---------------------------------------------------------------------------------

ACKNOWLEDGEMENT
---------------------------------------------------------------------------------
 ACKNOWLEDGEMENT

We would like to express our sincere thanks to our principal

Mr.P.RAJARATHINAM, M.E., M.B.A., for forwarding us to do our project and

offering adequate duration in completing our project.

We are also grateful to the Head of Department Mr.S.PUVIARASU,B.E.,

for her constructive suggestions & encouragement during our project.

With deep sense of gratitude, we extend our earnest & sincere thanks to our

guide Mr.S.PUVIARASU,B.E., Department of Mechanical for her kind guidance

& encouragement during this project.

We also express our indebt thanks to our TEACHING and NON

TEACHING staffs of MECHANICAL ENGINEERING DEPARTMENT

ADHIYAMAAN POLYTECHNIC COLLEGE,Dr.M.G.R Nagar,Hosur- 635109

---------------------------------------------------------------------------------
DESIGN AND FABRICATION OF AIR COMPRESSOR
USING SPEED BRAKER
---------------------------------------------------------------------------------
---------------------------------------------------------------------------------
CONTENTS
---------------------------------------------------------------------------------
 CONTENTS

AKNOWLEDGEMENT

1. ABSTRACT

2. INTRODUCTION

3. LITERATURE REVIEW

4. COMPONENTS AND DESCRIPTION

5. DESIGN CONCEPT

6. MANUFACTURING PROCESS

7. WORKING PRINCIPLE

8. 2D DRAWING

9. ADVANTAGES, DISADVANTAGES AND APPLICATIONS

10. LIST OF MATERIALS

11. COST ESTIMATION

12. CONCLUSION

REFERENCES

PHOTOGRAPH OF THE MODEL

--------------------------------------------------------------------------------------
CHAPTER 1
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
ABSTRACT
--------------------------------------------------------------------------------------
 CHAPTER-1
ABSTRACT
In this project we are collecting air from the air cylinder and store this

energy to the compressor tank as non-conventional method by simply running on

the vehicle in the speed brake. Non-conventional energy system is very essential

at this time to our nation. Non-conventional air compressor using speed braker

needs no fuel input power to produce the output of the air.

For this project the conversion of the force energy in to air. The control

mechanism carries the air cylinder, quick exhaust valve, non-return valve and

spring arrangement. We have discussed the various applications and further

extension also. The Indian highways are having several numbers of speed brake.

So this project is implemented to all speed brake, the air production is very high.

The initial cost of this arrangement is high.

--------------------------------------------------------------------------------------
CHAPTER 2
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
INTRODUCTION
--------------------------------------------------------------------------------------
 CHAPTER-2
INTRODUCTION
Man has needed and used energy at an increasing rate for his sustenance and

well being ever since he came on the earth a few million years ago. Primitive man

required energy primarily in the form of food. He derived this by eating plants or

animals, which he hunted.

Subsequently he discovered fire and his energy needs increased as he started

to make use of wood and other bio mass to supply the energy needs for cooking as

well as for keeping himself warm. With the passage of time, man started to

cultivate land for agriculture. He added a new dimension to the use of energy by

domesticating and training animals to work for him.

With further demand for energy, man began to use the wind for sailing ships

and for driving windmills, and the force of falling water to turn water for sailing

ships and for driving windmills, and the force of falling water to turn water wheels.

Till this time, it would not be wrong to say that the sun was supplying all the

energy needs of man either directly or indirectly and that man was using only

renewable sources of energy.

--------------------------------------------------------------------------------------
CHAPTER 3
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
LITERATURE REVIEW
--------------------------------------------------------------------------------------
 CHAPTER-3
LITERATURE REVIEW
An air compressor is a device that converts power (using an electric motor,

diesel or gasoline engine, etc.) into potential energy stored in pressurized air (i.e.,

compressed air). By one of several methods, an air compressor forces more and

more air into a storage tank, increasing the pressure. When tank pressure reaches

its upper limit the air compressor shuts off. The compressed air, then, is held in the

tank until called into use. The energy contained in the compressed air can be used

for a variety of applications, utilizing the kinetic energy of the air as it is released

and the tank depressurizes. When tank pressure reaches its lower limit, the air

compressor turns on again and re-pressurizes the tank.

There are numerous methods of air compression, divided into either

positive-displacement or negative-displacement types.The usage of compressed air

is not limited only to industries, but they are also used in manufacturing, welding,

constructions, power plants, ships, automobile plants, painting shops, and for

filling breathing apparatus too. Thus there are so many types of air compressors

used specifically for the above purposes. Let us discuss on various types of air

compressors.

In many ways out of which the common one is the classification based on

the principle of operation.

Types of Compressors

 Positive Displacement and

 Roto-Dynamic Compressors.

