4. CONTENTS
Sl.No NAME OF THE CONTENT PAGE NO.
1 SYNOPSIS 4
2 INTRODUCTION 6
3 PROJECT PLANNING 11
4 CONSTRUCTION 19
5 WORKING PRINCIPLE 22
6 LIST OF MATERIAL 24
7 SAFETY ,PRECAUTION 26
8 PLUMMER BLOCK 28
9 DRAWING 41
10 FEATURES OF THE PROJECT 43
11 COST ESTIMATION 46
12 CONCLUSION 48
13 BIBILIOGRAPHY 50
5. INTRODUCTION
OBJECTIVE;
1. To reduce the job setting ,marking and punching time
2. To reduce the labour cost by providing automatic job feeding and punching
machine.
DEFINITION OF PROBLEM;
In conventional punching machine, the job is to marked before punching
operation and set the alignment of the work piece with the punch tool. Moreover
the job is feeded manually for every punch holes. Due to the above reasons, the
entire process takes more time for series of punching hole operations. In this
geneva wheel intermittent drive, the job is feeding automatically during the
return stroke of punching operation.
SCOPE OF THE PROJECT;
Operation is very smooth and in this system we can get more output by
applying less effort.
Simple construction by introducing geneva wheel disc drive transmission.
The job is feeded automatically.
Low cost automation
Less maitenance
6. PRECAUTION BEFORE SELECTION OF THE PROJECT
Before rushing out of buy the material for the component, first determine thesize of
the punch required for punching operation .. Obviously the first thing
to look at is how punching is done on the job .
Whether the punch tool having an easier provisions to make hole against the job or
what extent we modify this. If the job is having easier provision to feed under the
punching tool against the Geneva mechanism and job feeding roller.
8. PROJECT PLANNING
CONCEPT OF THE PROJECT
Before starting every project its planning is to be done. In planning
functions are life the functions of nerves in our body. planning a project is a very
important task and should be taken up with great care as the efficiency of the
whole project largely depends upon its planning, while planning a project each and
every details should be worked out in anticipation should be carefully
consideredwith all the relative provisions aspects.
PROJECT CAPACITY
The capacity of the project must be decided considering theamount of
money which can be invested. The availability of materialand machines and
usefulness of the project.
9. DESIGN AND DRAWING
Having decided about the project to be manufactured at must be designed. Design
work should be done very considering all the relevantfactors.
After design the project detailed drawing are prepared.
DetailedSpecification for raw material and finished products should be
decidedCarefully along with the specification of the machine required for
themanufacture.
MATERIAL REQUIREMENTS
The list of material required for manufacture is prepared from the
drawing. The list is known as “Bill of materials”. Availability ofthese materials is
surveyed and purchased from the market.
OPERATION PLANNING
Next work of planning is to “select the best method” manufacturethe product, so
that the wastage of materials, labour, machines and time can be eliminated by
considering various methods. The best method is to be selected for fabrication and
other works.
10. The proper method and proper person and the purposes of operation,
Necessity operation, proper machine planning. The best method is the
developed and is applied to fabricate the project.
MACHINE LOADING
While planning proper care should be taken to find the machiningtime for the
operation as correct as possible. So that arrangement of full useof machines can be
made and the machine loading program can be decided.
PURCHASE CONSIDERATION
It is difficult to manufacture all the components needed for theproject in the
machine shop. In each case, we should decide whether tomake or buy about a
particular item. It is decided during the planning after making a complete study of
relative merits and demerits.
EQUIPMENT PROCEDURE
Results obtained from “operation planning” and machine loading help
in calculating the equipment require specification of the equipment should be laid
down by consideringthen drawings. Drawings will also help in deciding the
necessary requirement of tools and accessories.
13. CONSTRUCTION
This project consists of
1) 12 VDC Motor with built in speed reduction gear box
2) Chain drive mechanism
3) Job feeding rollers
4) Main shaft with Plummer block support
5) Geneva wheel mechanism
6) Crank wheel
7) Punching tool.
