pro matter

PROJECT REPORT 2015 MOTORIZED MULTI PURPOSE MACHINE
DEPARTMENT OF MECHANICAL 1 ISSAT
CHAPTER 1
INTRODUCTION
The various machining process in manufacturing industries are carried out by
separate machining machine. It need more space requirement and time with high
expenses. But the fabrication of multi operation machine, which contains three
operations in a single machine. The operations are namely drilling, slotting and
shaping. It is a new concept specially meant to reduce the work time and save the
cost. Instead of using a slotting machine we are using the special arrangements for
slotting operation in the drilling machine same for the shaping operation also, so we
can save the investment cost of exceed slotting and shaping machine in the industries.
The machine operates through drilling machine with the bevel gear and cam
mechanism arrangements. Hence exactly we can carry out three operations in this
machine, namely drilling, slotting and shaping. It is a simple in construction and easy
to operate. Driller, Bevel gear, Drill bit, Chuck, Cam mechanism, bearings, slotting
tool, Hacksaw and guide are the main parts used in this machine.
The various machining process in manufacturing industries are carried out by
separate machining machine. It need more space requirement and time with high
expenses. But the fabrication of multi operation machine, which contains three
operations in a single machine. The operations are namely drilling, slotting and
shaping. It is a new concept specially meant to reduce the work time and save the
cost. Instead of using a slotting machine we are using the special arrangements for
slotting operation in the drilling machine same for the shaping operation also, so we
can save the investment cost of exceed slotting and shaping machine in the industries.
The machine operates through drilling machine with the bevel gear and cam
mechanism arrangements. Hence exactly we can carry out three operations in this
machine, namely drilling, slotting and shaping. It is a simple in construction and easy
to operate. Driller, Bevel gear, Drill bit, Chuck, Cam mechanism, bearings, slotting
tool, Hacksaw and guide are the main parts used in this machine.
In this project we are fabricate the multi operating machine using for the
different application. These projects we are using motor and gear arrangement to
operate the machine are any multiple type various machining process variable
operation. Some needs of automation are described below.

1.1 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.The main advantages of all pneumatic systems are economy and
simplicity. Automation plays an important role in mass production.
Nowadays almost all the manufacturing process is being atomized in order to
deliver the products at a faster rate. The manufacturing operation is being atomized
for the following reasons.
 To reduce man power
 To reduce the work load
 To reduce the production time
 To reduce the fatigue of workers

CHAPTER 2
LITERATURE REVIEW
R.Maguteeswaran1, M.Dineshkumar, R.Dineshkumar, K.Karthi, R.Sabariselvan.
“Fabrication of multi process machine”. International journal of research in
Aeronautical and mechanical engineering.
The multi process machine is used to do the multi operations like Drilling,
Cutting, Slotting at a time and which is used to save the time and space requirement
of an industry. The main concept of machine is to do the operations like slotting and
shaping by the use of drilling operation using cam arrangement. Here the bevel gear
arrangement is used for carrying out the operations. Bevel gear is used to
perpendicular (90) power transmission. One of the bevel gear is connected with the
motor and another one with the drill chuck hence when the motor is rotated the drill
chuck also rotates. The motor pulley shaft is connected to a cam arrangement on the
other side. Cam arrangement converts rotary motion into reciprocating motion and the
reciprocating motion is used for the slotting and shaping operation. The slotting toll
and shaping tool are guided by a horizontal guide bush. The up down table is mounted
on a hydraulic bottle jack piston rod hence when the bottle jack handle is pumped the
table height can be adjusted according to the requirement when the after the process is
completed the pressure should be released through pressure relief valve to make the
table come down. A vice is mounted on the table to hold the work piece.
M. Anil Prakash, Nalla Japhia Sudarsan, K. Pavan Kumar and K.Ch.Sekhar.
“Advanced shaper”,International Monthly Refereed Journal of Research In
Management & Technology. Vol II july 13
A shaping machine (usually called shaper) is mainly used for producing flat
surfaces, which may be horizontal, vertical or inclined. Sometimes irregular or curved
surfaces are also produced by shapers. In existing shaping machines the stroke length
can be varied depends upon the changing the distance between centre of the bull gear
and pivot pin. It means the pivot pin will move away or towards the centre of the bull
gear.

In advanced shaping machine the vertical slots are provide on one side of the
shaping machine. The slots can be used to move vertically (either upwards or
downwards) the bull gear position. It makes us easy to change the bull gear position.
It means centre of the bull gear position can be moved away or towards the pivot pin.
When the bull gear is move downwards or towards the pivot pin, stroke length can be
increased or vice versa. In advanced shaping machine the stroke length can be varied
in two types, one is to change the distance between centre of the bull gear and crank
pin and another is to change the vertical distance between centre of the bull gear and
pivot pin. So in an advanced shaping machine, without changing the diameter of the
bull gear and height of shaping machine, we can increase the stroke length greatly.
D.V.Sabariananda1, V.Siddhartha1, B.Sushil Krishnana1, T.Mohanraj. “Design and
Fabrication of Automated Hacksaw Machine”. Second National Conference on
Trends in Automotive Parts Systems and Applications (TAPSA-2014). Volume 3,
Special Issue 2, April 2014.
The objective of this work is to automate the conventional power hacksaw
machine in order to achieve high productivity of work-pieces than the power hacksaw
machine using Microcontroller. The automated machine acquires two inputs from the
user namely the number of pieces to be cut and the length of each piece that is
required to be cut. The inputs are given by the user with the help of a keypad and an
LCD display, which will help the user to verify the data given by him. The operator
need not measure the length of the work-piece that is to be cut and to load and unload
the work-piece from the chuck each time after a piece has been cut. After acquiring
the two inputs from the user, the machine automatically feeds the given length of
work-piece in to a chuck and starts to cut till the given number of work-pieces has
been cut. The machine feeds the work-piece with the help of a conveyor, which is
driven by a DC motor and an IR sensor ensures that the feeding stops when the
specified length has been reached. A pneumatic cylinder is used for holding the work-
piece when cutting operation is done. An AC motor is used to bring about the
reciprocating motion required for cutting the work-pieces. There is a self-weight
attached with the reciprocating mechanism to provide the necessary downward force
required for penetration of hacksaw blade in to the work-piece. When a single piece
has been cut, a limit switch will get triggered by the self-weight mechanism, which is

