1

DESIGN AND FABRICATION OF PNEUMATIC AUTO FEED DRILLING MACHINE

A PROJECT REPORT

Submitted by

C G ARRUN RAVI

D.K.BALAJEE

KAUSHAL KUMAR JAIN

in partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

SRM ENGINEERING COLLEGE

KATTANKULATHUR

ANNA UNIVERSITY: CHENNAI 600 025

APRIL 2006

2

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF PNEUMATIC AUTO

FEED DRILLING MACHINE” is the bonafide work of “C G ARRUN RAVI, D.K.BALAJEE,

KAUSHAL KUMAR JAIN” who carried out the project work under my supervision.

SIGNATURE SIGNATURE Dr.S.KRISHNAN Mr.M.THIRUMURUGAN DEAN SUPERVISOR SCHOOL OF MECHANICAL ENGINEERING SRM ENGINEERING COLLEGE SRM ENGINEERING COLLEGE KATTANKULATHUR-603203 KATTANKULATHUR-603203

3

ACKNOWLEDGEMENT

We would like to thank Dr. S. Krishnan, DEAN, School of Mechanical Engineering for

permitting us to carry out this project work.

Our sincere thanks to Mr. M. Thirumurugan, for guiding us and for his invaluable support toward

our project. We are also grateful to Mr.Z.E.Kennedy for bearing with us throughout the project.

We would like to place on record, our sincere thanks to all the staff of Machine Shop and the

Thermal Lab for helping us with this project.

4

ABSTRACT

In small-scale industries and automobile maintenance shops, there are frequent needs of

tightening and loosening of screws, drilling, boring, grinding machine. Huge and complicated

designed parts cannot be machined with the help of an ordinary machine and further for every

operation separate machine is required therefore increasing the number of machines required and

increasing the area required for them to be accommodated and hence overall initial cost required

is increased.

In a single machine all the above specified operation can be carried out, i.e., after drilling,

the drill head is removed from the barrel key and the required tools like grinding wheels, boring

tool etc., can be attached, and the operation can be performed.

By the application of pneumatics, the pneumatic cylinder with piston which is operated

by an air compressor will give the successive action to operate this machine. By this we can

achieve our industrial requirements.

5

TABLE OF CONTENTS

CHAPTER

NO.

TITLE PAGE

NO.

ABSTRACT 4

LIST OF TABLES 6

LIST OF FIGURES 7

LIST OF ABBREVIATIONS

8

1 INTRODUCTION 9

2 LITERATURE SURVEY 11

3 DESCRIPTION OF EQUIPMENT 16

4 DESIGN AND DRAWING 26

5 FABRICATION 43

6 WORKING PRINCIPLE 44

7 MERITS AND DEMERITS 45

8 APPLICATIONS 45

9

10

11

12

LIST OF MATERIALS

COST ESTI MATION

CONCLUSION

REFERENCES

46

50

52

53

6

LIST OF TABLES

S.NO. TABLE NO. DESCRIPTION

PAGE

NO.

1 3.1 Cylinder Tube Materials 17

2 3.2 End Cover Materials 17

3 3.3 Piston Materials 18

4 3.4 Mount Materials 18

5 3.5 Piston Rod Materials 18

6 9.1 List of Materials 49

7 10.1 Cost Estimation 50

7

LIST OF FIGURES

S.NO. FIGURE NO. DESCRIPTION

PAGE

NO.

