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ABSTRACT
To design and fabricate a simple mechanical operated
power hammer by applying the principle of kinematic
arrangement and machine design concepts.
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POWER HAMMER PROJECT REPORT 2015
INDEX
1. INTRODUCTION……………………………………………..6
2. HISTORY AND DEVLOPMENT OF POWER HAMMER…15
3. EXPERIMENTAL WORK…………………………………...20
4. DESIGN CALCULATIONS……………………………...…..25
5. OPERATION SHEETS……………………………………….31
6. COST ESTIMATION………………………………………....36
7. PART AND ASSEMBLY DRAWINGS……………………...38
8. CONCLUSION………………………………………………..39
9. REFERENCE………………………………………………….40
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1.INTRODUCTION
ABOUT OF PROJECT WORK
The Aim of course can achieve By learning in classroom and
laboratory. however, Threw the project something extra
Knowledge can achieve.
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PREFACE
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APROJECT MEANS
PLANNING BEFORE
CARRYING OUT THE WORK.
ORGANIZATION OF THE
WORK.
TECHNIQUES
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The simplest and the basic kinematic chain is a four bar chain
or quadratic cycle chain, as shown in below fig. It consists of four
links p, q, l and s, each of them forms a turning pair. The four links
may be of different lengths. According to Grasshof’s law for a four
bar mechanism, the sum of the shortest and longest link lengths
should not be greater than the sum of the remaining two link
lengths if there is to be continuous relative motion between the two
links.
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Applications:-
Forging
Forging refers as the process of plastically deforming metals
or alloys to a specific shape by a compressive force exerted by
some external agency like hammer, Press, rolls, or by an upsetting
machine of some kind. The portion of a work in which forging is
done is termed the forge and the work is mainly performed by
means of heavy hammers, forging machines, and presses. Forging
processes are among the most important manufacturing techniques
since forging is used in small tools, railroad equipment,
automobile, and aviation industries.
A number of operations are used to change the shape of the
raw material to the finished form. The typical forging operations
are:-
1. Upsetting.
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2. Fullering.
3. Drawing down.
4. Setting down.
5. Punching.
6. Bending.
7. Welding.
8. Cutting.
All these operations are carried out with the metal in a heated
condition, which must be maintained by taking a ‘fresh’ heat when
the work shows sign of getting cold.
Forging Processes
The processes of reducing a metal billet between flat-dies or
in a closed impression die to obtain a part of predetermined size
and shape are called smith forging and impression-die forging
respectively. Depending on the equipments utilized they are further
sub-divided as hand forging, hammer forging, press forging, drop
forging, mechanical press forging, upset or machine forging.
Press
Press working involves production of final component from
sheet metal in cold condition. The machine which is used to apply
the required pressure of force in a short duration is called press.
The press consists of a frame, supporting bed and ram. The ram is
equipped with special punches and moves towards and into the die
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block which is attached to a rigid body. The punch and die block
assemble are generally referred to as a die set or simply die.
A disadvantage of press working is that the operations are
carried out at room temperature and the metal is less deformable of
strain hardening.
Classification of Presses
Presses are classified in various ways as listed below.
(i) Mechanical press.
(ii) Hydraulic press.
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2.PROBLEM DEFINITION
The conceptual design was based on the principle of design
by analysis [Norton, 2006]. The methodology adopted was to
examine the most critical defects of conventional hammer mills
and provide solutions. Thus the following defects or problems
were identified and corresponding solutions were proffered.
Problem 1
As a result of wear and corrosion the sieve screen holes enlarge or
burst thereby allowing larger than desired particles to pass through.
Solution 1
Eliminate sieve screens. Introduce an endless sieve that is a
dimensionally controlled “open gate”.
Problem 2
After several hours of hammer mill operation, the sieve screen
holes are clogged thereby reducing its efficiency and capacity.
Solution 2
The solution to problem 1 eliminates problem 2
Problem 3
Wet materials become elastic and therefore absorb most of the
impact energy of the hammer without breaking. This reduces the
efficiency of conventional hammer mills.
reduces the efficiency of conventional hammer mills.
