Submitted in the partial fulfillment of the requirement for the award of
“DIPLOMA
IN MECHANICAL ENGINEERING (FOUNDRY) ”
SUBMITTED BY:
1. G.K. MANIGANDAN
4. J. DHANAJEYAN
2. B. KARTHIKEYAN
5. D. DURAIVEL
3. P. BALASUBRAMANI BALASUBRAMANI
6. L. PRABHU
Under guidance of
Mr. V.K. RAJENDRAN,M.E. OCTOBER 2007. DEPARTMENT DEPARTMENT OF MECHANICAL ENGINEERING (FOUNDRY)
BONAFIDE CERTIFICATE This is to certify that this Project work on
”
“
submitted by …………………… ……………. Reg. No. …………… in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING(FOUNDRY) ENGINEERING(FOUNDRY)
This is the bonafide record of work carried out by him under our supervision during the year 2007 Submitted for the Viva-voce exam held on ……………..
HEAD OF THE DEPARTMENT
INTERNAL EXAMINER
PROJECT GUIDE
EXTERNAL EXAMINER
BONAFIDE CERTIFICATE This is to certify that this Project work on
”
“
submitted by …………………… ……………. Reg. No. …………… in partial fulfillment for the award of DIPLOMA IN MECHANICAL ENGINEERING(FOUNDRY) ENGINEERING(FOUNDRY)
This is the bonafide record of work carried out by him under our supervision during the year 2007 Submitted for the Viva-voce exam held on ……………..
HEAD OF THE DEPARTMENT
INTERNAL EXAMINER
PROJECT GUIDE
EXTERNAL EXAMINER
ACKNOWLEDGEMENT At the outset, we would like to emphasize our sincere thanks to the Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement and valuable advice.
we thank our Esquired Head of Department Mr R. RAJKUMAR, A.M.I.E, M.E., for presenting his felicitations on us.
We are grateful on our Entourages Mr. V.K.RAJENDRAN, M.E., for guiding in various aspects of the project making it a grand success.
We also also owe owe our sin sincere cere than thank ks to all all sta staff membe embers rs of the Mechanical Engineering (MTMR) Department.
Ultimately, we extend our thanks to all who had rendered their cooperation for the success of the project.
CONTENTS Chapter No.
TITLE
1.
INTRODUCTION
2.
SYNOPSIS
3.
CONSTRUCTION
4.
WORKING PRINCIPLE
5.
DESCRIPTION OF PNEUMATIC COMPONENTS
6.
PNEUMATIC CIRCUIT DIAGRAM
7.
MECHANICAL SPARE PARTS DETAILS
8.
ELECTRICAL PARTS DETAILS
9.
ELECTRICAL CIRCUIT DETAILS
10.
FINISHING AND PAINTING
11.
COST ESTIMATION
12.
CONCLUSION
13.
BIBILOGRAPHY
This is a self – assessment test on the part of the students to assess his competency in creativity. During the course of study, the student is put on a sound theoretical foundation of various mechanical engineering subjects and of course, to a satisfactory extent. Opportunities are made available to him to work on different kinds of machines, so that he is exposed to various kinds of manufacturing process. As a students learn more and more his hold on production technology becomes stronger. He attains a stage of perfection, when he himself is able to design and fabricate a device. This is the project work. That is the testimony for the strenuous training, which the student had in the institute. This assures that he is no more a student, he is an engineer. This report discuses the necessity of the project and various aspects of planning , design, selection of materials, fabrication, erection, estimation and testing.
A Hydraulically operated bush bearing puller is a device which enables the single persons to operate it alone and removes the bearing the from machine parts . No special skill is needed to operate or remove the bush bearing form the machine parts. It can widely used. It is easy to fit on the operate or remove the bearing from the machine parts.. This device is worked by the principle of hydraulic lifting system to exert the pulling power to remove the bearing from the machine blocks. This is operated by hydraulic power without use of man power. . As the bottom flange has a hole which is set below the bottom portion of the bush bearing in the machine block, makes to provide grip for pulling the bush bearing. Through this bottom flange hole a screw rod inserted . he other end of the screw rod is connected to the top flange which is moving towards upward direction by the action of hydraulic jack.
If we lift the jack, the top flange pulled the centre rod. So the centre rod rises with bottom flange gradually with the liner. Thus the liner is removed.
This unit consists of a) M.S. Fabricated stand b) Hydraulic jack and c) Handle A ) M.S .FABRICATED STAND ;
This stand is used to hold the hydraulic jack and support guide plate. The liner to be remove is placed at the bottom of the support .
HYDRAULIC JACK
A Hydraulic Jack is a device using Hydraulic Power in its simplest possible shape shown in figure and consists of five fundamental components.
