Project Report

on

TITLE OF PROJECT
Submitted in partial fulfillment of the
requirements for the award of the degree
of
BACHELOR OF TECHNOLOGY
in

MECHANICAL ENGINEERING
by

Manas Seth (1602740082)

Kripansh Mishra (1602740077)
Naman Mittal (1602740096)
Shubham Kashyap (1602740149)
Harshit Chandra (1602740066)

Under the supervision

Of
Mr. Rajat Goel
(Assistant Professor)
Department of Mechanical Engineering

AJAY KUMAR GARG ENGINEERING COLLEGE GHAZIABAD

27th Km Stone Delhi - Hapur Bypass Road, Adhyatmik Nagar Ghaziabad - 201009
DR. A. P. J. ABDUL KALAM TECHNICAL UNIVERSITY LUCKNOW
 AJAY KUMAR GARG ENGINEERING COLLEGE
GHAZIABAD

CANDIDATES’ DECLARATION

We hereby declare that the work being presented in the report entitled “PROJECT
TITLE” submitted to Ajay Kumar Garg Engineering College, Ghaziabad, in partial fulfillment
of the requirements for the award of the degree of Bachelor of Technology in Mechanical
Engineering of Dr. A. P. J. Abdul Kalam Technical University, Lucknow, is an authentic record
of our own work carried out during a period from July, 2019 to Dec, 2019 under the supervision
of Mr. Rajat Goel, Assistant Professor, Department of Mechanical Engineering. The matter
presented in this report has not been submitted to any other university or institution for the award
of any degree to the best of my knowledge.

Manas Seth Kripansh Mishra

(1602740082) (162740077)

Naman Mittal Shubham Kashyap

(1602740096) (1602740149)

Harshit Chandra
(1602740066)
 AJAY KUMAR GARG ENGINEERING COLLEGE
GHAZIABAD

CERTIFICATE

This is to certify that the project report entitled “PROJECT TITLE” submitted to Ajay Kumar
Garg Engineering College, Ghaziabad, in partial fulfillment of the requirements for the award
of the degree of Bachelor of Technology in Mechanical Engineering of Dr. A. P. J. Abdul
Kalam Technical University, Lucknow, is bona fide record of work submitted by Manas Seth
(1602740082), Kripansh Mishra (1602740077), Naman Mittal (1602740096), Shubham Kashyap
(1602740149) and Harshit Chandra (1602740066) under my supervision. The matter presented in
this report has not been submitted to any other university or institution for the award of any
degree to the best of my knowledge.

Rajat Goel Dr. Devendra Singh

Assistant Professor Prof & Head
Department of Mechanical Engineering Department of Mechanical
AKGEC, Ghaziabad Engineering
AKGEC, Ghaziabad
 ACKNOWLEDGEMENTS

The success and final outcome of this project required a lot of guidance and assistance from
many people and we are extremely privileged to have got this all along the completion of my
project. All that we have done is only due to such supervision and assistance and we would not
forget to thank them.

We take this opportunity to express our deep sense of gratitude and regard to our project
supervisor Mr. Rajat Goel, Assistant Professor, Department of Mechanical Engineering, Ajay
Kumar Garg Engineering College, Ghaziabad for his continuous encouragement and able
guidance. It is our privilege to express our sincerest regards to our project mentor, for his
valuable inputs, able guidance, encouragement, whole-hearted cooperation and constructive
criticism throughout the duration of our project.

We deeply express our sincere thanks to our Head of Department Prof. (Dr.) Devendra Singh
for encouraging and allowing us to present the project on the topic “Project Title” at our
department premises for the partial fulfillment of the requirements leading to the award of B.
Tech degree.

I would not forget to remember Mr. Vikram Singh Rajput of Mechanical Department for their
encouragement and more over for their timely support and guidance till the completion of our
project work.

I am thankful to and fortunate enough to get constant encouragement, support and guidance from
all Teaching staffs of Mechanical Department which helped us in successfully completing our
project work. Also, I would like to extend our sincere esteems to all staff in laboratory for their
timely support.