Positive displacement compressors cab be further divided into Reciprocating

and rotary compressors.

Under the classification of reciprocating compressors, we have

1. In-line compressors,

2. “V"-shaped compressors,

3. Tandem Piston compressors.

4. Single-acting compressors,

5. Double-acting compressors,

6. Diaphragm compressors.

The rotary compressors are divided into

1. Screw compressors,

2. Vane type compressors,

3. Lobe and scroll compressors and other types.

Under the Roto-dynamic compressors, we have

1. Centrifugal compressors, and the

2. Axial flow compressors.

The compressors are also classified based on other aspects like

1. Number of stages (single-stage, 2-stage and multi-stage),

2. Cooling method and medium (Air cooled, water cooled and oil-cooled),

3. Drive types ( Engine driven, Motor driven, Turbine driven, Belt, chain, gear

or direct coupling drives),

4. Lubrication method (Splash lubricated or forced lubrication or oil-free

compressors).

5. Service Pressure (Low, Medium, High)

RECIPROCATING IN-LINE COMPRESSORS

These are most commonly used compressors with varying pressure ranges.

These are simple in design with almost very little automation. The cylinders of

various stages are found in a straight line when seen from top. These compressors

are commonly direct driven by electric motors or diesel engines. Refer the attached

diagram of the reciprocating in-line compressors.

“V"-SHAPED COMPRESSORS

These are usually air cooled compressors with concentric valves mounted on

each cylinder head unit. The compressor has different units displaced usually by 90

degrees, may or may not be connected to same crank pin on the crank shaft. Higher

capacity compressors are water cooled. Better torque and balancing is achieved by

displacing the units by certain angle.

--------------------------------------------------------------------------------------
CHAPTER 4
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
COMPONENTS AND DESCRIPTION
--------------------------------------------------------------------------------------
 CHAPTER-4
COMPONENTS AND DESCRIPTION

The major parts that are effectively employed in the design and the

fabrication of the non conventional air compressorare described below:

 Pneumatic cylinder,

 Frame,

 Speed Breaker Arrangement,

 Pressure gauge,

 Bearing with bearing cap,

 PU connector, reducer and hose collar,

 Return spring.

PNEUMATIC CYLINDER

Mechanization is broadly defined as the replacement of manual effort by

mechanical power. Pneumatics is an attractive medium for low cost mechanization

particularly for sequential or repetitive operations. Many factories and plants

already have a compressed air system, which is capable of providing both the

power or energy requirements and the control system (although equally pneumatic

control systems may be economic and can be advantageously applied to other

forms of power).
 The main advantages of an all-pneumatic system are usually economy and

simplicity, the latter reducing maintenance to a low level. It can also have

outstanding advantages in terms of safety.

DOUBLE ACTING PNEUMATIC CYLINDER

The cylinder is a double acting cylinder one, which means that the air

pressure operates alternatively (forward and backward). The air from the

compressor is passed through the regulator which controls the pressure to required

amount by adjusting its knob. A pressure gauge is attached to the regulator for

showing the line pressure.

Then the compressed air is passed through the directional control valve for

supplying the air alternatively to either sides of the cylinder. Two hoses take the

output of the directional control valve and they are attached to two ends of the
cylinder by means of connectors. One of the outputs from the directional control

valve is taken to the flow control valve from taken to the cylinder.

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

compressed air i.e. pneumatic power is converted in to mechanical output power,

by reducing the pressure of the air to that of the atmosphere.

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

pneumatic cushioning and it is essential when the cylinder itself is required to

retard heavy messes. This can only be done at the end positions of the piston stock.

In all intermediate position a separate externally mounted cushioning derive most

be provided with the damping feature.

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

the stock is required. As a result the sit in the cushioning chamber is again

compressed since it cannot escape but slowly according to the setting made on

reverses. The air freely enters the cylinder and the piston stokes in the other

direction at full force and velocity.

SINGLE ACTING PNEUMATIC CYLINDER

A single-acting cylinder in a reciprocating engine is a cylinder in which

the working fluid acts on one side of the piston only. A single-acting cylinder relies

on the load, springs, other cylinders, or the momentum of a flywheel, to push the

piston back in the other direction. Single-acting cylinders are found in most kinds

of reciprocating engine. They are almost universal in internal combustion

engines (e.g. petrol and diesel engines) and are also used in many external

combustion engines such as Stirling engines and some steam engines. They are

also found in pumps and hydraulic rams.

FRAME

This is made of mild steel material. The whole parts are mounted on this

frame structure with the suitable arrangement. Boring of bearing sizes and open
bores done in one setting so as to align the bearings properly while assembling.

Provisions are made to cover the bearings with grease.

BEARING WITH BEARING CAP

The bearings are pressed smoothly to fit into the shafts because if hammered

the bearing may develop cracks. Bearing is made upof steel material and bearing

cap is mild steel.

