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MAJOR PROJECT Presentation onGUIDED BY:

Mr. Soham Munjal(Assistant Professor)FABRICATION OF POWER-HAMMERsubmitted BY:

r.balasubramanianRachit gourrohit chouhanrahul singhVIJAY YADAV

DEPARTMENT OF MECHANICAL ENGINEEERINGOBJECTIVETo design and fabricate a simple mechanical operated power hammer by applying the principle of kinematic arrangement and machine design concepts.

PROBLEM STATEMENTUntil now we have confined ourselves to study of hand tools used in smithy work. They certainly perform very well so far as the hand- forging is concerned, but their use for satisfactory production is limited to small forging only. It would not be difficult to understand that the intensity of blows, however great one may try to achieve through hand hammering, will not be sufficient enough to effect the proper plastic flow in a medium sized or heavy forging. For the above conditions, we have designed a cost-effective power hammer which is further implemented by means of various kinematic linkage arrangements so that the mechanical forging process can be run effectively.SOLUTION APPROACHPresently, available power hammers and formers tend to be bulky and occupy large footprints making them unsuitable for small-scale operations. In addition, presently available power hammers and formers can require precise, custom machined die sets, which may be unusable with other machinery, in order to provide proper operational clearance. Finally, presently available power hammers can be operated by linkage drives that have the capacity to literally destroy the machines if proper die set-ups and clearances are not maintained.Considering the above conditions, there is necessity of a feasible working process to be made for power hammering which we have made possible utilizing various resources.INTRODUCTIONPower hammers are mechanical forging hammers that use a non-muscular power source to raise the hammer preparatory to striking, and accelerate it onto the work being hammered. Also called "Open Die Power Forging Hammers." They have been used by blacksmiths, bladesmiths, metalworkers, and manufacturers since the late 1880s.Power hammers are rated by weight of moving parts that act directly on the work piece. This includes the weight of the parts that may consist of upper die, ram, mechanical linkage arms and spring(s) or ram, piston, and associated connecting rod(s). Specific design elements are dictated by the power source.

COMPONENTS USEDAluminum stripIron rods aluminum L-angles Iron bushesMild steel rodNuts & boltsDC MotorJockeyWooden block & support

ALUMINIUM ANGLE:-It is a supporting member which is used for supporting to the corner. It provides the strength to structure which is shown in figure.

Aluminum strip:- Here we use aluminum strip which is used as a lever.

DC Motor:-We use a high torque dc motor of 30-40 rpm of 12 volt/2 amperes.

Iron Bushes:-We use iron bushes for smooth and frictionless movement of the hammer ram.

WORKING * In power hammering we use the high torque motor which is attached to the wooden support which in turn drives the ram which is attached to the hammer by a lever arrangement. * When we start the motor ,the lever converts the rotary motion to vertical or reciprocating motion. By this our hammer is attached so by the help of this arrangement we run the hammer by dc motor.

DIMENSIONSHammer : 3 kg flat type Wooden base : 2x4 feetDC motor : 30 40 rpmBushes : length = 8cm, outer diameter = 4cm Al coated Iron material : 100cm Motor lever : 20cm (48 inches) Al L-angle : 1x1.5 inches Central support : 100cm (height)

CALCULATIONFor motor, N = 30 rpm Power = 2NT/60 = 30 WattsTorque on no load = 7.1 N-mTotal mass of hammer & link(M) = 4kg Force = Mg = 40 N

ADVANTAGESEasy to useEasy to operateEasy constructionReduces time required to handle the jobIt reduces the human effort

FAILURE Length of the lever taken was insufficient to maintain the necessary reciprocating motion for hammering.

The DC motor had to be mounted above some height for smooth and endless motion of the lever arrangement.COST ANALYSISITEMSRATE (In Rupees)Aluminium STRIPS350LEVERS350DC MOTOR2000Fe RODS 1500Welding 1000Other Equipments1000

TOTAL6200USESIt is used in small scale industry.It also used in small workshop where manpower is least.It is used in such workplace where job required is to be handled in proper time and the overall productivity is maintained.THANK YOU !