Solution 3
Introduce a fan to induce forced convection and rapid drying of
material
Problem 4
Adequately broken particles can be collected when they fall
through the sieve hole by gravity. Due to the relatively large gap
between the hammers and the screen, this will be inadequate and
therefore clearly inefficient.
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Solution 4
Solution 3 eliminates problem 4 as pressurized air can lift particles
of sufficient sizes through great distances. This is observed in
tornadoes and cyclones.
Problem 5
Materials being crushed by conventional hammer mills cannot be
recycled until they are reduced to the required size before trying to
force them through the sieve holes. This is probably the greatest
cause of burst holes.
Solution 5
A mechanical separator, which rotates at the same speed as the
shaft ensures that all solid particles above certain sizes are blown
back into the hammer mill chamber until they are ground or broken
by impact into fine particles.
Problem 6
Some of the particles produced by hammer mills are in the form of
dust. They usually constitute 5- 10% of the raw materials and are
lost as dust into the atmosphere. They constitute serious health
hazard to the human operators of the hammer mills as they enter
the lungs (which can lead to cancer) and ears (which can lead to
hearing loss), eyes (which can lead to blindness), et cetera
2The dust particles escaping into the atmosphere would eventually
settle on roofs of buildings, leaves of trees, and on animals thus
causing pollution and damaging the ecology of the immediate
environment.
Solution 6
Install a large sedimentation chamber with long tubes so as to
virtually remove all the dust at the point of generation. This is
greatly aided by solution 3 as the fan generates the required suction
pressure. The design factors considered to be of utmost importance
in this design were function, maintenance, reliability, safety and
cost (Norton, 1999). The introduction of a sieve less screen for
separating the right size of particles from the unwanted ones
ensures that most of the maintenance and reliability problems of
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Trip Hammer
Pneumatic hammer
The hammer has two cylinders compressor cylinder and ram
cylinder. Piston of the compressor cylinder compresses air, and
delivers it to the ram cylinder where it actuates the piston which is
integral with ram delivering the blows to the work. The
reciprocation of the compression piston is obtained from a crank
drive which is powered from a motor through a reducing gear. The
air distribution device between the two cylinders consists of rotary
valves with ports through which air passes into the ram cylinder,
below and above the piston, alternately. This drives the ram up and
down respectively.
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Hydraulic hammer
In this hammers instead of air oil was used. The cost
hydraulic hammer is high as compared to the pneumatic hammers.
Hydraulic hammer is used in high force applications. These are
noise less.
Power hammers
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3. EXPERIMENTAL WORK
Construction
As shown in above diagram it consists of 5 links, and one
fixed link. The five links are crank (link 1), link 3. Connecting rod
(link 4), Crank (link 5) and Ram die
(link 2).Column can be considered as a fixed link. The link 1
rotates about a turning pair F, it is rotated by a pin joint axis, the
link 3 and link 1 is connected by a turning pair E. The connecting
rod (link 4) and link 3 are connected by a turning pair D. The crank
(link 5) is fixed at a turning pair A and oscillates about the pin joint
axis. Crank(link 5) and connecting rod (link 4) are connected by a
turning pair B.
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Connecting Rod
A mild steel material of the required dimension is cut on the
power hack saw machine. After cutting process is over the fillet is
provided over the edges by using a hand grinder, after providing
fillets drilling operation of required diameter is done after
completing this process now we proceed towards milling the slot
of 65 x 8 x 6 mm3 by using an end mill cutter. Finally filing was
done on bench vice to remove unnecessary sharp corners.
Ram die
Mild steel material of required dimension is cut on power
hack saw. The material was fixed on the chuck in a lathe machine
for doing facing and turning operations. Polishing was done for
good surface finish. Chamfers were made for removing sharp
corners. A hole was drilled at the end of the ram of the required
size for fixing the slider pin. A slot was milled on the rod to insert
the connecting rod in the slot and fixing it in the slider pin. At the
other end of
The ram a hole of required size was made and then later it was
taped at the same end to make the fixing adjustment of the punch
with the help of a screw.
Composite Bush
It was manufactured by two different materials one of Mild
steel and other was liner made up of Gun metal. The outer one is
made up of Mild steel on which facing and turning operations were
done on a lathe and then the inner one was made up of Gun metal
on which facing and turning were carried out of the required size
then the liner was inserted in the outer bush by the application of a
press fit.