sensed by the microcontroller to start the cyclic operation again provided if the
specified number of work-pieces has not been cut.
Gautam Jodh , Piyush Sirsat , Nagnath Kakde , Sandeep Lutade. “Design of low Cost
CNC Drilling Machine”. International Journal of Engineering Research and General
Science Volume 2, Issue 2, Feb-Mar 2014.
A drilling machine is a device for making holes in components. The manuall
operated type of drilling machine creates problems such as low accuracy, high setup
time, low productivity, etc. A CNC machine overcomes all these problems but the
main disadvantage of a CNC drilling machine is the high initial cost and requirement
of skilled labour for operating the machine. Hence, there arises a need for a low cost
CNC machine which can not only drill holes with high accuracy and low machining
time but also have low initial cost. The need for skilled operator is eliminated by
providing a software with a more user friendly graphical user interface.
The observations about operator utilization, a rather controversial and complex
subject. If you would like to comment, please e-mail me and explain how your own
experiences compare with what I say. I’ll relate the responses I get in an upcoming
column. Columns From: 1/1/2008 Modern Machine Shop, Mike Lynch
Many companies use one operator to run more than one CNC machine.
Indeed, I’d bet the majority of companies in the United States use at least some of
their operators in this manner.
Several factors contribute to the wisdom of having one operator run two or
more CNC machines. Some of the most important considerations include lot sizes;
cycle times; setup times; machine costs versus operator costs; urgency of getting jobs
done; and even availability of skilled operators in your area
In many cases, I disagree with the decision to use one operator to run multiple
machines—at least from a cost standpoint. I’ve been in many companies in which
using operators in this fashion actually costs more than having a separate operator run
each machine.
I suspect that at least part of the reason some companies have one operator
running multiple machines are that management just can’t stand to see someone idle.
While this may be an important concern, a hasty decision to have one operator run

multiple machines often results in much lower overall machine output. Again, this
may cost more than having a separate operator run each machine.
My discussions will be limited to comparing costs from having a separate
operator for each machine, as opposed to one operator for two machines. This means,
of course, that you must know your costs. The only costs in this equation are machine
cost and operator cost.
2.1 MACHINE COST
For this purpose, machine cost is the hourly rate a company pays to use the
machine (not the cost your company charges for the machine’s use). At the very least,
it is the monthly payment a company makes (loan/lease) divided by the number of
hours per month the machine is in use.
There is usually much more involved with determining machine cost than just
the monthly payment. Cost of upkeep, which includes preventive maintenance,
lubricants, coolant and even crash repair, should be included in your machine-cost
calculation. Some companies also include the cost of floor space the machine
requires.
Note that I’m not including tooling of any kind in the machine cost. We need
only the amount of money your company must pay per hour for the machine’s use.
(By the way, if no one in your company can tell you the cost of each machine, find
out why.) Machine cost should be an important factor in determining the amount of
profit your company makes for each job you do or the product you sell.
For accounting purposes, some companies apply a blanket rate to the machines
they own. For these companies, every machine the company owns—be it a $5,000
knee mill or a $200,000 CNC machine—has the same cost per hour. This may be
good for approximating purposes, but it won’t be accurate enough for making wise
decisions related to operator utilization.
2.2 OPERATOR COST
Again, we’re looking for a cost per hour. This cost will, of course, include the
operator’s wages. But like machine cost, there is more involved with determining
operator cost. All benefits the operator receives (insurance, employment taxes and
retirement-fund contributions) are among the costs you must consider.

It is not unusual for the total of all benefits to equal or exceed the operator’s
hourly wage. For our examples, we’ll simply double the operator’s hourly wage for
the operator cost.
2.3 QUICK COMPARISON
The more the operator’s cost, the more advantageous it will be to have one
operator run two or more machines. The more each machine’s cost, the less
advantageous it will be to have one operator run two or more machines.
In many companies I’ve visited, a manager can point out every penny that
goes into what an operator costs (again, wages plus benefits). One company I visited
even includes the cost of the parking space the operator uses to park his or her car.
However, when it comes to machine costs, they are not nearly so knowledgeable and
diligent. Again, having an accurate value for both operator and machine cost is of
paramount importance to making wise operator-utilization decisions. Inflated operator
costs and/or devalued machine costs lead to poor operator-utilization decisions. It will
appear that using one operator for two or more machines is more cost-effective than it
really is.
Though I may be getting ahead of myself a bit, note that the maximum cost
benefit you can expect per hour is the cost of one operator. Think about it. When you
have one operator running two machines instead of a separate operator for each
machine, the most you can gain per hour is the hourly cost of one operator.
The VAS-T machines incorporate secondary operations with traditional thread
rolling and bending.
Machines are capable of performing the following operations:
 Wire feeding and straightening by Videx’s reciprocating straightener.
 Cutting to precise length, using a positive stop with a short cut sensor.
 Secondary Operations Including; Chamfer Cutting, Cross Drilling, End
Drilling, Flattening, Stamping, Marking, Grooving, or even Assembly
of pins, washers, or flux balls, etc.