We pay our respects and love to our parents and all other family members and friends for their
love and encouragement through-out our career. Last but not the least we express our thanks to
our friends for their cooperation and support.
 ABSTRACT

The project “Project Title” that we aim to develop is a technology that at the moment of writing
this text is not prevalent in the world of 3D Printing. It thus aims to solve a few fundamental
problems associated with the process of the printing of objects through conventional 3D Printers.

This project of ours incorporates significant differences in terms of both design and functionality
fundamentally in the sense that the key component of the 3D Printer, the extruder is modified in
the final product we aim to achieve.

The extruder unit that we aim to develop for our project incorporates a mechanism that is capable
of pulling in materials from two separate inputs into its core. The input of materials although
happens one at a time only.

The materials may be the same of be different according to the printing requirements. The output
of this extruder unit only allows the selected material input at the time to exit the core for the
actual printing purpose.

This advantage in the regulation of the material input at the users’ will provides the elimination
of several problems in the printing processes and the secondary processes associated with it. The
most prominent ones are associated with the cutting down of costs due to the usage of cheaper
materials in regions of non-significant printing.

The proposed modification also provides additional advantage of better dimensional accuracy
while the actual printing of the parts involved.

This extruder unit has a custom-built Aluminum block with two input material pathways and a
single output material pathway. CNC machining is done to manufacture this aluminium block.

Furthermore, the electronic integration for this extruder unit is done using the Arduino Uno
chipset and the .stl file generation is done by open source 3D Printing software.
 TABLE OF CONTENTS

Description Page No.

CANDIDATE'S DECLARATION i
CERTIFICATE ii

ACKNOWLEDGEMENT iii
ABSTRACT iv
TABLE OF CONTENTS v
LIST OF FIGURES xv
LIST OF TABLES xvii
NOMENCLATURE xvii
ABBREVIATIONS xviii
Chapter 1: Introduction
1.0 Preamble 1
1.1 Present State of Research in Manufacturing 2
1.2 Organization of the Project Report 13
Chapter 2: Literature Review

LIST OF FIGURES

Figure No. Caption Page

1.1 A schematic of journal bearing 3
 LIST OF TABLES

Table No. Caption Page

1.1 Velocity profile of journal bearing 2
 NOMENCLATURE

Symbol Description
v Linear velocity (m/s)
ABBREVIATIONS
 CHAPTER 1

INTRODUCTION

1.1 Basics of 3D Printing

3D Printing is an additive manufacturing process in which a certain material is pulled into
a heating element of the print assembly and it gets melted into a semisolid form inside
this component. This semisolid material is then fed to the extruder part of the assembly
which is essentially similar to a pen whose output is ink. Only in this case the output of
the extruder is the semisolid melted material through a much smaller output diameter.
This melted material then is placed on a flat surface called the printing bed which is
usually a large, flat and clean slab of glass. Upon this printing bed, the output material is
allowed to cool and solidify one layer at a time. Thus, a layer can only be added on top of
another layer only when the previous layer has already been solidified. This is done by
regulating the corresponding printing speed which is mainly dependent on the type of
material used in the printing process. In this way the object is finally build from a layer
by layer sequential additive process after cooling and solidification.

1.2 Guiding Systems in a 3D printer Assembly

A guiding system is a pretty important design consideration in a 3D printing setup. This
system designates the manner in which the material enters the core of the assembly. The
material used for 3D printing comes in the form of a condensed wire which sound around a
spool of base material. This wire then is pulled into the heating element of the system core
for heating and extrusion. The guiding system thus dictates in which way is the guiding is to
be done of the material filament wire. There re, broadly speaking, two ways or methods to
consider in these systems.
1.2.1 Direct Extrusion System
1.2.1.1 Advantages

 Better Extrusion: Since a direct extruder is mounted to the print head, the motor can easily
push filament through the nozzle, allowing for better extrusion.
 Faster Retraction: Because the extruder is close to the nozzle, the direct extruder can
quickly retract filament.
 Less Powerful Motor: Due to the short distance between the extruder and nozzle, less torque
from the motor is required to push filament.
 Wider Range of Filaments: A direct extruder is compatible with a wide range of filaments.
Even with flex

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1.2.1.2 Disadvantages
Burdened Movements: With the extruder mounted to the print head, weight is obviously
added. This extra weight adds speed constraints, causing more wobble and possibly a loss
of accuracy in the X and Y axes.

