Chapter 1

Design of Machine in Solid Modelling

Page 1
Page 2
 Chapter2

Introduction

The glass edge polishing machine for any kind of glass could be
implemented using a motor which will help to make the edges uniform & satin.
The two rollers are also fitted on which the belt made up of polishing paper is
fitted or implemented.

The rollers are rotated with required speed using pedestal bearing &inn
which shafts attached to the rollers are inserted. A rubber belt is used to drive
one of the rollers which will purposely rotate the other roller with the help of
polishing belt, pulley is attached to the end of that roller & by that rubber belt
is connected to pulley of attached to the shaft of motor.

Whenever we look up in the glass manufacturing industry. It is always

an difficult & time consuming job to polish the edges of glass ( cut ) manually
with hand using polish paper for the workers. But using glass edge polishing
machine will help to reduce time needed to polish the edges of glass & it is
also less dangerous. Even if it cant polish large piece of glass but for medium
it is efficient.

Page 3
 Chapter3

Scope of Project :-
Glass edger is very sharp and dangerous for human body. So the edge
polishing machine is important.

We are produce a glass edge polish machine its efficiency is equal to

other machines. This machine have less skilled operator. It is less costly than
other machines, easy to work this machine is easily operate in home. If we
want polish edges of glass in home then this machine is best option. This
machine required less space, less costly & equal efficient, easy to operate. So
this is best option for Mass Production.

Page 4
 Chapter4

Material used

4.1 Mild Steel :-

It is a common form of steel. It is not brittle, it is cheap. It is often used
when large amounts of steel are needed. Mild steel is a carbon steel typically
with a maximum of 0.25% carbon and 0.4% to 0.7% manganese, 0.1% to
0.5% silicon and some traces of other elements such as phosphorous, it may
also contain lead.

Many everyday objects are made by of mild steel.

Mild steel is a general term for a range of low carbon steels that have
good strength and can be bent, worked or can be welded into an endless
variety of shapes.

Mild steel is good for use that it is inexpensive and strong it is also
possible to paint the mild steel.

It is popular type of steel because it is cheap and its material properties

fit into many product applications.

Mild steel has a relatively low tensile strength, but it is cheap and
malleable and its surface hardness increases by a different processes like
carburizing.

Mild steel is ductile and can easily machined. It is a grade of steel that
does not harden when heated and chilled with cold water. So, further
machining can be easy.

5 Main advantages of Mild Steel

1) Easily machined
2) Weldable
3) Ductile
4) Easily available and low cost and
5) Easily painted
6) Low tensile strength.

Page 5
We are use M.S. for –
1. Shaft
2. Roller
3. Base
4. A.C. Motor casing
5. Power Screw
6. Nuts & Bolts

Page 6
4.2 Belt Material
Shaping material of the belt is abrasive most commonly use. Abrasive
grain for glass edge, polishing belt is silicon carbide grain. It is sharper but it is
brittle silicon carbide grain, tends to be more aggressive, but short in life.

Backing material of glass edge polishing machine belt is made from

cloth. Cloth is use cotton or polyster or some combinations of two. It is a water
resistant.

Page 7
 Chapter5

Part List :

Part Name Quantity Material Used

0.75 HP AC Motor 1 M.S

Shaft 2 M.S

Roller 2 M.S

Pedestal Bearing 4 S.S

Pulley Belt 1 Rubber

Pulley 2 M.S

Glass Polish Belt 1 Silicon Carbide grain

Power Screw 1 M.S

Nuts & Bolts 12 M.S

Page 8
 Chapter 6

Design Procedure for Shaft

Given data –

- Diameter of Shaft (d) = 19.84

- N (rpm) = 1440
- Power (p) = 0.75 HP
= 0.75 X 746
= 559.5 watt

To find torque –

By Formula,

2  NT
P=
60
60 x P
T=
2N

60 x 559.5
=
2 x x 1440

= 3.71 N - m

= 3.71 x 103N – mm

Now find Shear stress (  )

16 T
 =
 d3

16 x 3.71 x 103
=
x 19.84

 = 952.39 N / mm2

Page 9
 Chapter 7

Introduction of Parts :-

7.1 Base

Dimensions –

Material :- M.S
Length:- 910 mm
Height:- 340 mm

Function :-

It is a rigid. It support all assembly. All other components are mounted

on it. It is absorb all the vibrations. The base is capable of handling all the
forces.