 Thread Rolling on a planetary system, using the “Controlled Start
Technique”.
 Bending optional) using the “Slide Die Bender” adjustable throughout
the machine range.
The VAS-T line is used for production of a wide range of parts such as B7
Studs, Weld Studs, Long blanks for long Headed Bolts, Bicycle Shafts with rounded
ends, Pre-pointed Bolts, Blanks for High Tensile Steel and Stainless Steel Threaded
Rods.
The chips from the turning process are separated and diverted into a bin
outside the machine. The machines are equipped with a Quick-Change System, which
allows effective manufacturing of short production batches, using less skilled
operators. The VAS-T line has the capacity to combine any number and any
combination of operations in one machine. Expected production rates are 30-60 PPM,
depending upon the type of secondary operations.

CHAPTER 3
DESCRIPTION OF EQUIPMENTS
Different equipments are used in fabrication of multipurpose machine, and
they are described below
3.1 INDUCTION MOTOR (IM)
An induction motor (IM) is a type of alternating current motor where power is
supplied to the rotating device by means of electromagnetic induction. It is also called
asynchronous motor.
An electric motor converts electrical power to mechanical power in its rotor
(rotating part). There are several ways to supply power to the rotor. In a DC motor
this power is supplied to the armature directly from a DC source, while in an
induction motor this power is induced in the rotating device.
Fig.3.1 Motor

An induction motor is sometimes called a rotating transformer because the
stator (stationary part) is essentially the primary side of the transformer and the rotor
(rotating part) is the secondary side. Induction motors are widely used, especially
polyphase induction motors, which are frequently used in industrial drives.
Induction motors are now the preferred choice for industrial motors due to
their rugged construction, absence of brushes (which are required in most DC motors)
and thanks to modern power electronics the ability to control the speed of the motor.
3.2 PRINCIPLE OF OPERATION AND COMPARISON TO SYNCHRONOUS
MOTORS
The basic difference between an induction motor and a synchronous AC motor
is that in the latter a current is supplied onto the rotor. This then creates a magnetic
field which, through magnetic interaction, links to the rotating magnetic field in the
stator which in turn causes the rotor to turn. It is called synchronous because at steady
state the speed of the rotor is the same as the speed of the rotating magnetic field in
the stator.
By way of contrast, the induction motor does not have any direct supply onto
the rotor; instead, a secondary current is induced in the rotor. To achieve this, stator
windings are arranged around the rotor so that when energized with a polyphase
supply they create a rotating magnetic field pattern which sweeps past the rotor. This
changing magnetic field pattern induces current in the rotor conductors. These
currents interact with the rotating magnetic field created by the stator and in effect
cause a rotational motion on the rotor.
However, for these currents to be induced, the speed of the physical rotor and
the speed of the rotating magnetic field in the stator must be different, or else the
magnetic field will not be moving relative to the rotor conductors and no currents will
be induced. If by some chance this happens, the rotor typically slows slightly until a
current is re-induced and then the rotor continues as before. This difference between
the speed of the rotor and speed of the rotating magnetic field in the stator is called
slip. It is unit less and is the ratio between the relative speed of the magnetic field as

seen by the rotor (the slip speed) to the speed of the rotating stator field. Due to this
an induction motor is sometimes referred to as an asynchronous machine.
3.3 CONSTRUCTION
The stator consists of wound 'poles' that carry the supply current to induce a
magnetic field that penetrates the rotor. In a very simple motor, there would be a
single projecting piece of the stator (a salient pole) for each pole, with windings
around it; in fact, to optimize the distribution of the magnetic field, the windings are
distributed in many slots located around the stator, but the magnetic field still has the
same number of north-south alternations. The number of 'poles' can vary between
motor types but the poles are always in pairs (i.e. 2, 4, 6, etc.).
Induction motors are most commonly built to run on single-phase or three-
phase power, but two-phase motors also exist. In theory, two-phase and more than
three phase induction motors are possible; many single-phase motors having two
windings and requiring a capacitor can actually be viewed as two-phase motors, since
the capacitor generates a second power phase 90 degrees from the single-phase supply
and feeds it to a separate motor winding. Single-phase power is more widely available
in residential buildings, but cannot produce a rotating field in the motor (the field
merely oscillates back and forth), so single-phase induction motors must incorporate
some kind of starting mechanism to produce a rotating field. They would, using the
simplified analogy of salient poles, have one salient pole per pole number; a four-pole
motor would have four salient poles. Three-phase motors have three salient poles per
pole number, so a four-pole motor would have twelve salient poles. This allows the
motor to produce a rotating field, allowing the motor to start with no extra equipment
and run more efficiently than a similar single-phase motor.

