Mechanical Engg.
S.R.G.P.T.C Triprayar