Page 10
7.2 Electric Motor

Motor Horse Power :- 0.75 HP

Motor RPM :- 1440 rpm
Phase :- Single Phase
Material :- M.S.
Function :-

An electric motor is an electric machine that converts electrical energy

into mechanical energy. The reverse of this would be the conversion of
mechanical energy into electrical energy and is done by
an electric generator. The rotational motion of motor is utilize to rotate rollers
through pulley arrangement. The shaft of motor is connected to pulley and
power is transmitted via belt to other pulley and then finally to roller shaft. The
electric motor is fixed on base with four nut and bolts.

Page 11
7.3 Pedestal Bearings

Materials:-

Parts - Materials

Bearing Raceways - Martensite stainless steel (equivalent to SUS440C)

Rolling element -Martensite stainless steel (SUS440C)

Slinger, Retainer- Austenite stainless steel (SUS304)

Rubber seal- Nitryl rubber

Set bolt (W shape bolt head) - Martensite stainless steel (SUS410)

Bearing housing - Austenite stainless steel casting (SCS13)

Cover - Austenite stainless steel (SUS304)

Dimension :- Bearing Diameter 20mm

Function:-

Pedestal bearing are stainless series feature ball bearings inserted into
housings made of stainless that provide superior resistance to corrosion as
compared to standard series cast iron units. The solid grease lubricating the
bearing has been heathardened and is a mixture of lubricant and ultra
highmoleculer weight polyethylene. The solid grease reduces leakage,
prolonging lubricant life. The bearings are mounted on base with help of nut
and bolts. The shafts are inserted inside bearing so that they can consume
less torque and transmit more power.

Page 12
7.4 Rollers

Dimension

Inner Diameter - 117.5 mm

Outer Diameter- 121.9 mm

Material:- M.S.

Function :-

The two rollers are provided which are in tight tension with glass polish
belt. The rollers are rod welded to two shafts which are connected to pedestal
bearings in series.The first roller is stationery and other one is moving one to
adjust tension between belt. The tension in belt is adjusted with help of bolt
machanism. As the bolt rotates in anticlockwise direction itmoves roller in
backward direction which results in tightening of belt. And when belt is rotated
in clockwise direction the roller moves forward which results in slackening or
loose in tension in belt.

Page 13
7.5 Shaft

Dimension :-

Length :- 417 mm

Diameter:- 19.84 mm

Material :- M.S.

Function :-

It carries roller itself. At one end of pulley is fixed and other end roller is
fixed and in middle the shaft passes through pedestal bearings. Rotational
motion leads to rotation of roller which in turn helps in polishing the glass.
Shaft is a mechanical component for transmitting torque and rotation ,usually
used to connect other components of a drive train that cannot be connected
directly because of distance or the need to allow for relative movement
between them.

As torque carries ,drive shaft are subjected to torsion and shear stress,
equivalent to the difference between the input torquee and the load. They
must therefore be strong enough to bear stress, while avoiding too much
additional weight as that would in turn increase their inertia.

Page 14
7.6 Glass Polish Belt

Dimension

Material:-Silicon Carbide Grain

Function:-

The glass polish belt is mounted on two rollers. As the roller rotates the
rotational motion of roller is given to belt which in turn rotate the belt which
results in polish of belt. The proper tension has to be maintain between the
belt and the rollers to avoid sleeping phenomenon of belt and loss of power
transmission. The work of giving proper tension to belt is done by roller and
srew mechanism. The bolt which is attached to base provides sliding motion
to roller second thus roller change its position and this results in tension to
belt.

Page 15
7.7 Bolt and Nut Mechanism

Dimension

Material:-M.S.

Function:-

The bolt and nut is mounted on base by welding. The bolt is connected
to bracket by welding.

The roller which is to be slide is placed inside bracket along with

pedestal bearing. As the nut rotates in anticlockwise direction it moves roller
in backward direction which results in tightening of belt. And when nut is
rotated in clockwise direction the roller moves forward which results in
slackening or loose in tension in belt. The bolt is inserted through a hole
drilled in each item to be fastened together, then the nut is threaded onto
the bolt from the other side and tightened, to give a strong connection. These
Bolts are used in corrosive atmospheres are often made from a special grade
of steel known as stainless steel, which has a high nickel or chrome
content. Bolts, nuts and screws are also available in other materials such as
high-strength steel, brass, aluminium.