3.4 TYPES OF ROTOR
There are different types of rotor are avalabile for the opereations called slip
ring rotor, solid core rotor
3.4.1 Squirrel-Cage Rotor
The most common rotor is a squirrel-cage rotor. It is made up of bars of either
solid copper (most common) or aluminum that span the length of the rotor, and are
connected through a ring at each end. The rotor bars in squirrel-cage induction motors
are not straight, but have some skew to reduce noise and harmonics.
3.4.2 Slip Ring Rotor
A slip ring rotor replaces the bars of the squirrel-cage rotor with windings that
are connected to slip rings. When these slip rings are shorted, the rotor behaves
similarly to a squirrel-cage rotor; they can also be connected to resistors to produce a
high-resistance rotor circuit, which can be beneficial in starting
3.4.3 Solid Core Rotor
A rotor can be made from solid mild steel. The induced current causes the
rotation.
3.5 DRILLING MACHINE
Drilling is a machine process by which a hole is produced or enlarged by a
drill. Drill is a revolving tool. It is usually the most effective and economic method of
producing hole in solid materials. The hole is produced either by giving movement to
the rotating drill or moving the work axially against the rotating drill. Drilling
machine is more suitable than lathe and vertical milling machine. Drilling machine
can also be used for boring, reaming, tapping and spot facing. It is specific type of end
cutting tool called drill. It is used for drilling holes. It carries the cutting edge at the
flat end or at the end of flute.

Fig.3.2 Drill Bit Nomenclature
Drilling tool is a cylindrical end-cutting tool used to originate or enlarge circular holes
in solid material.
Usually, drills are rotated by a drilling machine and fed into stationary work,
but on other types of machines a stationary drill may be fed into rotating work or drill
and work may rotate in opposite directions. To form the two cutting edges and to
permit the admission of a coolant and the ejection of chips, two longitudinal or helical
grooves or flutes are provided. The point, or tip, of a drill is usually conical in shape,
and it has cutting edges where the flutes end. The angle formed by the tapering sides
of the point determines how large a chip is taken off with each rotation of the drill.
The degree of twist of the helical flutes also affects the drill’s cutting and chip-
removal properties. For general-purpose twist drills the helix angle is about 32°. The
angle formed by the two sides of the tapering point is 118° for standard drills, while
for drilling tough metals, a flatter point with a 135° angle is recommended.
The peripheral portion of the drill body not cut away by the flutes is called the
land, and to reduce friction and prevent the land from rubbing against the sides of the
hole, most of the land is cut away, leaving a narrow ridge called the margin that
follows the edge of the side of the flute that forms the cutting edge. The fluted part, or
body, of a drill is either hardened high-carbon steel or high-speed steel; other drills

have inserts of cemented carbide to form cutting edges or are made from sintered-
carbide rods. The shanks of twist drills are either straight or tapered and when not
integral with the body are made from low-carbon steel and welded to the body.
Straight-shank drills must be gripped in a chuck; tapered shanks fit with a sticking
taper in matching holes in the machine and are driven partly by the taper and partly by
a tang that fits in a slot in the machine. For enlarging cored, punched, or drilled holes,
core drills are particularly suited. These have three or four flutes, and because the
cutting edges do not extend to the centre of the drill, they cannot originate holes in
solid materials. Cutting is accomplished by a chamfered edge at the end of each flute.
3.6 BELT AND PULLEY
Belt and pulley mechanism is provided for transmitting drive from the motor
to drill spindle and cam arrangement.
3.6.1 Pulley
A pulley is a wheel with a groove along its edge, also called a sheave, for
holding a rope or cable. Pulleys are usually used in sets designed to reduce the amount
of force needed to lift a load. The same amount of work is necessary for the load to
reach the same height as it would without the pulleys. The magnitude of the force is
reduced, but it must act through a longer distance. The effort needed to pull a load up
is roughly the weight of the load divided by the number of wheels. The more wheels
there are, the less efficient a system is, because of more friction between the rope and
the wheels.
The pulleys and lines are weightless, and that there is no energy loss due to
friction. It is also assumed that the lines do not stretch. With this assumption, it
follows that, in equilibrium, the total force on the pulley must be zero. This means
that the force on the axle of the pulley is shared equally by the two lines looping
through the pulley. The lines are not parallel, the tensions in each line are still equal,
but now the vector sum of all forces is zero.
A second basic equation for the pulley follows from the conservation of
energy the product of the weight lifted times the distance it is moved is equal to the
product of the lifting force times the distance the lifting line is moved. The weight
lifted divided by the lifting force is defined as the advantage of the pulley system. It is

important to notice that the amount of work done in an ideal pulley is always the
same. The work is given by the effort times the distance moved. The pulley simply
allows trading effort for distance.
3.6.2 Belt
Belts are used to mechanically link two or more rotating items. They may be
used as a source of motion, to transmit power at up to 98% efficiency between two
points, or to track relative movement.
Fig. 3.3 Pulley and Belt
As a source of motion, a conveyor belt is one application where the belt is
adapted to continually carry a load between two points. A belt may also be looped
between two points so that the direction of rotation is reversed at the other point.
Power transmission is achieved by specially designed belts and pulleys. The demands
on a belt drive transmission system.
Belts normally transmit power only on the tension side of the loop. Designs
for continuously variable transmissions exist that use belts that are a series of solid
metal blocks, linked together as in a chain, transmitting power on the compression
side of the loop.
3.7 CAM
A cam is a projecting part of a rotating wheel or shaft that strikes a lever at
one or more points on its circular path. The cam can be a simple tooth, as is used to
deliver pulses of power to a steam hammer, for example, or an eccentric disc or other
shape that produces a smooth reciprocating (back and forth) motion in the follower
which is a lever making contact with the cam.