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Column
The Column is made up of Mild Steel of required dimension.
First the marking for the holes to fix the links were done on the
column. The outer profile was marked and then made to cut on a
gas cutter, and then it was milled to the required size and then
finally chamfering was done to remove unnecessary sharp corners
and edges. Drills were drilled on the column for bearings, turning
pairs F and A. Then the composite bush was welded on the
column. Vice was fitted on the column by the application of
welded joints for holding the work piece.
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n = 3(υ-1) -2j
n = 3(6-1) -2 x 7
n=3x5–2x7
n = 15 – 14
n=1
Therefore, the mechanism has single degree of freedom.
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4.DESIGN CALCULATIONS
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Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross
sectional area in the entire mechanism. We know that stress is
inversely proportional to the area, so the minimum area leads to
increase the stress. So it is always preferred to design any machine
by taking minimum cross sectional area as effective area.
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The below diagram is for the finite width plate with a transverse
hole.
=0.6×1000×9.81
= 5886N
Therefore,
σnom=5886
(20 - a)6
Kt = σnom
σmax
σnom=σ max
kt
5886 =150
(20 - a)6 2.3
5886 =65.22
(20 - 6a)
5886 = 65.22(120-6a)
5886 = 7826.5 – 391.32a
5886 – 7826.5 = - 391.32a
- 1940.5 = - 391.32a
Therefore, a=1940 .5
391 .32
a = d (diameter) = 4.99mm
Due to dynamic characteristics of links the diameter of pin is
selected as 6 mm.
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Bearing stress(σ)= P
d+n
P = 0.6 + 1000×9.81N
d = 6mm
t = 6mm
n=2
(σb) ≥ 0.6 ×1000 ×9.81
6×6×2
≥81.75 N/mm²
The bearing stress is greater than 81.75 N/mm² , so the design is
satisfactory
4Design for punching operation
Permissible shear stress is given by,
σ Y =0.6σy
=0.6 × 300
= 180 N/mm²
τ Y ≥load
shear area
τ Y ≥6000
shear area
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5. OPERATION SHEETS
1. CRANK (LINK 1)
Description : Crank 1
Part No :1
Material : Mild Steel.
Required size : 120mm x 20mm x 6mm
SL. MACHINE OPERATION TOOL GAUGE
NO
1 Power saw Cutting Hacksaw Vernier
caliper,
steel
rule
2 Grinding Fillet Grinding -
Wheel
3 Drilling Drill bit Vernier
Drillɸ6 x 6 Caliper
4 Drill bit Vernier
Drilling Drillɸ6 x 6 Caliper
5 Bench vice Filing Flat file -
2. RAM DIE
Description : Die
Part No :2
Material : Mild Steel.
Required size : ɸ20mm x 420mm
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3. LINK 3
Description : LINK 3
Part No :3
Material : Mild Steel.
Required size : 440mm x 20mm x 6mm
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5. CRANK (LINK 5)
tool
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6. COST ESTIMATION
Cost of Standard components
Name of Quantity Cost/piece Cost in Rupees
component
Bearing (6mm) 4 15 60
M6 bolt and nut 5 8 40
½ inch bolt and 1 26 26
nut
M5 8 1.5 12
Countersunk
bolt
and nut
M6 2 3 6
Countersunk
bolt
and nut
TOTAL COST 144
Material Cost
Name of Quantity Cost in Rupees
component
M.S Flat for links 1 150
M.S Rod for ram 1 100
M.S sheet for base 1 2000
Bush (M.S and 1 156
gunmetal)
TOTAL COST 2406
Machining Cost
Machine Cost in Rupees
Lathe 500
Drilling 300
Gas Cutting 170
Welding 200
Milling 660
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1. CRANK (LINK 1)
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2. RAM DIE
3. LINK 3
4. CONNECTING ROD
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5. CRANK (LINK 5)
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6. COMPOSITE BUSH
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7. ELECTRIC MOTER
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DETAIL DRAWING
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ASSEMBLY DRAWING
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8.CONCLUSION
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9.REFERENCE
• www.slideshare.com
• www.wikipedia.org
• www.nptel.in
• www.google.com
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