Page 16
7.8 Pulleys

Dimension:-

Internal Diameter of Roller Pulley – 19.84 mm

External Diameter of Roller Pulley - 76.58 mm

Internal Diameter of Motor Pulley – 12.04 mm

External Diameter of Motor Pulley – 77.96 mm

Material:- M.S.

Function:-

The two pulleys equal in diameter are used in power transmission. The
first pulley is press fitted to electric motor shaft. And other pulley is connected
to shaft of first roller. The two pulleys are connected to each other vai belt. As
the electric motor starts rotating the first pulley is rotated the power from first
pulley is transmitted to second pulley through belt. And hence forth the power
of second pulley is transmitted to roller via shaft.

Page 17
7.9 Sliding Mechanism

Dimension -

Power Screw Length - 310 mm

Power Screw Diameter – 19.9 mm

Material :- M.S.

Consist of 2 slide angle with the one power screw, nuts and bolts.

Function :-

Sliding mechanism is the most important component in our project. The

tension in belt is very important for efficient work. The sliding mechanism
gives tension to the belt.

It is depended on power screw. If screw rotate anti clockwise direction

then mechanism comes with bearing and shaft at backward direction and
gives tension to the belt.

Then the screw rotate at clockwise direction then mechanism goes with
direction bearing and shaft at forward direction and reduce the tension in the
belt. Then we replace the belt easily.

Page 18
 Chapter8

Assembly of Project

Page 19
Page 20
Page 21
 Chapter9

Construction :-
1) Motor is mounted on frame.
2) A shaft of roller is attached to shaft of engine with the 2 pulleys.
3) Rubber belt is wounded over pulleys.
4) Polish paper belt is wounded over 2 rollers.
5) Polish paper belt – attached to 2nd roller.

Page 22
 Chapter10

Working :-

The working of the glass edge polishing machine is easy as it seems.

As when we start the switch the motor will start rotating its shaft & with the
help of pulley attached to the shaft one roller will also starts rotating at the
speed of the shaft of motor. The both the pulleys are able to rotate at same
speed because of rubber belt wounded on the pulleys. The other roller will
also starts rotating with the roller with pulley because the polish belt with
enough tension is attached to it is provided for the other roller so as to
maintain its tension. When the belt ( polishing ) rotates with enough tension
the edge of glass must come in contact with polishing belt. We just simply
have to put or force the edge of glass on the polish paper on towards the
direction of rotating polish paper belt.

Page 23
 Chapter11

Costing

Sr.No. Components Quantity Cost RS.

1 Frame / Stand 1 1200

2 0.75 HP AC Motor 1 2000

3 Bearing 4 500

4 Rollers 2 200

5 Shaft 2 400

6 Nuts& Bolts -- 50

7 Screw 1 250

8 Belt 1 54

9 Pulley 2 170

10 Polish Belt 1 55

11 Fabrication -- 1500

Total 3879

Page 24
 Chapter 12

10.1 Precaution:-
1) Use glows to avoid injury of fingers which can be caused due to sharp
edges of glass.
2) Use shoes to avoid injury.
3) To check proper tension in Belt.
4) Use Apron.

10.2 Advantages:-

1) Low Maintenance Cost.

2) Skilled operator is not required.
3) Simple to operate.
4) Cost is low.
5) Simple in construction.
6) Suitable for Mass Production
7) Any type of glass can be polish having high Flexibility.

10.3 Disadvantages:-

1) Low lifespan of belt due to wear and tear takes place of belt because of
glass.
2) Tension in belt is necessary.

Page 25
 Chapter 13

Conclusion:-
In this project we have done by using glass polish machine, smooth
edges of glass are obtained.

This machine is developed because when the person in industry

manually make the glass edge smooth, then at that process glass can be cut
to his hand, so to avoid this accident glass polish machine has being
developed.

Whenever the glass is manually polished in that industry or factory

more time, less accuracy and more chances of injury takes place, But by
using this machine we can obtain more accuracy, Fast operation and less
chances of injury.

Page 26
References:-

1) Production Technology, R.K. Jain,Khanna Pusblishers,2003

2) Machine Design, R.S.Khurmi, S.Chand, 2005
3) Mechanical & Industrial Measurement, R.K.Jain, Khanna Publishers,2003
4) Workshop Technology, R.S.Khurmi and J.K Gupta, S.Chand, 2006

Source of Internet -
1) www.alibaba.com

Page 27