INTRODUCTION

Ball and roller bearings are used widely in instruments and machines in

order to minimize friction and power loss. While the concept of the ball bearing

dates back at least to Leonardo da Vinci, their design and manufacture has become

remarkably sophisticated.

This technology was brought to its p resent state o f perfection only

after a long period of research and development. The benefits of such

specialized research can be obtained when it is possible to use a standardized

bearing of the proper size and type.

However, such bearings cannot be used indiscriminately without a careful

study of the loads and operating conditions. In addition, the bearing must be

provided with adequate mounting, lubrication and sealing. Design engineers have
usually two possible sources for obtaining information which they can use to select

a bearing for their particular application:

a) Textbooks

b) Manufacturers’

Catalogs Textbooks are excellent sources; however, they tend to be overly

detailed and aimed at the student of the subject matter rather than the practicing

designer. They, in most cases, contain information on how to design rather than

how to select a bearing for a particular application. Manufacturers’ catalogs, in

turn, are also excellent and contain a wealth of information which relates to the

products of the particular manufacturer. These catalogs, however, fail to provide

alternatives – which may divert the designer’s interest to products not

manufactured by them. Our Company, however, provides the broadest selection of

many types of bearings made by different manufacturers.

For this reason, we are interested in providing a condensed overview of the

subject matter in an objective manner, using data obtained from different texts,

handbooks and manufacturers’ literature. This information will enable the reader

to select the proper bearing in an expeditious manner. If the designer’s interest

exceeds the scope of the presented material, a list of references is provided at the
end of the Technical Section. At the same time, we are expressing our thanks and

are providing credit to the sources whichsupplied the material presented here.

Construction and Types of Ball Bearings

A ball bearing usually consists of four parts: an inner ring, an outer ring, the

balls and the cage or separator.

To increase the contact area and permit larger loads to be carried, the balls

run in curvilinear grooves in the rings. The radius of the groove is slightly larger

than the radius of the ball, and a very slight amount of radial play must be

provided. The bearing is thus permitted to adjust itself to small amounts of angular

misalignment between the assembled shaft and mounting. The separator keeps the

balls evenly spaced and prevents them from touching each other on the sides where

their relative velocities are the greatest. Ball bearings are made in a wide variety of

types and sizes. Single-row radial bearings are made in four series, extra light,

light, medium, and heavy, for each bore, as illustrated in Fig. 1-3(a), (b), and (c).

100 Series 200 Series 300 Series Axial Thrust Angular Contact Self-aligning Bearing
 The heavy series of bearings is designated by 400. Most, but not all,

manufacturers use a numbering system so devised that if the last two digits are

multiplied by 5, the result will be the bore in millimeters. The digit in the third

place from the right indicates the series number. Thus, bearing 307 signifies a

medium-series bearing of 35-mm bore. For additional digits, which may be

present in the catalog number of a bearing, refer to manufacturer’s details.

Some makers list deep groove bearings and bearings with two rows of balls. For

bearing designations of Quality Bearings & Components (QBC), see special pages

devoted to this purpose. The radial bearing is able to carry a considerable amount

of axial thrust.

However, when the load is directed entirely along the axis, the thrust type of

bearing should be used. The angular contact bearing will take care of both radial

and axial loads. The self-aligning ball bearing will take care of large amounts

of angular misalignment. An increase in radial capacity may be secured by

using rings with deep grooves, or by employing a double-row radial bearing.

Radial bearings are divided into two general classes, depending on the method of

assembly. These are the Conrad, or nonfilling-notch type, and the maximum or

filling-notch type. In the Conrad bearing, the balls are placed between the rings as

shown in Fig. 1-4(a). Then they are evenly spaced and the separator is riveted in

place. In the maximum-type bearing, the balls are a (a) (b) (c) (d) (e) (f) 100

Series Extra Light 200 Series Light 300 Series Medium Axial Thrust Bearing

Angular Contact Bearing Self-aligning Bearing Fig. 1-3 Types of Ball Bearings

Fig. 1-4 Methods of Assembly for Ball Bearings (a) Conrad or non-filling

notch type (b) Maximum or filling notch type.

SPEED BREAKER ARRANGEMENT

This is made up of mild steel. The complete set up is fixed in a box. The two

L-angles frame is fixed in the above two ends of the box. Bellow this l-angle

window, the actual speed brake arrangement is constructed. This L-angle window

pushes the speed brake when the time of vehicle moving on these arrangement.
PRESSURE GAUGE

Many techniques have been developed for the measurement

of pressure andvacuum. Instruments used to measure pressure are called pressure

gauges orvacuum gauges.

A manometer is an instrument that uses a column of liquid to measure

pressure, although the term is currently often used to mean any pressure measuring

instrument.