1. pump
2. reservoir 3. cylinder 4. suction valve and 5. delivery valve
WORKING PRINCPLE
This device is worked by the principle of hydraulic lifting system to excert the pulling power to remove the bush bearing from the machine blocks. This is operated by hydraulic power without use of man power. As the bottom flange has a hole which is set below the bottom portion of the bush bearing in the machine block, makes to provide grip for pulling the bush bearing. Through this bottom flange hole a screw rod inserted . he other end of the screw rod is connected to the top flange which is moving towards upward direction by the action of hydraulic jack. If we lift the jack, the top flange pulled the centre rod. So the centre rod rises with bottom flange gradually with the bush bearing. Thus the bush bearing is removed.
HYDRAULIC JACK
A Hydraulic Jack or for that matter any device using Hydraulic Power in its simplest possible shape consists of five fundamental components.
A. The Hydraulic Reservoir storing the Hydraulic Oil (Oil is used as the
medium to transmit force and motion-such fluids are called Hydraulic Oils) should be thoroughly clean, whether integrally built-in or used as a separate tank.
B. Pump, either of the integral or the remote control type, comprises of
highly precision engineered pump plunger, cylinder, suction and delivery valves, safety valves with conical or steel balls matched with micron tolerances. Very often O Rings and special seals are used, made from specially treated leather or synthetic nitrile rubber or Teflon or other modern substitutes for greater resistance to wear and sealing ower.
It is imperative that these must function at peak efficiency by regular cleaning and flushing of foreign particles which enter into the hydraulic system and may clog the delicate valves, damage the seals and affect the functioning of other elements in the hydraulic circuit.
C. A pump by itself would be useless without a system of VALVES to govern the flow of hydraulic oil to perform the desired function.
D. The transmission of hydraulic oil from the reservoir by the pump
through the valves to Ram & Cylinder which converts the hydraulic pressure into a mechanical force is by means of a Hydraulic Circuit which is nothing but a network of passages in hydraulic systems. These passages are formed with the help of Steel Tubes, Flexible Hydraulic Hoses or through internal holes or cavities in metal blocks. It is of the utmost importance that the circuit is always leak proof as well as free from obstacles. Each joint or coupling must be securely tightened or replaced forthwith.
No air lock or foreign particles
should be allowed to interrupt or block the free flow of hydraulic oil.
E. All hydraulic cylinders consists of two basic elements – the outer
housing is called the Cylinder body and the inner sliding elements is called the Ram (or piston or plunger) which actually converts the hydraulic pressure into mechanical force and transmits to the desired point for performing the function. The movement of Ram is always in line with cylinder under pressure.
Hydraulic Oil is pumped into the cylinder and as more and more oil is forced into the cylinder pressure builds up and when enough oil is forced into the cylinder the resultant pressure will cause the ram, plunger or piston to move and consequently lift, press, push, pull or bend any object any object as the case may be.
The Ram and Cylinder are also precision engineered and mostly fitted with high quality seals which give it the necessary compression holding capacity and prevent leakages.
The five fundamental components already illustrated and described combined together perform the specified job by a synchronous follow through of their individual functions.
1. The release valve is closed tightly to ensure flow of oil from the pump to the cylinder only.
2. As soon as the pump is operated oil is sucked in from the reservoir.
As the Pump Plunger is raised up oil passes from the reservoir into the pump cylinder with the Suction Valve opening up to allow oil from reservoir to enter into pump cylinder.
3. When the Pump Plunger is pressed down the Delivery Valve opens up
to allow the passage of oil from the pump into the cylinder, at the same time the suction valve automatically closes to prevent oil returning to the reservoir.
4. By repeating the above two operations successively more and more oil is pumped into the cylinder resulting in the generation of pressure by the action of the load being lifted.
5. When the load is desired to be lowered the pressure within the
cylinder is released by operating the Release Valve. The oil flows back into the reservoir shown in the diagram in page 1.
6. Due to neglect or other causes pressure within the system may continue to increase beyond the predetermined safe working limit. To prevent damage to the system a safety relief valve is located between the cylinder and the reservoir excessive pressure by the opening up of the safety valve and discharge of oil into the reservoir (very often the safety overload preventive relief valve is located in between the reservoir and the pump – the pump automatically cuts off without delivery of oil to the cylinder due to generation of excessive pressure within the pump).
The simple diagram shown in page 1 shall help to understand the working of the hydraulic system in a more graphic manner.
By using this device many numbers of cylinders bearings are removed.removing.
It is very much useful in repairing automobile
workshops and electrical motor and pump repair shop.
Any other type or size of cylinder bush bearings can be removed by varying the dimensions of bottom flange relative to the dimension of the bearings to be removed. Thus it can be useful for the following types of bush bearings in i)
Generators coupled centrifugal pump
ii)
Oil Engines and to other engines.
1. Single person is enough to operate this efficiently to remove bearings. 2. Easy and efficient handling of liner puller without wastage or damage
to the puller, machine block and to any other parts. 3. Increase the bearing life.
4. Least maintenance of the equipment. 5. Need not require any individual work place. 6. Can be worked in the work spot. 7. Suited for removing bearing in oil engine generators.