The reason the cam acts as a lever is because the hole is not directly in the
centre, therefore moving the cam rather than just spinning. On the other hand, some
cams are made with a hole exactly in the centre and their sides act as cams to move
the levers touching them to move up and down or to go back and forth.
3.8 HYDRAULIC BOTTLE JACK
Bottle jacks are hydraulic jacks that are placed in a horizontal position. These
jacks push against a lever, which lifts the main lift arm. Bottle jacks have a longer
handle than most hydraulic jacks, however, and it is possible to get more lift per
stroke with the increased leverage they provide when compared to regular models of
jacks. Bottle jacks are versatile because their horizontal position makes it possible to
place them in tight spots and provides good leverage. Recently bottle jacks have
proven useful in search and rescue missions following earthquake damage. As a
result, bottle jacks are standard equipment in firehouses and for search and rescue
teams. They are also used for lifting, spreading, bending, pushing, pressing, or
straightening requirements. The base and cylinders of bottle jacks are electrically
welded for strength, and all models are capable of working in upright, angled, or
horizontal positions.
Fig. 3.4 Hydraulic Jack

3.8.1 Characteristics and Properties for Hydraulic Oils
Low temperature sensitivity of viscosity;
Thermal and chemical stability;
Low compressibility;
Good lubrication (anti-wear and anti-stick properties, low coefficient of friction);
Hydrolitic stability (ability to retain properties in the high humidity environment);
Low pour point (the lowest temperature, at which the oil may flow);
Water emulsifying ability;
Filterability;
Rust and oxidation protection properties;
Low flash point(the lowest temperature, at which the oil vapors are ignitable);
Resistance to cavitation;
Low foaming;
Compatibility with sealant materials.
3.8.2 Types of Hydraulic Fluids
Optimal properties of hydraulic oils are achieved by a combination of a base
oil and additives (anti-wear additives, detergents, Anti-oxidants, anti-foaming agents,
Corrosion inhibitors etc.).
1. Mineral hydraulic oil (petroleum base).
Mineral based oils are the most common and low cost hydraulic fluids. They
possess most of the characteristics important for hydraulic oils. The disadvantages of
mineral (petroleum) based oils are their low fire resistance (low flash point), toxicity
and very low biodegradability.

2. Phosphate ester based synthetic hydraulic fluids.
Phosphate esters are produced by the reaction of phosphoric acid with
aromatic alcohols. Phosphate esters based hydraulic fluids possess excellent fire
resistance; however they are not compatible with paints, adhesives, some polymers
and sealant materials. They are also toxic.
3. Polyol ester based synthetic hydraulic fluids.
Polyol esters are produced by the reaction of long-chain fatty acids and
synthesized alcohols. Polyol ester based hydraulic fluids are fire resistant and possess
very good lubrication properties. They are environmentally friendly but their use is
limited by high cost.
4. Water glycol synthetic hydraulic fluids.
Water glycol based fluids contain 35-60% of water in form of solution (not
emulsion) and additives (anti-foam, anti-freeze, rust and corrosion inhibitors, anti-
wear etc.). Water glycol based hydraulic fluids possess excellent fire resistance, they
are non-toxic and biodegradable. However their temperature range is relatively low:
32°F - 120°F (0°C - 49°C). Water evaporation causes deterioration of the hydraulic
fluids properties.
5. Vegetable hydraulic oils.
Vegetable hydraulic oils are produced mainly from Canola oil. Their chemical
structure is similar to that of polyol esters. Vegetable hydraulic oils possess very good
lubrication properties and high viscosity index (low temperature sensitivity of
viscosity). They are non-toxic and biodegradable. The main disadvantage of vegetable
hydraulic oils is their relatively low oxidation resistance.
3.8.3 Viscosity of Hydraulic Oils
Viscosity of a hydraulic fluid depends on its composition and the temperature.
Low viscosity limit is determined by the lubrication properties of the oil and its
resistance to cavitation. Upper viscosity value is limited by the ability of the oil to be
pumped.

Common viscosity of hydraulic oils is in the range 16 - 100 centistokes.
Optimum viscosity value is 16 - 36 centistokes.
3.8.4 Safety Instructions
1. Park the vehicle or load to be lifted on a flat firm surface and place wedges under
the wheels to stop movement.
2. Position de jack on a solid, even and horizontal surface, never use the jack on a
slope.
3. The jack should be positioned so as to avoid the user from having to operate it
under the vehicle. Every vehicle lifted by a jack should always have a secondary
safety support such as mechanical stands.
4. It is imperative that all possible precautions are taken to avoid unexpected
movement of the load when it is being lifted.
5. The load to be lifted should never exceed the rated capacity of the jack.
6. Never operate the jack beyond its maximum stroke.
7. If these basic rules are not followed, injury to the user, the jack or the load being
lifted may result.
8. As an additional safety feature the jack is equipped with a valve to prevent the unit
from being overloaded. This unit is factory set and must no be tampered with.
3.8.5 Use and Operation
1. Before operating the jack you must purge its hydraulic circuit in order to eliminate
any possible air in the system. To purge the system open the release valve, turning it
anti-clockwise. Then with the aid of the lever operate the pump several times.
2. Close the release valve with the lever in a clockwise direction until it is fully
closed. The jack is now ready for use.
3. To lower the jack, turn the release valve very slowly in an anti-clockwise direction.