1 4.1 Flange 1 29

2 4.2 Flange 2 30

3 4.3 Vane Cover 31

4 4.4 Bearing 1 32

5 4.5 Bearing 2 33

6 4.6 Stand 34

7 4.7 Base 35

8 4.8 Vane 36

9 4.9 Barrel 37

10 4.10 Pneumatic Cylinder 38

11 4.11 Solenoid Valve 39 12 4.12 Pneumatic Double Acting Cylinder 40 13 4.13 Hose Collar 41 14 4.14 Pneumatic Auto Feed Drilling Machine 42

8

LIST OF ABBREVATIONS

A - Area of cylinder (m²)

D - Diameter of Piston (m)

F - Force exerted on the piston (N)

H - Height (m)

L - Length (m)

P - Pressure (N/m²)

V - Volume (m³)

CHAPTER-1

INTRODUCTION

The main objective of our project is to perform various machining operations using

“Auto feed mechanism” in drilling machine with the help of pneumatic sources. For a

developing industry the operation performed and the parts (or) components produced should

have it minimum possible production cost for it to run profitability.

In small-scale industries and automobile maintenance shops, there are frequent needs of

tightening and loosening of screws, drilling, boring, grinding machine. Huge and complicated

designed parts cannot be machined with the help of an ordinary machine and further for every

operation separate machine is required therefore increasing the number of machines required and

increasing the area required for them to be accommodated and hence overall initial cost required.

In our project the above complicated problems are minimized.

NEED FOR AUTOMATION:

Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc., of

these sources, pneumatics form an attractive medium for low cost automation.

9

The main advantage of a pneumatic system is that it is economical and simple in construction

which makes it different from other sources of automation.

Automation plays an important role in mass production. Nowadays almost all the

manufacturing process is changing to automated machines in order to deliver the products with

better quality and at a faster rate. The manufacturing operation is being automated for the

following reasons.

� To achieve mass production

� To reduce man power

� To increase the efficiency of the plant

� To reduce the work load

� To reduce the production cost

� To reduce the production time

� To reduce the material handling

� To reduce the fatigue of workers

� To achieve good product quality

� Less Maintenance

10

CHAPTER-2

LITERATURE SURVEY

PNEUMATICS:

The word ‘pneuma’ comes from Greek and means breather wind. The word pneumatics is

the study of air movement and its phenomena is derived from the word pneuma. Today

pneumatics is mainly understood to means the application of air as a working medium in

industry especially in driving and controlling of machines and equipment.

Pneumatics has been considered to be used to carry out simple mechanical tasks. But, in

today’s world it is playing an important role by becoming one of the major sources for

automation, and the recent developments in this field has made it a useful technology in the field

of complex automated applications.

Pneumatic systems operate on a supply of compressed air which must be available in

sufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic

system is being adopted for the first time, however it will indeed be necessary to deal with the

section of compressed air supply.

The key part of any pneumatic machine is supply of compressed air is by means

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure

and delivers the air at a high pressure.

Compressor capacity is the actual quantity of air compressed and delivered. And the

volume expressed is that of the air at intake conditions namely at atmosphere pressure and

normal ambient temperature.

The compressibility of the air was first investigated by Robert Boyle in 1962 and found

that the product of pressure and volume of a particular quantity of gas is constant.

This is usually written as:

11

PV = C (or) PıVı = P2V2

In this equation the pressure is the absolute pressure which is about 14.7 Psi. Any gas can

be used in pneumatic system but air is the mostly used system now a days.

SELECTION OF PNEUMATICS:

Mechanization is broadly defined as the replacement of manual effort by mechanical

power. Pneumatic is an attractive medium for low cost mechanizations particularly for sequential

(or) repetitive operations. Many factories and plants already have a compressed air system,

which is capable of providing the power (or) energy requirements and the control system

(although equally pneumatic control systems may be economic and can be advantageously

applied to other forms of power).

The main advantage of a pneumatic system is it is economically cheap and simple in

design, also reducing maintenance costs. It can also have an out standing advantage in terms of

safety.

PNEUMATIC POWER

Pneumatic systems use pressurised gas to transmit and control power. Pneumatic

systems typically use air as the fluid medium because air is safe, free and readily available.

The Advantages of Pneumatics:

1. Air used in pneumatic systems can be directly exhausted in to the surrounding

environment and hence the need of special reservoirs and no-leak system designs

are eliminated.