1)12 VDC Motor with built in speed reduction gear box;
This DC motor is shunt type 12V DC motor. This motor is having built in type
speed reduction gear box unit. It has high torque and low speed capacity. The
electrical supply to the motor is from 12 V DC power supply. The DC Motor
drives the chain wheel and geneva wheel mechanism.
14.
15. 2.Crankand connecting rod mechanism;
A crankshaft has one (or more) offset sections where a connecting rod is attached
around it. The connecting rod moves back-and-forth (or up-and-down) ONCE for
every rotation of the crankshaft. The crank will always move in a circle, moving
the connecting rod in a smooth sine wave like motion. The power can flow in
either direction. That is, the crankshaft can drive the connecting rod, or the
connecting rod can drive the crankshaft.
2) Chain drive mechanism;
Chain drive is a way of transmitting mechanical power from one place to another.
It is often used to convey power to the wheels of a vehicle, particularly bicycles
and motorcycles. It is also used in a wide variety of machines besides vehicles.
Most often, the power is conveyed by a roller chain, known as the drive chain or
transmission chain,[1]
passing over a sprocket gear, with the teeth of the gear
meshing with the holes in the links of the chain. The gear is turned, and this pulls
the chain putting mechanical force into the system.
3)Job feeding rollers;
These rollers are used to feed the sheet for punching the holes. The sheet to be
punched is inserted between these two rollers. The input of the job feed roller have
one sprocket wheel.The drive from the motor is connected to crank disc having one
pin called drive pin. Through the drive pin , the power is transmitted to geneva
16. wheel via geneva drive slot . The sprocket wheel is fitted on the other end of the
geneva wheel holding shaft . through the sprocket and chain drive the power is
transmitted to the job feed rollers.when the driving roller is rotated , the driven
roller also rotated by frictional drive .
The job feed rollers have 40mm diameter and 300mm length and made in M.S.
tube.
4.Frame Stand
This base frame stand made in 25mm x 3mm M.S. material square tube and is
used to hold the entire mechanism and support the motor also.
19. PRINCIPLE OF DC MOTOR
A DC motor is a dc machine working as a motor to convert dc electrical
energy into mechanical energy (dc) motor are very commonly used in cars, trucks,
aircrafts, etc. They are also used in large ratings, where wide range of speed
control is necessary.
When a conductor is carried a current and in lying in magnetic filed. Force
acting on the conductor. This is the principle of a Dc motor. The conductor is
housed in armature slots and current is applied from the dc source through brushes
and commutator. The field poles provide the magnetic field.
The construction of dc motor and generator are similar. However their
external appearance may be somewhat different. A motor has a rather closed
frame because it is may be operating in dusty environment and unskilled workers
may be working in its vicinity.
RATINGS OF MOTOR
Motors are rated by their voltage, current draw, output speed, and torque.
Operating Voltage
20. Operating voltage specifies the nominal (normal) voltage the manufacturer
recommends for the motor. Most small DC motors are designed for 1.5 to 12 volt
operation, with the majority in the 3-6 volt range. Larger DC motors designed for
heavy-duty applications usually require 12 to 24 volts, with some needing upwards
of 90 volts. Often, but not always, the higher the voltage, the more powerful the
motor (this does not apply to stepper motors, where very low voltages — on the
order of just a few volts — are common for heavy-duty motors). Most motors can
be run at operating voltages higher or lower than the specified rating.
Lower voltages reduce torque and speed.
Higher voltages increase torque and speed.
(Note: For stepper motors, speed is not greatly altered by changing the voltage.)
Avoid applying excessively high voltages to a motor, or else it could overheat and
burn out. R/C servo motors contain their own electronics which are not designed
for use over about 7.2 volts.
Current Draw
Current draw is the amount of current, specified in milliamps or amps, that the
motor requires to produce a certain amount of torque. Motors consume different
amounts of current depending on how they are operated:
No-load. A motor that doesn‟t have anything attached to its shaft isn‟t doing
any work, and is said to be free-running. No-load current tends to be very low.
Load. As the motor does work, its load and current draw increases.
Manufacturers rate the current draw under load using different standards,
making it hard to judge a motor using this specification alone.