4. Always keep the jack in vertical position, with the ram, extension screw and pump
retracted after use.
5. If you require operating the jack in a horizontal manner the pump should be located
on the lower side of the jack.
3.8.6 Maintenance
1. Lubricate all moving parts at regular intervals.
2. Always keep the jack clean and protected from aggressive conditions.
3. If you have to replace the oil, the correct volume is indicated in the parts list. Make
sure the piston is fully retracted.
Important: An excess of oil will render the jack inoperative.
4. Use only hydraulic oil, type HL or HM, with an ISO grade cinematic viscosity of
30 c St at 40º C or an Engler viscosity of 3 at 50º C.
Very important: Never use brake fluid.
5. When ordering spare parts, please make note of the part number as shown in the
exploded view drawing provided. A repair kit is available containing all the common
spare parts
3.8.7 Repair
Both maintenance and repair of this jack shall be carried out by qualified persons
who on base of their education and experience have enough knowledge in jacks and
associated equipment.
3.9 BEVEL GEAR
Two important concepts in gearing are pitch surface and pitch angle. The pitch
surface of a gear is the imaginary toothless surface that you would have by averaging
out the peaks and valleys of the individual teeth. The pitch surface of an ordinary gear
is the shape of a cylinder. The pitch angle of a gear is the angle between the face of

the pitch surface and the axis. The most familiar kinds of bevel gears have pitch
angles of less than 90 degrees and therefore are cone-shaped. This type of bevel gear
is called external because the gear teeth point outward. The pitch surfaces of meshed
external bevel gears are coaxial with the gear shafts; the apexes of the two surfaces
are at the point of intersection of the shaft axes. Bevel gears that have pitch angles of
greater than ninety degrees have teeth that point inward and are
called internal bevel gears.
Fig. 3.5 Bevel Gear
3.10 BEARING
A bearing is a device to permit constrained relative motion between two parts,
typically rotation or linear movement. Bearings may be classified broadly according
to the motions they allow and according to their principle of operation. Low friction
bearings are often important for efficiency, to reduce wear and to facilitate high
speeds. Essentially, a bearing can reduce friction by virtue of its shape, by its material,
or by introducing and containing a fluid between surfaces.
By shape, gains advantage usually by using spheres or rollers. By material,
exploits the nature of the bearing material used. Sliding bearings, usually called
bushes bushings journal bearings sleeve bearings rifle bearings or plain bearings.
Rolling-element bearings such as ball bearings and roller bearings. Jewel bearings, in

which the load is carried by rolling the axle slightly off-center. fluid bearings, in
which the load is carried by a gas or liquid magnetic bearings, in which the load is
carried by a magnetic field. Flexure bearings, in which the motion is supported by a
load element which bends. Bearings vary greatly over the forces and speeds that they
can support. Forces can be radial, axial (thrust bearings) or moments perpendicular to
the main axis. Bearings very typically involve some degree of relative movement
between surfaces, and different types have limits as to the maximum relative surface
speeds they can handle, and this can be specified as a speed in ft/s or m/s.
The moving parts there is considerable overlap between capabilities, but plain
bearings can generally handle the lowest speeds while rolling element bearings are
faster, hydrostatic bearings faster still, followed by gas bearings and finally magnetic
bearings which have no known upper speed limit.
A linear-motion bearing or linear slide is a bearing designed to provide free
motion in one dimension. There are many different types of linear motion bearings
and this family of products is generally broken down into two sub-categories: rolling-
element and plane.
Motorized linear slides such as machine slides, XY tables, roller tables and
some dovetail slides are bearings moved by drive mechanisms. Not all linear slides
are motorized and non-motorized dovetail slides, ball bearing slides and roller slides
provide low-friction linear movement for equipment powered by inertia or by hand.
All linear slides provide linear motion based on bearings, whether they are ball
bearings, dovetail bearings or linear roller bearings. XY Tables, linear stages,
machine slides and other advanced slides use linear motion bearings to provide
movement along both X and Y multiple axis.
There are many types of bearings, each used for different purposes either
singularly or in combinations. These include ball bearings, roller bearings, ball thrust
bearings, roller thrust bearings and tapered roller thrust bearings.

3.10.1 Ball bearings
Fig. 3.6 Ball Bearing
Ball bearings, as shown to the left, are the most common type by far. They are
found in everything from skate boards to washing machines to PC hard drives. These
bearings are capable of taking both radial and thrust loads, and are usually found in
applications where the load is light to medium and is constant in nature (ie not shock
loading). The bearing shown here has the outer ring cut away revealing the balls and
ball retainer.
3.10.2 Roller bearings
Fig. 3.7 Roller Bearing
Roller bearings like the one shown to the left are normally used in heavy duty
applications such as conveyer belt rollers, where they must hold heavy radial loads. In
these bearings the roller is a cylinder, so the contact between the inner and outer race
is not a point (like the ball bearing above) but a line. This spreads the load out over a
larger area, allowing the roller bearing to handle much greater loads than a ball
bearing. However, this type of bearing cannot handle thrust loads to any significant
degree. A variation of this bearing design is called the needle bearing. The needle
roller bearing uses cylindrical rollers like those above but with a very small diameter.
This allows the bearing to fit into tight places such as gear boxes that rotate at higher
speeds.

3.10.3 Thrust ball bearings
Fig.3.8 Thrust Bearing
Ball thrust bearings like the one shown to the left are mostly used for low-
speed non precision applications. They cannot take much radial load and are usually
found in lazy susan turntables and low precision farm equipment.
3.10.4 Roller thrust bearing
Fig.3.9 Roller Thrust Bearing
Roller thrust bearings like the one illustrated to the left can support very large
thrust loads. They are often found in gearsets like car transmissions between gear
sprockets, and between the housing and the rotating shafts. The helical gears used in
most transmissions have angled teeth; this can causes a high thrust load that must be
supported by this type of bearing.
3.10.5 Taper roller bearing
Fig. 3.10 Taper Roller Bearing
Tapered roller bearings are designed to support large radial and large thrust
loads. These loads can take the form of constant loads or shock loads. Tapered roller