2. Pneumatic systems are simple in design and economical.

3. Control of pneumatic systems is easier.

The Disadvantages of Pneumatics:

1. Pneumatic systems exhibit spongy characteristics due to compressibility of air.

12

2. Pneumatic pressures are quite low due to compressor design limitations (less that 250

psi).

PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made available

in sufficient quantity and at a pressure to suit the capacity of the system.

The key part of any pneumatic system for supply of compressed air is by means using

reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure

and delivers it at a higher pressure. Compressor capacity is the actual quantity of air compressed

and delivered. And the volume expressed is that of the air at intake conditions namely at

atmosphere pressure and normal ambient temperature.

Clean condition of the suction air is one of the factors, which decides the life of a

compressor. Warm and moist suction air will result in increased precipitation of condense from

the compressed air. Compressor may be classified in two general types.

1. Positive displacement compressor.

2. Turbo compressor

Positive displacement compressors are most frequently employed for compressed air

plant and have proved highly successful for pneumatic control application.

The different types of positive compressors are:

1. Reciprocating type compressor

2. Rotary type compressor

13

Turbo compressors are employed where large capacity of air required at low discharge

pressures. They cannot attain pressure necessary for pneumatic control application unless built in

multistage designs and are seldom encountered in pneumatic service.

RECIPROCATING COMPRESSORS

Built for either stationary (or) portable service the reciprocating compressor is by far the

most common type. Reciprocating compressors deliver more than 500 m³/min. In single stage

compressor, even if the air pressure is of 6 bar, the machines can discharge pressure of 15 bars.

Discharge pressure in the range of 250 bars can be obtained with high pressure reciprocating

compressors that of three & four stages. Single stage and 1200 stage models are particularly

suitable for pneumatic applications , with preferences going to the two stage design as soon as

the discharge pressure exceeds 6 bar, because it in capable of matching the performance of single

stage machine at lower costs per driving powers in the range

Objective:

The pneumatic auto feed drilling machine can be widely used in low cost automation in

manufacturing industries. Drilling speed is high. The manpower requirement is reduced also

reducing the machining time.

14

CHAPTER-3

DESCRIPTION OF EQUIPMENT

3.1 PNEUMATIC CONTROL COMPONENT

3.1.1 Pneumatic cylinder

An air cylinder is an operative device in which the state input energy of compressed air

i.e. pneumatic power is converted in to mechanical output power, by reducing the pressure of the

air to that of the atmosphere.

3.1.1 a) Single acting cylinder

Single acting cylinder is only capable of performing an operating medium in only

one direction. Single acting cylinders are equipped with one inlet for the operating air pressure,

and can be produced in several designs. Single cylinders develop power in one direction only.

Therefore no heavy control equipment should be attached to them, which is required to

be moved on the piston return stoke. Single action cylinder requires only about half the air

volume consumed by a double acting for one operating cycle.

3.1.1 b) Double acting cylinders:

A double acting cylinder is employed in control systems with the full pneumatic

cushioning and it is essential when the cylinder itself is required to retard heavy loads. This can

only be done at the end positions of the piston stock. In all intermediate positions a separate

externally mounted cushioning device must be provided with the damping feature.

The normal escape of air is out off by a cushioning piston before the end of the stock is

required. As a result the sit in the cushioning chamber is again compressed since it cannot escape

but slowly according to the setting made on reverses.

The air freely enters the cylinder and the piston stokes in the other direction at full force

and velocity.

GENERALLY USED MATERIALS:

15

Table 3.1 Cylinder Tube Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Plastic Hard drawn brass tube hard drawn brass tube.

2. Hard drawn Aluminium Castings Hard drawn steel tube

Aluminium tube

4. Hard drawn Brass, Bronze, Iron or

Brass tube Castings, welded steel tube

Table 3.2 End Cover Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium stock Aluminium stock Hard tensile

(Fabricated) (Fabricated) Castings

2. Brass stock Brass stock

(Fabricated) (Fabricated)

3. Aluminium Aluminium, Brass,

Castings iron or steel Castings.