1.2.2 Bowden Tube Extrusion System

1.2.2.1 Advantages

 Cleaner Movements: Since a Bowden extruder is mounted on the printer’s frame rather than
on the print head, much less weight is on the carriage. Less weight means faster, quieter, and
higher quality prints.
 Larger Build Volume: A Bowden extruder allows for a smaller print head carriage, which,
in turn, allows for increased build volume.
 Compact Size: Bowden extruders are typically more compact, taking up less space than a
normal direct extruder. 

1.2.2.2 Disadvantages

 More Powerful Motor: Because a Bowden extruder is pushing and pulling filament through
a long tube, a certain amount of friction exists between the two. This friction calls for more
torque to control filament.
 Slower Response Time: More friction in the Bowden tube also translates to slow response
time. Bowden extruders require longer and faster retraction to avoid stringing.
 Smaller Range of Materials: Some flexible and abrasive filaments can easily bind or wear
in Bowden tubes. 

1.3 Material Choices

1.3.1 Polylactic Acid (PLA)
 This is an excellent choice for material for 3D Printing.
 The reason being this material’s properties of high tensile strength.
 It has an ultimate strength of around 46MPa.
 The major drawbacks of using this material is that it is very brittle in nature.
 Owing to these properties, it is advisable for frame structures.

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1.3.2 Nylon
 Nylon is another material available for 3D Printing processes.
 It has excellent impact resistance and abrasion resistance.
 The drawbacks are that it is expensive and requires additional auxiliary equipment to print.
1.3.3 PETG
 This material has excellent surface finish properties.
 It has the downside of being applicable to only the specific industry of water resistant
products.
1.3.4 Carbon Fiber ABS
 This is the final printing material that is chosen in terms of this project.
 This being due to the superior strength of this material against all the others discussed.
 It has a tensile strength of around 65MPa and an ultimate strength of 90MPa.
 It has the additional advantages of being less brittle than most of the other choices
available.
 Thus, it is far more applicable in a variety of industries for manufacturing parts and
structures.

1.4 Components of the final assembly

 Extruder
 Mounting frame
 Enclosure
 Cooling system
 Drive system
 Heated Printing Bed
 Electronics system

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 CHAPTER 2

LITERATURE REVIEW

2.1 More than two authors: Halil l. Tekinalp, Vlastimil Kunc, Gregorio M. Velez-Garcia
(2014) analyzed the processability, microstructure, mechanical performance and physical
characteristics of short-fiber (0.2-0.4mm) infused ABS filament in terms of 3D printing. 00%,
respectively. 3D-printing yielded samples with very high fiber orientation in the printing
direction (up to 91.5%), whereas, compression molding process yielded samples with
significantly lower fiber orientation. Microstructure–mechanical property relationships revealed
that although a relatively high porosity is observed in 3D-printed composites as compared to
those produced by the conventional compression molding technique, they both exhibited
comparable tensile strength and modulus. This phenomenon is explained based on the changes in
fiber orientation, dispersion and void formation.

2.2 More than two authors: Longwei Yan, Huichao Sun, Xingtian Qu and Wei Zhou (2016)
studied the developments in 3D Printing techniques and catalogued them. Conclusively, they
stated that the Fused Deposition Modelling technique is the most effective one when it comes to
rapid prototyping.

2.3 More than two authors: Chuncheng Yang, Xiayong Tian, Tengfei Liu, Yi Cao (2017)
analyzed the mechanical performance of continuous fiber reinforced thermoplastic composites. It
was found that for 10% Wt. CFABS composite achieved a flexural strength of 127 MPa for the
printed parts and the flexural modulus attained was 7.72 GPa. The fracture mode found for the
thermoplastic was surface tension fracture, in which the thermoplastic matrix is fractured by
tensile stresses first and then the fibers are pulled out from the matrix. The tensile strength found
out was about 147 MPa and the tensile modulus was found out to be 4.85 GPa. However the
interlaminar shear stress found out for the same thermoplastic specimen was found out to be
around 2.81 MPa.