21. Stalled. When the motor shaft stops rotating, it “stalls” and draws as much
current as will flow through the windings. This specification is useful for
“worst case scenario” engineering planning.
Shorted. Maximum current flows into the motor when the coils are shorted
out. The motor will not run, and like any short circuit, if operated in this way
for any length of time, serious damage can result to other systems on the
robot.
Torque
Torque is the way the strength of the motor is measured. It is typically calculated
by attaching a lever to the end of the motor shaft, and a weight or gauge on the end
of that lever. The length of the lever usually depends on the unit of measurement
given for the weight. Examples:
Metric measurements use Newton meters (Nm), kilograms-force meters (kgf-
m), or sometimes gram-centimeters (gm-cm).
Standard measurements use ounce-inches (oz-in), or pound-feet (lb-ft), or
pound-inches (lb-in). It‟s common to reverse the nomenclature and call it
foot-pounds and inch-pounds.
Speed
The speed of the motor indicates how fast its shaft is turning. DC motors without a
gearbox spin at 3,000 to over 12,000 RPM (revolutions per minute). With a gear
box, the speed can vary from under 1 RPM, on up.
Stepping motors are not rated in RPM, but pulses (or steps) per second. The speed
of a stepper motor is a function of the number of steps required to make one full
22. revolution, times the number of steps applied to the motor each second. Typical
values are 200 or 300 PPS.
24. WORKING PRINCIPLE
In this auto roll punching machine consists of two sections. One sections is
automatic metal sheet feeding mechanism and the second section is conversion of
rotary motion into linear reciprocating motion of punching tool . The first section
consists of geneva wheel disc keyed with a shaft at one end and the other end is
connected with chain sprocket wheel. This geneva wheel shaft is supported on
two Plummer block bearings. This sprocket wheel transmit the rotary motion from
the Geneva wheel to the metal sheet feeding rollers through a chain drive. Hence
when the geneva wheel is rotated , the metal sheet also moved for punching
operation.
The second section consists of electrically operated DC motor,plummer block
bearings, crank wheel with a pin ,connecting rod and punching tool. The second
section is used to convert the rotary motion of the crank wheel into reciprocating
motion of punching tool. The rotating shaft is keyed to the crank wheel at one end
and the other end is connected to DC motor. This shaft is supported on two
plummer block bearings. The punch tool slide is reciprocated by the connecting the
crank wheel through the connecting rod .The metal sheet is feeded automatically
by the rotation of geneva wheel.
25. Working principle;
When the switch is ON , the motor rotates the crank wheel. Hence the
punching slide with punching tool moved up and down and make a punch on the
metal sheet. The crank wheel face have a pin which touches the slot in the geneva
wheel and also rotates (indexing) the geneva wheel .Due to the rotation or indexing
of geneva wheel , the metal sheet feeding rollers are rotated through the chain
drive mechanism and hence the metal sheet is feeded automatically.
34. FEATURES OF AUTO PUNCHING MACHINE
It is compact in size
It can be move
electrical power consumption is less
It can be utilized at our work shop
It is simple in construction
Low cost
Less weight and easy to handle
It reduces the man power
It is compact in size.
35. FINISHING AND PAINTING
JOB PREPARATION;
Before welding, remove any bend in the L angle with the sludge hammer on the
anvil block. Then it is cut to the required length with the hacksaw blade and
fabricated to required dimensional shape with arc welding.
FINISHING OPERATION BEFORE PAINTING;
After welding, any slag on the welded area is removed with the chipping hammer
and cleaned with the metal wire brush. Then all the surfaces are rubbed with the
emery sheet.
Metal primer is applied on the surfaces with the brush .After drying the metal
primer, the second coating is applied with the paint.
37. SAFETY,CARE AND MAINTENANCE
Before using the machine, some of the points to be noted for safety purpose,
1. Before starting the operation, check the following items
(1) Check the mechanism for proper operation .
(2) Check the alignment of chain drives, job feed rollers and bearing
in the unit.
(3) Don‟t insert the any material or object between the during
operation of punching.
(4) Check the lubrication of chain drive in the unit.