Table 3.3 Piston Materials:

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1.Aluminium

Castings

Aluminium Castings

Brass (Fabricated)

Aluminium Forgings,

Aluminium Castings.

2. Bronze (Fabricated) Bronze (Fabricated)

3. Iron and Steel

Castings

Brass, Bronze, Iron or

Steel Castings.

Table 3.4 Mount Materials:

16

LIGHT DUTY MEDIUM DUTY HEAVY DUTY

1. Aluminium

Castings

Aluminium, Brass

And Steel Castings

High Tensile

Steel Castings

2. Light Alloy

(Fabricated)

High Tensile

Steel Fabrication

Table 3.5 Piston Rod Materials:

MATERIAL FINISH REMARKS

MILD STEEL Ground and polished hardened,

ground and polished.

Generally preferred chrome

plated

STAINLESS STEEL Ground and Polished Less scratch resistant than

chrome plated piston rod

3.2 VALVES

Solenoid Valve:

The directional valve is one of the important parts of a pneumatic system. Commonly

known as DCV, this valve is used to control the direction of air flow in the pneumatic system.

The directional valve does this by changing the position of its internal movable parts.

This valve was selected for speedy operation and to reduce the manual effort and also for the

modification of the machine into automatic machine by means of using a solenoid valve.

A solenoid is an electrical device that converts electrical energy into straight line motion

and force. These are also used to operate a mechanical operation which in turn operates the

valve mechanism. Solenoids may be push type or pull type. The push type solenoid is one in

17

which the plunger is pushed when the solenoid is energized electrically. The pull type solenoid

is one is which the plunger is pulled when the solenoid is energized.

18

Figure 3.1 5/2 Solenoid Valve

19

Parts of a Solenoid Valve

1. Coil:

The solenoid coil is made of copper wire. The layers of wire are separated by insulating

layer. The entire solenoid coil is covered with a varnish that is not affected by solvents,

moisture, cutting oil or often fluids. Coils are rated in various voltages such as 115 volts AC,

230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts

DC & 230 Volts DC. They are designed for such frequencies as 50 Hz to 60 Hz.

2. Frame:

The solenoid frame serves several purposes. Since it is made of laminated sheets, it is

magnetized when the current passes through the coil. The magnetized coil attracts the metal

plunger to move. The frame has provisions for attaching the mounting. They are usually bolted

or welded to the frame. The frame has provisions for receivers, the plunger. The wear strips are

mounted to the solenoid frame, and are made of materials such as metal or impregnated less fiber

cloth.

3. Solenoid Plunger:

The Solenoid plunger is the mover mechanism of the solenoid. The plunger is made of

steel laminations which are riveted together under high pressure, so that there will be no

movement of the lamination with respect to one another. At the top of the plunger a pin hole is

placed for making a connection to some device. The solenoid plunger is moved by a magnetic

force in one direction and is usually returned by spring action.

Solenoid operated valves are usually provided with cover over either the solenoid or the

entire valve. This protects the solenoid from dirt and other foreign matter, and protects the

actuator. In many applications it is necessary to use explosion proof solenoids.

Working of Solenoid Valve:

20

The solenoid valve has 5 openings. This ensures easy exhausting of 5/2 valve. The

spool of the 5/2 valve slide inside the main bore according to spool position; the ports get

connected and disconnected. The working principle is as follows.

Position-1

When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’ and ‘S’

remains closed while ‘A’ gets connected to ‘R’

Poisition-2

When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to each

other and ‘B’ to ‘S’ while port ‘R’ remains closed.

SOLENOID VALVE (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off valve or solenoid

valve. This solenoid cut off valve is controlled by the electronic control unit.

In our project separate solenoid valve is used for flow direction of vice cylinder. It is

used to flow the air from compressor to the single acting cylinder.