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2.4 More than two authors: Shanling Han, Yu Xiao, Tao Qi, Zhiyong Li, and Qingliang
Zeng (2017) designed and analyzed the multiple types of material being sequentially input into
the extruder unit setup. They ascertained through their research paper that Fused deposition
modeling (FDM) has been one of the most widely used rapid prototyping (RP) technologies
leading to the increase in market attention. Obviously, it is desirable to print 3D objects;
however, existing FDM printers are restricted to printing only monochrome objects because of
the entry-level nozzle structure, and literature on the topic is also sparse. In this paper, the CAD
model of the nozzle is established first by UG (Unigraphics NX) software to show the structure
of fused deposition modeling 3D printer nozzle for color mixing. Second, the flow channel
model of the nozzle is extracted and simplified. Then, the CAD and finite element model are
established by UG and ICEM CFD software, respectively, to prepare for the simulation. The
flow field is simulated by Fluent software. The nozzle’s suitable temperature at different
extrusion speeds is obtained, and the reason for the blockage at the intersection of the heating
block is revealed. Finally, test verification of the nozzle is performed, which can produce mixed-
color artifacts stably.

2.5 More than two authors: Md. Muzammal Hoque, Dr. Md. Hasrat Kabir, Md. Mehedi
Hasan Jony (2018) developed and designed the Bowden tube extrusion system for 1.75mm
filament for 3D Printing. Easily maintainable and usable Bowden extruder of FDM technology
was designed and implemented on a 3D printer. The results are presented here. Two models of
different material (ABS & PLA) were printed at different temperature (230 degree Celsius to 250
degrees Celsius), when the bed temperature was fixed. It is observed that, the printer with this
extruder prints the model almost accurately. Although, in some cases a deviation is observed at
the thin and sharp edge of the model. A little warping problem is also found occasionally found.

2.6 More than two authors: Athanasios Galatas, Hany Hassanin, Yaha Zweiri (2018)
developed a hybrid material which incorporated a material sandwich of CFABS thermoplastic
and ABS sandwiched between the former’s sheets in terms of unmanned aerospace vehicle
applications. The results showed an improvement of specific strength and elastic modulus with

5
increasing the number of CFABS. The specific strength of the samples improved from 20 to 145
KN·m/kg while the Young’s modulus increased from 0.63 to 10.1 GPa when laminating the
samples with CFABS layers.

CHAPTER 3

PROBLEM IDENTIFICATION

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 CHAPTER 4

METHODOLOGY (OR) EXPERIMENTAL SETUP

7
 CHAPTER 5

RESULTS AND DISCUSSION

8
 CHAPTER 6

CONCLUSION AND FUTURE SCOPE OF WORK

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 REFERENCES

Books:
[Sl.No.] Author, “Title of the Book”, Year of Publication, Name of Publisher, Place of
Publication, Edition No., Chapter No., Page No.
Journals:
[Sl. No.] Author/s, Year, “Title of the research paper”, Name of the Journal, Vol., issue, page,

Examples:
Journals:
[1] Singla, Y, 1990, Optimum Spacing of Tubewells in Relation to Channel Losses and Lining. J.
ASCE, Irrigation and Drainage Div. 117 (5): 791-799.
[2] Singh, S and Tiwari, B. C. 1992. Performance Evaluation of Double Hub Paddle Wheel
Aerator. Journal of Environmental Engng, ASCE 135(7): 562-566.
[3] Reddy, A., Chowdary, V.M., Mal, B.C. and Billib, M. 1995. Application of the WEPP Model
for Prioritization and Evaluation of Best Management Practices in an Indian Watershed.
Hydrological Processes. 23: 2997-3005.

Books
[4] Mal, B.C. 1995. Introduction to Soil and Water Conservation Engineering. Kalyani
Publishers, New Delhi. First Ed. Ch 16, pp 403-406.
Website

http://www.gobbeldygook.co.uk (accessed on Date)

***The reference will contain full details of authors (not like as given in literature review)

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APPENDIX

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