A vacuum gauge is used to measure the pressure in a vacuum—which is

further divided into two subcategories: high and low vacuum (and sometimes ultra-

high vacuum). The applicable pressure ranges of many of the techniques used to

measure vacuums have an overlap. Hence, by combining several different types of

gauge, it is possible to measure system pressure continuously from 10 mbar down

to 10−11 mbar.

The Bourdon pressure gauge uses the principle that a flattened tube tends to

straighten or regain its circular form in cross-section when pressurized. Although

this change in cross-section may be hardly noticeable, and thus involving

moderate stresses within the elastic range of easily workable materials, the strain of

the material of the tube is magnified by forming the tube into a C shape or even a

helix, such that the entire tube tends to straighten out or uncoil, elastically, as it is
pressurized. Eugene Bourdonpatented his gauge in France in 1849, and it was

widely adopted because of its superior sensitivity, linearity, and accuracy; Edward

Ashcroft purchased Bourdon's American patent rights in 1852 and became a major

manufacturer of gauges. Also in 1849, Bernard Schaeffer in Magdeburg, Germany

patented a successful diaphragm (see below) pressure gauge, which, together with

the Bourdon gauge, revolutionized pressure measurement in industry. But in 1875

after Bourdon's patents expired, his companySchaeffer and Budenberg also

manufactured Bourdon tube gauges.

In practice, a flattened thin-wall, closed-end tube is connected at the hollow

end to a fixed pipe containing the fluid pressure to be measured. As the pressure

increases, the closed end moves in an arc, and this motion is converted into the

rotation of a (segment of a) gear by a connecting link that is usually adjustable. A

small-diameter pinion gear is on the pointer shaft, so the motion is magnified

further by the gear ratio. The positioning of the indicator card behind the pointer,

the initial pointer shaft position, the linkage length and initial position, all provide

means to calibrate the pointer to indicate the desired range of pressure for

variations in the behavior of the Bourdon tube itself. Differential pressure can be

measured by gauges containing two different Bourdon tubes, with connecting

linkages.
 Bourdon tubes measure gauge pressure, relative to ambient atmospheric

pressure, as opposed to absolute pressure; vacuum is sensed as a reverse motion.

Some aneroid barometers use Bourdon tubes closed at both ends (but most use

diaphragms or capsules, see below). When the measured pressure is rapidly

pulsing, such as when the gauge is near a reciprocating pump, an orifice restriction

in the connecting pipe is frequently used to avoid unnecessary wear on the gears

and provide an average reading; when the whole gauge is subject to mechanical

vibration, the entire case including the pointer and indicator card can be filled with

an oil or glycerin. Tapping on the face of the gauge is not recommended as it will

tend to falsify actual readings initially presented by the gauge. The Bourdon tube is

separate from the face of the gauge and thus has no effect on the actual reading of

pressure. Typical high-quality modern gauges provide an accuracy of ±2% of span,

and a special high-precision gauge can be as accurate as 0.1% of full scale. [7]

PU CONNECTOR, REDUCER AND HOSE COLLAR

In our pneumatic system there are two types of connectors used; one is the

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

an adapter (connector) hose nipple and cap nut. These types of connectors are

made up of brass or Aluminium or hardened steel. Reducers are used to provide

inter connection between two pipes or hoses of different sizes.

 They may be fitted straight, tee, “V” or other configurations. These reducers

are made up of gunmetal or other materials like hardened steel etc.

RETURN SPRING

A spring is an elastic object used to store mechanical energy. Springs are

usually made out of spring steel. There are a large number of spring designs; in

everyday usage the term often refers to coil springs. Small springs can be wound

from pre-hardened stock, while larger ones are made from annealed steel and

hardened after fabrication. Some non-ferrous metals are also used

including phosphor bronze and titanium for parts requiring corrosion resistance

and beryllium copper for springs carrying electrical current (because of its low

electrical resistance). When a coil spring is compressed or stretched slightly from

rest, the force it exerts is approximately proportional to its change in length (this

approximation breaks down for larger deflections). The rate or spring constant of a

spring is the change in the forceit exerts, divided by the change in deflection of the

spring. That is, it is the gradient of the force versus deflection curve. An

extension or compression spring has units of force divided by distance, for

example lbf/in or N/m. Torsion springs have units of torque divided by angle, such

as N·m/rad or ft·lbf/degree. The inverse of spring rate is compliance, that is: if a

spring has a rate of 10 N/mm, it has a compliance of 0.1 mm/N. The stiffness (or

rate) of springs in parallel is additive, as is the compliance of springs in series.

Depending on the design and required operating environment, any material can be

used to construct a spring, so long as the material has the required combination of

rigidity and elasticity: technically, a wooden bow is a form of spring.