(5) Handle carefully while punching the work .
40. HANDLING THE PLUMMER BLOCK AND BEARING
Rolling bearings are precision components. To maintain
accuracies, they must be handled very carefully. In particular, they
must be kept clean, not be subjected to long impact, and be
protected against possible rusting. Plummer blocks also need
similar handling practices.
I. INSPECTION BEFORE INSTALLATION
Before installation a bearing and a plummer block, the blowing
point must be thoroughly checked and inspected.
INSPECTION BEFORE INSTALLATION
Prepare installation tools, measured instruments, oil stone,
lubricant and factory cloth. Before the installation work,
remove dust and impurities from these tools
Make sure that the shaft is free from bends or other damages
and that it has been dimensioned and formed as specified.
41. Remove dent marks even through very small from the mating
faces with an oil stone or fine emery paper. Check that the
contact face to the seal has specified surface roughness. Wipe
dust away from the shaft with clean factory cloth.
Remove possible dust and metal chips from the inside of
plumber block.
Check the flatness of the mounting face of the plummer block.
When placed on a frame, the plummer block must be stably
seated.
II. PREPARATION FOR INSTALLINT THE BEARING
42. Unpack the bearing just before the installation work.
If the bearing is to be grease-lubricated, the rust-proof
coating on it may remain unremoved. If it is to be oil-
lubricated, remove the coating with benzene or kerosene.
Preparation for Installing the Bearing
For a bearing with an adapter, check its radial clearance
before the installation work. To do so, place it on a flat work
bench, and fit a thickness gage between the uppermost roller
and the raceway surface on the outer ring to measure the
clearance . Do not force the thickness gage in or turn the
bearing. Otherwise, the resultant clearance measurement will
be greater than the actual clearance.
III. INSTALLATION OF THE BEARING AND ASSOCIATED
COMPONENTS
Once careful checking is complete, install the bearing and
associated components. For the positional relationship.
43. INSTALLATION OF THE BEARING AND ASSOCIATED COMPONENTS
When a bearing is installed onto a shaft or into a housing. Do
not directly hit its end face with a hammer. Otherwise, its design
performance can be lost. Always evenly exert force around the
entire bearing ring face. Also, do not apply force to one bearing ring.
o EXAMPLE; Outer ring
44. To convey the force via the rolling elements to the other bearing ring
inner ring to install the latter. Otherwise, a dent mark or other
damage can occur on either or both rings.
When installing a
cylindrical bore bearing,
whose interference is relatively small, its whole inner rings can
be uniformly press-fitted at an ordinary temperature as
illustrated .Usually, the inner ring is press-fitted by tapping the
sleeve with a hammer. However, when many bearings must be
installed at a time, a mechanical or hydraulic press will be
helpful.
45. When installing a non-separable bearing to the shaft and
housing at a time, apply a press-fitting force to both the inner and
outer rings by using a pressure distribution pad.
IV.ASSEMBLING THE PLUMMER BLOCKS
When installing two or more plummer blocks on a shaft, use
one block to locate the outer ring of a bearing in the axial direction,
and arrange the other block (s) so that the outer ring (s) of bearing
(s) in the latter block (s) can more freely in the axial direction.
ASSEMBLING THE PLUMMER BLOCKS
Once the bearing has been installed to the shaft and the
associated components have been inserted over the shaft, assemble
the plummer blocks according to the following procedure.
V. MAINTENANCE AND INSPECTION
To be able to use a bearing to its design life and avoid by
accident, check the following points at regular servals.
1. Running sound on bearing.
2. Temperature on bearing or plummer block.
3. Vibration on shaft.
4. Leaking grease or worn oil seal.
5. Loose tightening and mounting bolts.
6. Trouble- free operation of the lubrication system, and loosening
or leakage with piping.
46. The bearing arrangement must be inspected while it is a
standstill, check it for the following points:
1. Check appearance the of bearing for any irregularity.
2. Fouling of grease ,or contaminants in grease.
3. Loose adapter sleeve.
4. Worn or damage seal.
VI.BEARING DISASSEMBLY
Straighten the bent tab on the washer, and loosen the nut by
two or three turns. Place a drift to a face of the nut. Sightly tap the
drift to turn the sleeve. Once be sleeve is shifted in the axial can be
direction, the bearing easily removed.