3.2.2 Flow control valve:

In any fluid power circuit, flow control valve is used to control the speed of the actuator.

The flow control can be achieved by varying the area of flow through which the air in passing.

When area is increased, more quantity of air will be sent to actuator as a result its speed

will increase. If the quantity of air entering into the actuator is reduced, the speed of the actuator

is reduced.

3.2.3 Pressure Control Valve:

The main function of the pressure control valve is to limit (or) control the pressure

required in a pneumatic circuit.

Depending upon the method of controlling they are classified as

21

1. Pressure relief Valve

2. Pressure reducing Valve

3.3 DRILLING HEAD :

3.3.1 Barrel :

It is made out of mild steel. It is hollow cylinder. It has a length of 100 mm and

inner diameter of 36 mm. It has two outlet holes on its top and two inlet holes drilled at angles

for placing nozzles. It has threads at each end.

3.3.2. Shaft:

It’s made up of mild steel. It is a straight rod having a step. It is supported by two

bearings in the cylinder. The diameter of rod is 15 mm for a length of 150 mm and 13.5 mm

diameter for 22 mm length. The fan is fitted on the shaft through flanges. The fan is fixed to

flanges and the flanges are fixed to the shaft through drilled holes.

3.3.3 Couplings:

The couplings are made out of mild steel. Couplings cover the slides of barrel.

The couplings have internal threads. With help of threads the couplings are fitted to barrel. It has

a smaller diameter hole to place the bearings.

3.3.4 Flanges:

The flanges are made out of mild steel. It’s a cylindrical tube having a flange at its one of

the ends. It also has a centre drill of 16 mm. There are holes are drilled in flanges

correspondingly such that the holes drilled in the two flanges coincide each other. The fan is

placed between the two flanges and screwed.

22

3.3.5 Vane:

The vane 18 made out of aluminum. It is placed the flanges, which are fitted to

the shaft through nuts and bolts. Air is forced on the fan and it is rotated and the rotation is

transmitted to the shaft. The fan is twisted such that it could be driven in either direction.

3.4 HOSES

Hoses used in this pneumatic system are made up of polyurethane. These hose can with

stand at a maximum pressure level of 10 N/m².

3.4.1. Connectors:

In our system there are two type of connectors used. One is the hose

connector and the other is the reducer. Hose connectors normally comprise an adoptee hose

nipple and cap nut. These types of connectors are made up of brass (or) Aluminum (or) hardened

pneumatic steel.

3.5 CONTROL UNIT

A pneumatic multipurpose device is an air-operated device used for many small

operations. It is a portable one. Compressed air is the source of energy for this device. The

compressed air is allowed to pass through the nozzle in such a way that the rotation obtained is

utilized for machining.

The nozzles welded to the fan can be rotated in either direction. The rpm and torque of

the shaft depends upon the pressure of the air admitted so by varying the pressure, the RPM and

torque can be varied. Thick tubes interconnect the parts. The Clamps are used at the connecting

parts to prevent leakage. In thread parts seals are used to prevent leakage.

The compressed air from the compressor first enters the control unit. In the control unit

the pressure of the air is controlled and sent to the barrel to rotate the fan in the required

direction. The gate valve controls the pressure and volume of air. Then the pressure is read by a

pressure gauge. Later the air is admitted to the barrel, a shaft is placed and it carries the fan. The

23

shaft is supported by bearing. The bearings are placed in the couplings, which covers the end of

barrel.