--------------------------------------------------------------------------------------
CHAPTER 5
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
DESIGN CONCEPT
--------------------------------------------------------------------------------------
 CHAPTER-5
DESIGN CONCEPT

CAD/CAE

Computer aided design or CAD has very broad meaning and can be defined

as the use of computers in creation, modification, analysis and optimization of a

design. CAE (Computer Aided Engineering) is referred to computers in

engineering analysis like stress/strain, heat transfer, flow analysis. CAD/CAE is

said to have more potential to radically increase productivity than any development

since electricity. CAD/CAE builds quality form concept to final product. Instead of

bringing in quality control during the final inspection it helps to develop a process

in which quality is there through the life cycle of the product. CAD/CAE can

eliminate the need for prototypes. But it required prototypes can be used to

confirm rather predict performance and other characteristics. CAD/CAE is

employed in numerous industries like manufacturing, automotive, aerospace,

casting, mould making, plastic, electronics and other general-purpose industries.

CAD/CAE systems can be broadly divided into low end, mid end and high-end

systems.

Low-end systems are those systems which do only 2D modeling and with

only little 3D modeling capabilities. According to industry static’s 70-80% of all

mechanical designers still uses 2D CAD applications. This may be mainly due to
the high cost of high-end systems and a lack of expertise.Mid-end systems are

actually similar high-end systems with all their design capabilities with the

difference that they are offered at much lower prices. 3D sold modeling on the PC

is burgeoning because of many reasons like affordable and powerful hardware,

strong sound software that offers windows case of use shortened design and

production cycles and smooth integration with downstream application. More and

more designers and engineers are shifting to mid end system.

High-end CAD/CAE software’s are for the complete modeling, analysis and

manufacturing of products. High-end systems can be visualized as the brain of

concurrent engineering. The design and development of products, which took years

in the past to complete, is now made in days with the help of high-end CAD/CAE

systems and concurrent engineering.

MODELING

Model is a Representation of an object, a system, or an idea in some form other

than that of the entity itself. Modeling is the process of producing a model; a model

is a representation of the construction and working of some system of interest. A

model is similar to but simpler than the system it represents. One purpose of a

model is to enable the analyst to predict the effect of changes to the system. On the

one hand, a model should be a close approximation to the real system and
incorporate most of its salient features. On the other hand, it should not be so

complex that it is impossible to understand and experiment with it. A good model

is a judicious tradeoff between realism and simplicity. Simulation practitioners

recommend increasing the complexity of a model iteratively. An important issue in

modeling is model validity. Model validation techniques include simulating the

model under known input conditions and comparing model output with system

output. Generally, a model intended for a simulation study is a mathematical

model developed with the help of simulation software.

Software for modeling:

 Solid works

 Creo

 CATIA

 Unigraphics, etc

CREO

Creo Elements/Pro (formerly Pro/ENGINEER), PTC's parametric, integrated

3D CAD/CAM/CAE solution, is used by discrete manufacturers for mechanical

engineering, design and manufacturing. Created by Dr. Samuel P. Geisberg in the

mid-1980s, Pro/ENGINEER was the industry's first successful rule-based

constraint (sometimes called "parametric" or "variational") 3D CAD modeling

system. The parametric modelling approach uses parameters, dimensions, features,

and relationships to capture intended product behaviour and create a recipe which

enables design automation and the optimization of design and product

development processes. This design approach is used by companies whose product

strategy is family-based or platform-driven, where a prescriptive design strategy is

fundamental to the success of the design process by embedding engineering

constraints and relationships to quickly optimize the design, or where the resulting

geometry may be complex or based upon equations. Creo Elements/Pro provides a

complete set of design, analysis and manufacturing capabilities on one, integral,

scalable platform. These required capabilities include Solid Modeling, Surfacing,

Rendering, Data Interoperability, Routed Systems Design, Simulation, Tolerance

Analysis, and NC and Tooling Design. Like any software it is continually being

developed to include new functionality. The details below aim to outline the scope

of capabilities to give an overview rather than giving specific details on the

individual functionality of the product.

Creo Elements/Pro is a software application within the CAD/CAM/CAE

category, along with other similar products currently on the market. Creo

Elements/Pro is a parametric, feature-based modeling architecture incorporated

into a single database philosophy with advanced rule-based design capabilities. It

provides in-depth control of complex geometry, as exemplified by

the trajpar parameter. The capabilities of the product can be split into the three

main headings of Engineering Design, Analysis and Manufacturing.

ENGINEERING DESIGN

Creo Elements/Pro offers a range of tools to enable the generation of a

complete digital representation of the product being designed. In addition to the

general geometry tools there is also the ability to generate geometry of other

integrated design disciplines such as industrial and standard pipe work and

complete wiring definitions. Tools are also available to support collaborative

development.