Note,however,when the nut as been excessively loosened
and only a few ridges remain engaged,and if the nut is further
tapped,the threading on the sleeve or nut may be stripped.
47. VII.CYLINDRICAL BORE BEARING
Usually, a cylindrical bore bearing is interference-fitted.
Thus, the bearing is simply drawn out by placing a jig to yhr face of
the inner ring and exerting a forces illustied with a hand press.
However,be careful not to apply a force to the outer ring. When
using this tool, make sure that the jig is fully engaged with the face
of the inner ring.
VIII.CLEANING THE BEARING
Clean the removed bearing with diesel oil or kerosene.
USE TWO VESSELS.
One for rough cleaning and the other for finish cleaning.
Prepare a cleaning station that has a metal screen as illustrated. So
that the bearing does not directly contact the fouling on the bottom
of vessel. In rough cleaning,virtually all oil and foreign matters
should be removed from the bearing which should be immediately
transferred to the finish vessel. The finish vessel must be provide
with a filter unit to maintain the cleaning agent clean.
Once cleaned, the bearing must be immediately rust-proofed.
The bearings (which have been carefully removed) must be
checked whether they can be reused. The judging criterion for reuse
48. should be determined considering the following criteria through a
trial-and-error basis.
1. Scheduled operating duration to next regular inspection.
2. Importance of the machine that uses the bearing in question
3. Operating conditions such as loading and bearing speed.
4. Severity of damage on the rolling contact surface.
5. Tendency of increasing bearing clearance and wear on the
cage.
6. Loss in accuracy, etc.,
IX. STORING THE BEARING
When storing a bearing, pay particular attention to rust
prevention. Note that the rust-proofing grease in the bearing will
run away at a temperature of 50 to 60 C. Therefore, store a bearing
in a dry, cool location at a height at least 30cm above the floor.
Remember that wooden crate attracts moisture. Thus, immediately
unpack the delivered bearings, and store them on shelves.
50. POWER SUPPLY UNIT
INTRODUCTION:
All the electronic components starting from diode to Intel IC‟s only work
with a DC supply ranging from +5V to +12V. We are utilizing for the same, the
cheapest and commonly available energy source of 230V-50Hz and stepping
down, rectifying, filtering and regulating the voltage.
STEP DOWN TRANSFORMER:
When AC is applied to the primary winding of the power transformer, it can
either be stepped down or stepped up depending on the value of DC needed. In our
circuit the transformer of 230V/15-0-15V is used to perform the step down
operation where a 230V AC appears as 15V AC across the secondary winding.
Apart from stepping down voltages, it gives isolation between the power source
and power supply circuitries.
RECTIFIER UNIT:
In the power supply unit, rectification is normally achieved using a solid
state diode. Diode has the property that will let the electron flow easily in one
direction at proper biasing condition. As AC is applied to the diode, electrons only
flow when the anode and cathode is negative. Reversing the polarity of voltage
will not permit electron flow. A commonly used circuit for supplying large
51. amounts of DCpower is the bridge rectifier. A bridge rectifier of four diodes (4 x
IN4007) are used to achieve full wave rectification. Two diodes will conduct
during the negative cycle and the other two will conduct during the positive half
cycle, and only one diode conducts. At the same time one of the other two diodes
conducts for the negative voltage that is applied from the bottom winding due to
the forward bias for that diode. In this circuit due to positive half cycle D1 & D2
will conduct to give 0.8V pulsating DC. The DC output has a ripple frequency of
100Hz. Since each alteration produces a resulting output pulse, frequency = 2 x 50
Hz. The output obtained is not a pure DC and therefore filtration has to be done.
The DC voltage appearing across the output terminals of the bridge rectifier
will be somewhat less than 90% of the applied rms value. Normally one alteration
of the input voltage will reverse the polarities. Opposite ends of the transformer
will therefore always be 180 degree out of phase with each other. For a positive
cycle, two diodes are connected to the positive voltage at the top winding.