CHAPTER –4

DESIGN OF EQUIPMENT AND DRAWING

4.1 Pneumatic components and its specification

The pneumatic auto feed drilling machine consists of the following components:

1. Double acting pneumatic cylinder

2. Solenoid Valve

3. Flow control Valve

4. Connectors

5. Hoses

1. Double acting pneumatic cylinder

Technical Data

Stroke length : Cylinder stoker length 170 mm = 0.17 m

Piston diameter : 45 mm

Piston rod : 15 mm

Quantity : 1

Seals : Nitride (Buna-N) Elastomer

End cones : Cast iron

Piston : EN – 8

Media : Air

Temperature : 0-80 º C

Pressure Range: : 8 N/m²

2. Solenoid Valve:

24

Technical data

Size : 0.635 x 10 ¯² m

Part size : G 0.635 x 10 ¯² m

Max pressure range : 0-10 bar

Quantity : 2

3. Flow control Valve:

Technical Data

Port size : 0.635 x 10ֿ ² m

Pressure : 0-8 bar

Media : Air

Quantity : 1

4. Connectors:

Technical data

Max working pressure : 10 bar

Temperature : 0-100 º C

Fluid media : Air

Material : Brass

5. Hoses:

Technical data

Max pressure : 10 bar

Outer diameter : 6 mm = 6 x 10 ¯ ³m

Inner diameter : 3.5 mm = 3.5 x 10 ¯ ³m

4.2 General machine Specifications:

Drill unit

Short capacity : 0.635 x 10ֿ ² m

25

Barrel diameter (ID) : 40 mm = 40 x 10¯ ³m

Clamping unit

Clamping : Auto clamping

Max Clamping Size : 100 mm = 0.1m

Pneumatic unit

Type of cylinder : Double acting cylinder

Type of valve : Flow control valve & solenoid valve

Max air pressure : 8 bar

General unit

Size of machine (L x H) : 0.6096 m x 0.6096 m

Weight : 45 kg = 441.45 N

4.3 DESIGN CALCULATIONS:

Max pressure applied in the cylinder (p) : 8 bar

Area of cylinder (A) : (3.14 D²) / 4

: 12.56 cm² = 12.56 x 10-2 m2

Force exerted in the piston (F) : Pressure applied x area of cylinder.

26

Figure 4.1 Flange1

Figure 4.2 Flange2

27

Figure 4.3 Vane Cover

28

29

Figure 4.4 Bearing1

Figure 4.5 Bearing2

30

Figure 4.6 Stand

31

Figure 4.7 Base

32

33

Figure 4.8 Vane

Figure 4.9 Barrel

34

Figure 4.10 Pneumatic Cylinder

35

36

Figure 4.11 Solenoid Valve

Figure 4.12 Pneumatic Double Acting Cylinder

37

Figure 4.13 Hose Collar

38

PNEUMATIC AUTOFEED DRILLING MACHINE

39

Figure 4.14 Pneumatic Auto Feed Drilling Machine

40

CHAPTER-V

FABRICATION

Method of Fabrication:

The stand (or) base carries the whole machine. The rod is vertically fixed on the stand by

means of welding. One cylinder is mounted on the rod by using clamp and the other cylinder is

fixed in stand (or) base by means of bolt and nuts. The lugs are connected with the piston rod of

pneumatic cylinder.

The hose is connected from solenoid valve to each cylinder. Before that the air goes

through drill head through tubes. Barrel unit is fixed to the rod.

The tubes are also connected by the nozzle head. The clamping unit is also fixed in the

stand by means of welding. Finally the unit is connected to the compressor.

CHAPTER-VI

WORKING PRINCIPLE

The compressed air from the compressor is used as the force medium for this operation.

One Single acting and double acting cylinder is used in this machine .The air from the

compressor enters into the flow control Valve.

Air enters in to the barrel unit through one way and the other way of air enters to the

solenoid valve. When air enters to the cylinder 1, due to pressure difference work blank is

41

clamped and when air enters to the other cylinder due to pressure difference drilling operation

takes place as the drilling head comes down and drills the work piece.

After this operation the cylinder releases the clamping and drilling head comes to its

original position.

CHAPTER-VII

MERITS

� It reduces the manual work.

� Quick in operation

� Accuracy is more

� Low cost machine

� Its used multipurpose device like Grinding, screw driving.