A number of concept design tools that provide up-front Industrial Design

concepts can then be used in the downstream process of engineering the product.

These range from conceptual Industrial design sketches, reverse engineering with

point cloud data and comprehensive free-form surface tools.

We created 3D model of this projectby using CREO software. The models

are shown below.

--------------------------------------------------------------------------------------
CHAPTER 6
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
MANUFACTURING PROCESS
--------------------------------------------------------------------------------------
 CHAPTER-6
MANUFACTURING PROCESS

Manufacturing processes are the steps through which raw materials are

transformed into a final product. The manufacturing process begins with the

creation of the materials from which the design is made. These materials are then

modified through manufacturing processes to become the required part.

Manufacturing processes can include treating (such as heat treating or coating),

machining, or reshaping the material. The manufacturing process also includes

tests and checks for quality assurance during or after the manufacturing, and

planning the production process prior to manufacturing.

METAL CUTTING

Metal cutting or machining is the process of by removing unwanted material

from a block of metal in the form of chips.

Cutting processes work by causing fracture of the material that is processed.

Usually, the portion that is fractured away is in small sized pieces, called chips.

Common cutting processes include sawing, shaping (or planning), broaching,

drilling, grinding, turning and milling. Although the actual machines, tools and

processes for cutting look very different from each other, the basic mechanism for
causing the fracture can be understood by just a simple model called for orthogonal

cutting.

In all machining processes, the work piece is a shape that can entirely cover

the final part shape. The objective is to cut away the excess material and obtain the

final part. This cutting usually requires to be completed in several steps – in each

step, the part is held in a fixture, and the exposed portion can be accessed by the

tool to machine in that portion. Common fixtures include vise, clamps, 3-jaw or 4-

jaw chucks, etc. Each position of holding the part is called a setup. One or more
cutting operation may be performed, using one or more cutting tools, in each setup.

To switch from one setup to the next, we must release the part from the previous

fixture, change the fixture on the machine, clamp the part in the new position on

the new fixture, set the coordinates of the machine tool with respect to the new

location of the part, and finally start the machining operations for this setup.

Therefore, setup changes are time-consuming and expensive, and so we

should try to do the entire cutting process in a minimum number of setups; the task

of determining the sequence of the individual operations, grouping them into (a

minimum number of) setups, and determination of the fixture used for each setup,

is called process planning.

These notes will be organized in three sections:

(i) Introduction to the processes,

(ii) The orthogonal cutting model and tool life optimization and

(iii) Process planning and machining planning for milling.

SAWING

Cold saws are saws that make use of a circular saw blade to cut through

various types of metal, including sheet metal. The name of the saw has to do with

the action that takes place during the cutting process, which manages to keep both

the metal and the blade from becoming too hot. A cold saw is powered with
electricity and is usually a stationary type of saw machine rather than a portable

type of saw.

The circular saw blades used with a cold saw are often constructed of high

speed steel. Steel blades of this type are resistant to wear even under daily usage.

The end result is that it is possible to complete a number of cutting projects before

there is a need to replace the blade. High speed steel blades are especially useful

when the saws are used for cutting through thicker sections of metal.

Along with the high speed steel blades, a cold saw may also be equipped

with a blade that is tipped with tungsten carbide. This type of blade construction

also helps to resist wear and tear. One major difference is that tungsten tipped
blades can be re-sharpened from time to time, extending the life of the blade. This

type of blade is a good fit for use with sheet metal and other metallic components

that are relatively thin in design.

WELDING

Welding is a process for joining similar metals. Welding joins metals by

melting and fusing 1, the base metals being joined and 2, the filler metal applied.

Welding employs pinpointed, localized heat input. Most welding involves ferrous-

based metals such as steel and stainless steel.Weld joints are usually stronger than

or as strong as the base metals being joined.

 Welding is used for making permanent joints. It is used in the manufacture

of automobile bodies, aircraft frames, railway wagons, machine frames, structural

works, tanks, furniture, boilers, general repair work and ship building.

OPERATION

Several welding processes are based on heating with an electric arc, only a

few are considered here, starting with the oldest, simple arc welding, also known

as shielded metal arc welding (SMAW) or stick welding.

In this process an electrical machine (which may be DC or AC, but nowadays is

usually AC) supplies current to an electrode holder which carries an electrode

which is normally coated with a mixture of chemicals or flux. An earth cable

connects the work piece to the welding machine to provide a return path for the

current. The weld is initiated by tapping ('striking') the tip of the electrode against

the work piece which initiates an electric arc. The high temperature generated

(about 6000oC) almost instantly produces a molten pool and the end of the

electrode continuously melts into this pool and forms the joint.
 The operator needs to control the gap between the electrode tip and the work

piece while moving the electrode along the joint.