BASIC SAFETY RULES FOR HYDRAULIC JACKS; The nature of lifting operation should determine the choice of jacking equipment-integral or remote control pump type jacks. Capacity and the hydraulic lifting stroke are vital aspects to be carefully determined before selection.
Lifting any load calls for precise and safe jacking points. Jack should be centrally loaded eccentric loading causes dangerous accidents and damages beyond repair.
The world over prudent safety minded operators observe the flowing basic safety rules :
A. To overpower the load, whether one or a dozen cylinders are used to lift the load, the cylinder lifting capacity should be two times the weight of
the load. This allows for a reduction in the oil pressure, prevents strain and possible break-down of the cylinder.
B. To balance the load, for large, heavy and uneven loads, it is recommended dividing the load evenly between a number of cylinders. These cylinders should be placed beneath the load at points providing the best support, balance and stability. For example, to lift a 200-tonns load, the necessary 400-tonnes capacity could be handled by four 100-tonnes cylinders.
C. Never raise the hydraulic ram beyond the specified stroke (lift).
D. Never drop (shock) load on the hydraulic ram.
E. Never go under a load supported by hydraulic ram only.
F. Never extend the hydraulic ram by means other than the pump.
G. Never use hydraulic equipment with observed leakages.
H. Use safety lock nut type jacks for supporting load on jack for long periods.
I. Use steel plates or heavy wooden sleepers where ground surface is soft and yielding
J. Do not disturb the factory preset internal safety valve provided for preventing overloading.
K. Do not load more than 50% of the rated head capacity on the toe (claw) of toe lifting jacks. Positioning the Jack
Jack should be centrally loaded, jack base and upper jacking point must be in level.
Raising the Jack
Turn the release valve in clockwise direction till tight, use end of slotted operating handles. Start pumping with a regular handle movement. Make only few fast and rapid download delivery strokes, Jack handle slightly downward, in case the delivery does not close instantly. Check that the saddles rests firmly against the Jacking point.
Lowering the Jack
Turn the release valve SLOWLY anticlockwise.
Jack Storage
Retract ram completely, close oil filler, keep the Jack away in a safe clean place.
Caution
Do not use the Jack beyond rated capacity and lift mentioned on the name plate.
Making Jack ready for use
VANJAX Hydraulic Jacks are supplied ready for use. Unlock the release valve half a turn and operate the pump few times to flush the hydraulic unit free from airlocking.
DO’S AND DON’TS
Air
Do’s venting is an
precaution
for
the
important Under
no
Don’ts circumstances
the
successful equipment should be used beyond
performance of any hydraulic jack rated capacity or rated stroke. It is or hydraulically operated device, in the interest of the user and for the equipment or system.
protection of his costly equipment to ensure
correct
selection
of the
capacity and restricting the stroke within the rated stroke length. All couplings and other fasteners Do not forcibly hammer should be properly tightened.
fit
accessories if falling short by a fraction of the required length or spread.
Use the next higher size
equipment.
Abuse of accessories
and attachments are hazardous both for the equipment and the personnel.
At all times the entire equipments Do not expose the equipment to should be kept free from dust areas of excessive heat or where dirt, through regular systematic cleaning.
dust and heavily laden fumes / smoke
are
prevalent.
If
the
equipment is used in such areas it is absolutely essential to service it at once. Check oil level each time before Do not refill without a reliable use.
strainer
Every time the hydraulic hose is Do not use brake fluid as refill. attached to the pump and the ram cylinder assembly unit, it should be thoroughly flushed. Release
valve
to
be
properly Do not hammer to open guide nuts.
tightened by turning it in clock-wise direction when applying load. For releasing
pressure
open
release
valve gradually by turning it in anticlockwise direction.
Open by guide nut spanner.
The equipment must be centrally Do not apply extra force to close the loaded. The pressure screw in a release hydraulic
puller
should
valve.
Normal
hand
be pressure is enough.
absolutely perpendicular to the axis of the load. As refill we recommend IOC Code Do not use fluffy cloth or cotton No. Servo System 32 and 46, HPC waste for cleaning cylinder ram, Hydrol
0232
or
any
other valve, pump and oil tank.
equivalent. VANJAX cannot be held responsible for damage or injury caused by unsafe use, maintenance or application of its products.
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.
COST ESTIMATION
COST ESTIMATION
1.Work holding support and pulling rod
800,00
2. hydraulic jack
3800.00
3 . M.S. Fabricted housing unit
600.00
5. Painting cost
200.00
6. transport cost
200.00 TOTAL COST
5600.00
CONCLUSION
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 fabrication work and how the welding is doing and material selection for particular components etc., It is concluded that any fabrication work can be done with the help of welding. We have successfully completed the project work on using welding work at our Institute.
Once again we express our sincere thanks to our staff members.
1. WORKSHOP TECHNOLOGY
-HAJRA CHOWDRY
2. PRODUCTION TECHNOLOGY
-R.S. KHURMI
3. MACHINE SHOP TECHNOLOGY
-S.S.MANIAN
4. JIG AND FIXTURE DESIGN
- R.K.JAIN