bearings are used in many car hubs, where they are usually mounted in pairs facing
opposite directions. This gives them the ability to take thrust loads in both directions.
The cutaway taper roller on the left shows the specially designed tapered rollers and
demonstrates their angular mounting which gives their dual load ability.
The above bearing types are some of the most common. There are thousands
of other designs, some standard and some specific applications but all perform the
same basic function. Essentially further types of bearings usually take all or some of
the characteristics of the above bearings and blend them into one design. Through the
use of careful material selection and applying the correct degree of machining
precision, a successful bearing solution can usually be found.
3.11 VICE
It is a device consisting of two parallel jaws for holding a work piece; one of
the jaws is fixed and the other movable by a screw, a lever, or a cam. When used for
holding a work piece during hand operations, such as filing, hammering, or sawing,
the vise may be permanently bolted to a bench. In vises designed to hold metallic
work pieces, the active faces of the jaws are hardened steel plates, often removable,
with serrations that grip the work piece; to prevent damage to soft parts, the
permanent jaws can be covered with temporary jaws made from sheet copper or
leather. Pipe vises have double V-shaped jaws that grip in four places instead of only
two. Woodworking vises have smooth jaws, often of wood, and rely on friction alone
rather than on serrations.
For holding work pieces on the tables of machine tools, vises with smooth
hardened-steel jaws and flat bases are used. These machine vises are portable but may
be clamped to the machine table when in use; means may also be provided for
swiveling the active part of the vise so that the work piece can be held in a variety of
positions relative to the base. For holding parts that cannot be clamped with flat jaws,
special jaws can be provided.

For holding parts that cannot be clamped with flat jaws, special jaws can be provided.
Fig. 3.11 Vice
3.12 HACK SAW
A hacksaw is a fine-toothed saw, originally and principally for cutting metal.
They can also cut various other materials, such as plastic and wood; for
example, plumbers and electricians often cut plastic pipe and plastic conduit with
them. There are hand saw versions and powered versions (power hacksaws). Most
hacksaws are hand saws with a C-shaped frame that holds a blade under tension. Such
hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow
disposable blade. The frames may also be adjustable to accommodate blades of
different sizes. A screw or other mechanism is used to put the thin blade under
tension. Panel hacksaws forgo the frame and instead have a sheet metal body; they
can cut into a sheet metal panel further than a frame would allow. These saws are no
longer commonly available, but hacksaw blade holders enable standard hacksaw
blades to be used similarly to a keyhole saw or pad saw. Power tools including
nibblers, jigsaws, and angle grinders fitted with metal-cutting blades and discs are
now used for longer cuts in sheet metals.
On hacksaws, as with most frame saws, the blade can be mounted with the
teeth facing toward or away from the handle, resulting in cutting action on either the

push or pull stroke. In normal use, cutting vertically downwards with work held in a
bench vice, hacksaw blades should be set to be facing forwards. Some frame saws,
including Fret Saws and Piercing Saws, have their blades set to be facing the handle
because they are used to cut by being pulled down against a horizontal surface.
3.13 CUTTING TOOL
In the context of machining, a cutting tool (or cutter) is any tool that is used to
remove material from the work piece by means of shear deformation. Cutting may be
accomplished by single-point or multipoint tools. Single-point tools are used in
turning, shaping, planning and similar operations, and remove material by means of
one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools
are also multipoint tools. Each grain of abrasive functions as a microscopic single-
point cutting edge (although of high negative rake angle), and shears a tiny chip.
Cutting tools must be made of a material harder than the material which is to
be cut, and the tool must be able to withstand the heat generated in the metal-cutting
process. Also, the tool must have a specific geometry, with clearance angles designed
so that the cutting edge can contact the work piece without the rest of the tool
dragging on the work piece surface. The angle of the cutting face is also important, as
is the flute width, number of flutes or teeth, and margin size. In order to have a long
working life, all of the above must be optimized, plus the speeds and feeds at which
the tool is run.

CHAPTER 4
DESIGN AND DRAWING
The mechanical multipurpose machine is consists of the following
components to full fill the requirements of complete operation of the machine.
4.1 MACHINE COMPONENTS
1. Motor
2. Bevel gear
3. Cam
4. Belt and pulley
5. Hydraulic bottle jack
6. Bevel gear
7. Clamping vice
8. Bearing block
9. Driller

4.2 DRAWING FOR MOTORIZED MULTI PURPOSE MACHINE
(DRILLING, SLOTTING AND CUTTING)
Fig. 4.1 Motorized Multipurpose Machine
Item Description Quantity Meterial
1 Motor 1
2 Hacksaw frame 1 M.S
3 Pulley 1 C.I
4 Drill chuck 1 M.S
5 Column 1 M.S
6 Slotting tool 1 M.S
7 Belt 1 Nylon
8 Bearing 5 S.S
9 Bevel gear 1 S.S

FABRICATED MOTORIZED MULTIPURPOSE MACHINE
Fig.4.2 Fabricated MMPM

4.3 CALCULATIONS
1. Drilling Speed
Np = Ng x (Tg/Tp) rpm (1)
Where, Np = Speed of drill spindle in rpm
Ng = Speed of gear=120rpm
Tg = No. of gear teeth=17
Tp = No. of pinion teeth=13
Hence,Np = 120x(17/13)=156rpm
2. Slotting Velocity
V = L xN x(1+K)/1000 m/min (2)
Where, L = Stroke Length=80mm
N = No. of Cutting stroke/ min=145
K = return stroke time/ cutting stroke time=1
Hence, V = 80x145x(1+1)/1000=23.2m/min
3. Cutting Speed of Hack saw
Ns = Da/Db x Nm rpm (3)
Where, Ns = wheel speed in rpm
Nm= speed of motor in rpm=1400rpm
Da = dia of small pulley in mm=30mm
Db = dia of large pulley in mm =290mm
Hence,Ns = (30/290)x1400=145rpm