 In the shielded metal arc welding process (SMAW) the 'stick' electrode is

covered with an extruded coating of flux. The heat of the arc melts the flux which

generates a gaseous shield to keep air away from the molten pool and also flux

ingredients react with unwanted impurities such as surface oxides, creating a slag

which floats to the surface of the weld pool. This forms a crust which protects the

weld while it is cooling. When the weld is cold the slag is chipped off.

The SMAW process cannot be used on steel thinner than about 3mm and

being a discontinuous process it is only suitable for manual operation. It is very

widely used in jobbing shops and for onsite steel construction work. A wide range

of electrode materials and coatings are available enabling the process to be applied

to most steels, heat resisting alloys and many types of cast iron.

DRILLNG

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole of

circular cross-section in solid materials. The drill bit is a rotary cutting tool, often

multipoint. The bit is pressed against the workpiece and rotated at rates from

hundreds to thousands of revolutions per minute. This forces the cutting edge

against the workpiece, cutting off chips (swarf) from the hole as it is drilled.
OPERATION

The geometry of the common twist drill tool (called drill bit) is complex; it

has straight cutting teeth at the bottom – these teeth do most of the metal cutting,

and it has curved cutting teeth along its cylindrical surface. The grooves created by

the helical teeth are called flutes, and are useful in pushing the chips out from the

hole as it is being machined. Clearly, the velocity of the tip of the drill is zero, and

so this region of the tool cannot do much cutting. Therefore it is common to

machine a small hole in the material, called a center-hole, before utilizing the drill.

Center-holes are made by special drills called center-drills; they also provide a

good way for the drill bit to get aligned with the location of the center of the hole.
There are hundreds of different types of drill shapes and sizes; here, we will only

restrict ourselves to some general facts about drills.

Common drill bit materials include hardened steel (High Speed Steel,

Titanium Nitride coated steel); for cutting harder materials, drills with hard inserts,

e.g. carbide or CBN inserts, are used;

In general, drills for cutting softer materials have smaller point angle, while

those for cutting hard and brittle materials have larger point angle;

If the Length/Diameter ratio of the hole to be machined is large, then we

need a special guiding support for the drill, which itself has to be very long; such

operations are called gun-drilling. This process is used for holes with diameter of
few mm or more, and L/D ratio up to 300. These are used for making barrels of

guns;

Drilling is not useful for very small diameter holes (e.g. < 0.5 mm), since

the tool may break and get stuck in the work piece; - Usually, the size of the hole

made by a drill is slightly larger than the measured diameter of the drill – this is
mainly because of vibration of the tool spindle as it rotates, possible misalignment

of the drill with the spindle axis, and some other factors;

For tight dimension control on hole diameter, we first drill a hole that is

slightly smaller than required size (e.g. 0.25 mm smaller), and then use a special

type of drill called a reamer. Reaming has very low material removal rate, low

depth of cut, but gives good dimension accuracy.

INSPECTION

Critical appraisalinvolvingexamination, measurement, testing, gauging, and

comparison of materials or items. An inspection determines if the material or item

is in proper quantity and condition, and if it conforms to the applicable or specified

requirements. Inspection is generally divided into three categories: (1) Receiving

inspection, (2) In-process inspection, and (3) Final inspection. In quality control

(which is guided by the principle that "Quality cannot be inspected into a product")

the role of inspection is to verify and validate the variancedata; it does not involve

separating the good from the bad.

ASSEMBLY

An assembly line is a manufacturing process (most of the time called

a progressive assembly) in which parts (usually interchangeable parts) are added as

the semi-finished assembly moves from work station to work station where the

parts are added in sequence until the final assembly is produced. By mechanically

moving the parts to the assembly work and moving the semi-finished assembly

from work station to work station, a finished product can be assembled much faster

and with much less labor than by having workers carry parts to a stationary piece

for assembly.
--------------------------------------------------------------------------------------
CHAPTER 7
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
WORKING PRINCIPLE
--------------------------------------------------------------------------------------
 CHAPTER-7

WORKING PRINCIPLE

The complete diagram of the non-conventional air compressor is given

below. L-angle window is inclined in certain small angle which is used to produce

the compressed air. The pushing power is converted into compressed air energy by

proper driving arrangement. The Pneumatic single acting cylinder is used for this

project. The spring arrangement is fixed at the inside of the pneumatic cylinder.

The spring is used to return the inclined L-angle window in same position by

releasing the load. The output air from the pneumatic cylinder is collected through

quick exhaust valve and non-return valve. The pneumatic cylinder retracting action

occurs with the help of quick exhaust valve and inside spring arrangement.
--------------------------------------------------------------------------------------
CHAPTER 8
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
2D DRAWING
--------------------------------------------------------------------------------------
CHAPTER-8
2D DRAWING
--------------------------------------------------------------------------------------
CHAPTER 9
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
ADVANTAGES, DISADVANTAGES AND APPLICATIONS
--------------------------------------------------------------------------------------
 CHAPTER-9
ADVANTAGES, DISADVANTAGES AND APPLICATIONS

ADVANTAGES

 Air production is simply running the vehicle on this arrangement

 Air also Produced by running or exercising on the brake.