FILTERING CIRCUIT:
Filter circuits which is usually capacitor acting as a surge arrester always
follow the rectifier unit. This capacitor is also called as a decoupling capacitor or a
bypassing capacitor, is used not only to „short‟ the ripple with frequency of 120Hz
52. to ground but also to leave the frequency of the DC to appear at the output. A load
resistor R1 is connected so that a reference to the ground is maintained. C1, R1 is
for bypassing ripples. C2, R2 is used as a low pass filter, i.e. it passes only low
frequency signals and bypasses high frequency signals. The load resistor should be
1% to 2.5% of the load.
1000f/25V : for the reduction of ripples from the pulsating
10f/25V : for maintaining the stability of the voltage at the load side.
0.1f : for bypassing the high frequency disturbances
BLOCK DIAGRAM FOR POWER SUPPLY
STEP DOWN BRIDGE POSITIVE
TRANSFORMER RECTIFIER CHARGE
CAPACITOR
5V 12V
REGULATOR REGULATOR
MOTHER DISPLAY
BOARD BOARD RELAY
VOLTAGE REGULATOR:
53. The voltage regulators play an important role in any power supply unit. The
primary purpose of a regulator is to aid the rectifier and filter circuit in providing a
constant DC voltage to the device. Power supplies without regulators have an
inherent problem of changing DC voltage values due to variations in the load or
due to fluctuations in the AC linear voltage. With a regulator connected to the DC
output, the voltage can be maintained within a close tolerant region of the desired
output. IC7812 and 7912 is used in this project for providing +12V and 12V DC
supply.
SPECIFICATION:
Resistors R1 and R2 maintain line load regulation.
At the secondary side of the transformer, applied vlltage = 15V
Conducting drop across the diodes = 2 * 0.6 = 1.2V
Without capacitor:
Vavg = (15-1.2)V = 13.8c pulsating DC
Frequency = 100Hz
With capacitor:
V = Vavg * 1.414 (form factor) = 19.51V
Frequency = 0 Hz
with 7812 voltage regulator:
55. ADVANTAGES ;
Compared to hydraulic and ,pneumatic system, it is economical.
No extra skill is required for operating this system.
Operation is very smooth and in this system we can get more output by applying less
effort.
64. RESULT AND DISCUSSION
The various type of punching machines are used for punching the
material.This is also one of the automatic job feeding and punching
which is now operated through the geneva mechanism .The operation
and mechanism of this unit and its function have been studied.
At the end, the machine is assembled.
This machine is more advantages ofother types of punching
machines since it has more easier to operate comfortable automatic
job feeding arrangement and also less time consumption, easy
handling etc.
66. CONCLUSION
We make this project entirely different from other projects. Since concepts
involved in our project is entirely different that a single unit is used to various
purposes, which is not developed by any of other team members.
By doing this project we gained the knowledge of various mechanism,
drives ,fabrication with welding and how it can be effectively used to generate the
punching on the job.
It is concluded that any system can be operated with the help of mechanism.
We have successfully completed the project work on using punching
machine at our college.
By doing this project work, we understood the working principle and uses of
DC Motor, Geneva mechanism, rollers, chain drives etc.,
Once again we express our sincere thanks to our staff members.
68. BIBILOGRAPHY
WORKSHOP : W.J. CHAPMAN
PRODUCTION TECHNOLOGY : R.K. JAIN
PRODUCTION TECHNOLOGY : R.K. JAIN & S.C. QUPTA
METAL FORMING PROCESS : R.S. KURMI
MANUFACTURING PROCESS : K. RAMACHANDRAN
MACHINE SHOP TECHNOLOGY : S.S. MANIAN &
RAJAGOPAL &
G. BALAJI SINGH
DESIGN OF MACHINE ELEMENTS : R.S. KURMI &
P.N. VENKATESAN
DESIGN OF MACHINE ELEMENTS : RAMACHANDRAN
DESIGN DATA BOOK : P.S.G.COLLEGE OF
TECHNOLOGY
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