CHAPTER 5
WORKING PRINCIPLE
Here the bevel gear arrangement is used for carrying out the operations. Bevel
gear is used to perpendicular (900) power transmission. One of the bevel gear is
connected with the motor and another one with the drill chuck hence when the motor
is rotated the drill chuck also rotates. The motor pulley shaft is connected to a cam
arrangement on the other side. Cam arrangement converts rotary motion into
reciprocating motion and the reciprocating motion is used for the slotting and cutting
operation. The slotting tool and cutting tool are guided by a horizontal guide bush.
The up down table is mounted on a hydraulic bottle jack piston rod hence when the
bottle jack handle is pumped the table height can be adjusted according to the
requirement when the after the process is completed the pressure should be released
through pressure relief valve to make the table come down. A vice is mounted on the
table to hold the work piece.

CHAPTER 6
MERITS & DEMERIT
6.1 MERITS
 Easy To Implement
 Low cost
 Low maintenance
 Easy to operate
 Reduces time and increases production rate
 Multi operations are performed at one time
 All Operations performed by only one motor
 Time Saving
 Less Man power is required
6.2 DEMERIT
 Uneven forces acts on the wok piece
 Only small components can be machined

CHAPTER 7
APPLICATION
 Used in small scale industries to reduce machine cost.
 In such places where frequent change in operation are required.

CHAPTER 8
LIST OF MATERIALS
The various factors which determine the choice of material are discussed
below.
8.1 PROPERTIES
The material selected must possess 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, eleastic limit, endurance limit, and modulus of elasticity, hardness,
wear resistance and sliding properties.
The various properties concerned from the manufacturing point of view are,
 Cast ability
 Weld ability
 Surface properties
 Shrinkage
 Deep drawing etc.

8.2 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.
8.3 QUALITY REQUIRED
This generally affects the manufacturing process and ultimately the material.
For example, it would never be desirable to go casting of a less number of
components which can be fabricated much more economically by welding or hand
forging the steel.
8.4 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.
8.5 SPACE CONSIDERATION
Sometimes high strength materials have to be selected because the forces involved are
high and space limitations are there.
8.6 COST
As in any other problem, in selection of material the cost of material plays an
important part and should not be ignored.
Sometimes factors like scrap utilization, appearance, and non-maintenance of
the designed part are involved in the selection of proper materials

Table 8.1 Cost of Particulars
Sl.No. Particulars Total Quantity
Cost Rs./- Per
Unit
Total Cost
1 Motor-1440 rpm 1 2250 2250
2 Pulley-290mm 1 450 450
3 Pulley-30mm 1 150 150
4 v-Belt 1 200 200
5 Ball bearing 5 100 500
5 Bevel Gear Set 1 850 850
6 Hydraulic Jack 1 1100 1100
7 Drill Chuck-3/8” 1 600 600
8 Vice 1 650 650
9 Hack Saw Frame 1 100 100
10 Material Cost 5350 5350
11 Labour Cost 4250 4250
12 Transport 500 500
13 Paint & Painting Items 350 350

CHAPTER 9
COST ESTIMATION
1. LABOUR COST
Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost
2. OVERGHEAD CHARGES
The overhead charges are arrived by” manufacturing cost”
Manufacturing Cost =Material Cost + Labor Cost
=5350+4250
=9600/-
Overhead Charges =20%of the manufacturing
=4850x20/100
=1070/-
3. TOTAL COST
Total cost = Material Cost +Labor Cost +Overhead Charges
=5350+4250+1070
=10670
Total cost for this project =10670/-

CHAPTER 10
FUTURE IMPLEMENTATION
 We can perform various operations like Cutting,Drilling,or Slotting individually
by introducing coupling (engagement and disengagement) between them
 We can perform Grinding Operation by introducing a grinding tool at the
Machining Shaft
 We can perform boring operation by introducing a boring tool by replacing
drilling tool.
 We can change the speed of Motor by Regulator.

CHAPTER 11
CONCLUSION
This project is made with pre planning, that it provides flexibility in operation.
This innovation has made the more desirable and economical. The project “Motorized
Multi Purpose Machine (Drilling, Slotting and Cutting)” is designed with the hope
that it is very much economical and helps full to power transmitter to the driving unit
with variable speed. This project helped us to know the periodic steps in completing a
project work. Thus we have completed the project successfully.

REFERANCE
[1] R Maguteeswaran1,M Dineshkumar,R Dineshkumar,K Karthi.“Fabrication of
multi process machine”. International journal of research in Aeronautical and
mechanical engineering.Vol 2 issue 2. PP 105-111
[2] 2013, M. Anil Prakash, Nalla Japhia Sudarsan, K. Pavan Kumar and
K.Ch.Sekhar. “Advanced shaper”,International Monthly Refereed Journal of
Research In Management & Technology. Vol II
[3] 2014, D.V.Sabariananda1, V.Siddhartha1, B.Sushil Krishnana1, T.Mohanraj.
“Design and Fabrication of Automated Hacksaw Machine”. Second National
Conference on Trends in Automotive Parts Systems and Applications
(TAPSA-2014). Volume 3, Special Issue 2.
[4] 2014 Gautam Jodh , Piyush Sirsat , Nagnath Kakde , Sandeep Lutade. “Design
of low Cost CNC Drilling Machine”. International Journal of Engineering
Research and General Science Volume 2, Issue 2, Feb-Mar 14.

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