 No need fuel input and Electrical Power input

 This is a Non-conventional system

 Pollution free system can be achieved.

 The cost of the system is low.

 Simple in construction.

 High efficiency.

 Easy to fabricate.

DISADVANTAGES

 Pushing Arrangement is required in the speed brake

 Mechanical moving parts is high

 Initial cost of this arrangement is high.

APPLICATIONS

These types of non conventional air compressors have a wide range of

applications in the fields like,

 All highways

 All road ways Speed brake

 Petrol Bunk

FUTURE SCOPE

This arrangement is slightly modified to construct in foot step and this

arrangement is fixed in

 schools,

 cinema theatres,

 Shopping complex and

 Many other buildings.

--------------------------------------------------------------------------------------
CHAPTER 10
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
LIST OF MATERIALS
--------------------------------------------------------------------------------------
 CHAPTER-10
LIST OF MATERIALS

Sl. No. PARTS Qty. Material

1 Single Acting pneumatic Cylinder 2 Mild Steel

2 Frame Stand 1 Mild Steel

3 Air Tank 1 Mild Steel

4 Gate Valve 1 Mild Steel

5 Hose collar and reducer - Brass

6 Connecting PU Tube - Polyurethene

7 Pressure Gauge 1 Mild Steel

8 Speed breaker setup 1 MS

9 Spring 4 Steel
--------------------------------------------------------------------------------------
CHAPTER 11
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
COST ESTIMATION
--------------------------------------------------------------------------------------
 CHAPTER-11
COST ESTIMATION

1. MATERIAL COST

Sl. No. PARTS Qty. Amount (Rs)

1 Single Acting pneumatic Cylinder 2 600

2 Frame Stand 1 400

3 Air Tank 1 700

4 Gate Valve 1 200

5 Hose collar and reducer - 400

6 Connecting PU Tube - 350

7 Pressure Gauge 1 250

8 Speed breaker setup 1 400

9 Spring 4 200

TOTAL = RS.3500
2. LABOUR COST

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

CUTTING:
Cost = 1200

3. OVERHEAD CHARGES

The overhead charges are arrived by “Manufacturing cost”

Manufacturing Cost = Material Cost + Labour cost

= 3500 + 1200
= 4700

Overhead Charges = 20% of the manufacturing cost

= 740

TOTAL COST

Total cost = Material Cost + Labour cost + Overhead Charges

= 3500 + 1200 + 940
= 5440

Total cost for this project = Rs.5440

--------------------------------------------------------------------------------------
CHAPTER 12
--------------------------------------------------------------------------------------

--------------------------------------------------------------------------------------
CONCLUSION
--------------------------------------------------------------------------------------
 CHAPTER-12
CONCLUSION

This project work has provided us an excellent opportunity and experience,

to use our limited knowledge. We gained a lot of practical knowledge regarding,

planning, purchasing, assembling and machining while doing this project work.

We feel that the project work is a good solution to bridge the gates between the

institution and the industries.

We are proud that we have completed the work with the limited time

successfully. The DESIGN AND FABRICATION OF AIR COMPRESSOR

USING SPEED BRAKER is working with satisfactory conditions. We can able

to understand the difficulties in maintaining the tolerances and also the quality. We

have done to our ability and skill making maximum use of available facilities.

In concluding the words of our project, since the non-conventional air

compressor get its energy requirements from the Non-renewable source of energy.

There is no need of power from the mains and there is less pollution in this source

of energy. It is very useful to the places all roads. It is able to extend this project by

using same arrangement and construct in the steps so that increase the air

production rate by fixing school and colleges, etc.

--------------------------------------------------------------------------------------
REFERENCES
--------------------------------------------------------------------------------------
 REFERENCES

 Manufacturing technology (Machine Processes & Types),

-G.K.Vijayaraghavan.

 Engineering economics & cost analysis (Cost of Material),

-S.Senthil, L.Madan, N.Rabindro Singh.

 Pneumatic Control System

- Stroll &Bernaud

 Pneumatic System
- Majumdhar

 Hydraulic and pneumatic systems

- Cesar millan

 Non conventional technologies

- William Crow

CYBER REFERENCE

 www.howstuffworks.com

 www.visionengineer.com

 www.tpup.com

 www.ijirset.com

 www.scribd.com
--------------------------------------------------------------------------------------
PHOTOGRAPH OF THE MODEL
--------------------------------------------------------------------------------------
PHOTOGRAPH OF THE MODEL