CHAPTER-VIII

APPLICATIONS

� Used in automobile workshops for drilling carburetor holes

� Used in small scale industries

� In welding shop for grinding

� For performing the operations in huge numbers which cannot be done in ordinary

machines. Since it’s portable.

� In such places where frequent change in operation is required.

42

CHAPTER-IX

LIST OF MATERIALS

FACTORS DETERMINING THE CHOICE OF MATERIALS The various factors which determine the choice of material are discussed below.

1. Properties:

The material selected must posses the necessary properties for the proposed application.

The various requirements to be satisfied can be weight, surface finish, rigidity, ability to

withstand 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 shear,

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.

43

• Cast ability,

• weld ability,

• Brazability,

• Forge ability,

• merchantability,

• surface properties,

• shrinkage,

• Deep drawing etc.

2. Manufacturing Case:

Sometimes the demand for lowest possible manufacturing cost or surface qualities

obtainable by the application of suitable coating substances may demand the use of special

materials.

3. Quality Required:

This generally affects the manufacturing process and ultimately the material. For

example, it would never be desirable to go for casting of a less number of components which can

be fabricated much more economically by welding or hand forging the steel.

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.

5. Space Consideration:

44

Sometimes high strength materials have to be selected because the forces involved are

high and the space limitations are there.

6. Cost:

As in any other problem, in selection of material the cost of material plays an important

part and should not be ignored.

Some times factors like scrap utilization, appearance, and non-maintenance of the

designed part are involved in the selection of proper materials.

Table 9.1 List of Materials

S. No. Description Qty Material

1 Double acting pneumatic cylinder 1 Aluminium

2 Solenoid Valve 2 Aluminium

3 Flow control Valve 1 Aluminium

4 Drill head 1 C.I

5 Control unit 1 Electronic

6 Pneumatic driller 1 M.S

7 PU Tubes 5 meter Polyurethene

8 Hose Collar 8 Brass

9 Reducer 8 Brass

10 Frame stand 1 M.S

11 Fixed Plate 1 M.S

12 Moving Plate 1 M.S

13 Column Support 1 M.S

45

CHAPTER-X

COST ESTIMATION

1. MATERIALS COST:

Table 10.1 Cost Estimation

S. No. Description Qty Material AMOUNT(RS)

1 Double acting pneumatic cylinder 1 Aluminium 2440

2 Solenoid Valve 2 Aluminium 2600+1400

3 Flow control Valve 1 Aluminium 950

4 Drill head 1 C.I 1960

5 Control unit 1 Electronic 1500

6 Pneumatic driller 1 M.S 2090

7 PU Tubes 5 meter Polyurethene 500

8 Hose Collar 8 Brass 80

9 Reducer 8 Brass 95

10 Frame stand 1 M.S 1500

11 Fixed Plate 1 M.S 75

12 Moving Plate 1 M.S 80

13 Column Support 1 M.S 150

2. LABOUR COST

LATHE, DRILLING, WELDING, GRINDING, POWER HACKSAW, GAS CUTTING:

Cost = Rs.1250/-

3. OVERHEAD CHARGES

46

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 14070 + 1250

= Rs.15320/-

TOTAL COST

Total cost = Material Cost + Labour cost

= Rs.15320/-

Total cost for this project = Rs.15320/-

CHAPTER – XI

CONCLUSION

The project carried out by us made an impressing task in the field of small scale

industries and automobile maintenance shops. It is very usefully for the workers to carry out a

number of operations in a single machine.

This project has also reduced the cost involved in the concern. Project has been designed

to perform the entire requirement task which has also been provided.

47

REFERENCES

1. Design data book - P.S.G. Tech.

2. Pneumatic hand book - R.H.Warrning

3. Machine tool design hand book - Central machine tool Institute,

Bangalore.

4. Strength of materials - R.S.Khurmi

5. Manufacturing Technology - M.Haslehurst.

6. Machine Design - R.S.Khurmi