Power Hammer

Abstract
Hammering is the most widely used industrial as well as construction activity.
Hammering or screws, metal sheets, parts etc requires a lot of time and effort. So here we
propose an automated hammering system that allows for fully automatic hammering
process. This allows for accurate, fast and automated hammering wherever and whenever
needed using a 12V battery. The person just needs to insert workpiece and start the
hammering machine. This machine can be used for automatic hammering work as and
when needed. We here use a dc motor in order to move the hammer. The DC motor
consists of a pulley attached to it which is connected to a larger pulley for efficient power
transfer and to increase torque. This large pulley is connected to a shaft that has a
connecting rod attached to it. This rod is used to achieve lateral motion from the spinning
shaft. We now connect the other end of hammer to this connecting rod through a mid-
swinging arrangement in order to achieve desired hammer motion with enough torque.
We now use a suitable bed where workpiece can be placed.
In the present scenario due to the technologies advancement there are lots of
demands of the products in the market for production of many components. This
invention is relates to fabricate a simple power hammer machine having low cost,
compact, easy to operate, and having less power requirement for a forging operation
performed by blacksmiths. More particularly this invention is relates use of power
hammer by small scale industries or workshops having less force requirement in forging
than the other hammer machines available in the market to produce or manufacture a
small parts like knives, medical equipment’s, sockets, hooks, clips, dental equipment’s,
rings, manifolds, couplings, etc.

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Index
Chapter No. Title of the Chapter Page No.
i Abstract 1
ii Index 2
Introduction
1 1.1 Introduction 3-5
1.2 Objective
2 Literature Review 6-7
3 Construction & Working of Project 8-9
4 Design of the Project 10-19
5 Manufacturing Process of the Project 20-32
6 Advantages, Disadvantages and Application of project 33
7 Conclusion 34
Reference 35

Chapter-1
Introduction:-
1.1 Introduction

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Forging is the one type of mechanical process in which metal is heated and

hammered by blacksmith, but in the present scenario the forging operation done by

means of hammer machine tool. Whole operation is replaced from manual to automatic.

The machine requires power source to perform the forging operation.

Power hammer is one type of machine tool which is used in forging operation.

This machine use power source for up-down the hammer to being hammered any parts or

components. They have been used by blacksmiths since 1880s, by replacing trip

hammers. Generally power hammer consists of Ram, Frame, Anvil, Hammer head, Dies,

Connecting Rod, Leaf Spring and power source like electric motor.

Simply, power hammer is the machine tool which uses the electric power source

to run the motor and this rotary motion of the motor is utilize to reciprocate the ram by

attaching the leaf spring between ram and connecting rod.

In this invention we have been modeling the machine in the software and made a

simple and compact layout of the machine as per requirement of forging operations.

This project is basically worried about the upset outline process and assembling

machine of programmed compact hammering machine. Prototype which can be defeated

the issue of off base hammering and strange effect of hammering in procedure of

manufacturing. A conceivable arrangement of the issue of moderate hammering speed

and anomalous hammering by a work is plan a programmed convenient hammering

machine given mechanical advances in assembling process technique. The suitability of

such an idea was explored as far as delivering reasonable and compacted plan for

specialist which can be exchange anyplace of this machine by any laborers.

Automatic portable hammering machine can be considered as the backbone of

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any hammering operation in mass production its principle function is to safely and

preciously hammering work like to perform the punching operation, filleting operation,

riveting operation and smithy operation i.e. upset forging etc for all designed operating

conditions. This paper describes cad modeling, design and analysis of automatic portable

hammering machine. A programmed hammering machine self-working machine going to

assume an imperative part in the assembling procedure (hammering process). Hammering

machine utilized as a part of the generation of material extending from instruments, to

pivots, car frame forming, molding of metal and so forth. The present development

identified with metal squeezing machine and forming machine included certain

outstanding challenges in regard of to drive nail, fit parts, forge metal and break separated

question. The innovation has for its question cure this downside and to empower, by

including helper implies, to drive nail, fit parts, manufacture metal and break separated

protest the like. Hammering is the most generally utilized in mechanical operation and

also development action. Hammering or screws

Now the project mainly concentrates on designing a suitable operating system. To

maintain simplicity and economy in the design the locally fabricated unit has been used.

Our project achieves higher safety, reduces human effort, increases the efficiency,

reduces the work load, reduces the fatigue of workers and reduces maintenance cost.

2. Objective of the project

 To understand the basic principal of the our project

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 Describe the construction and working of various parts of our project

 Development of the working model of the our project

Chapter-2
Literature Review

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[1]. John Byron Henry, et.al. Invention relates to power hammers, and particularly

to steam forge hammers including a supporting frame, a hammer operating power

cylinder provided with a piston and piston rod carrying a ram or hammer attached.

[2]. Richard W. Hall, et.al, invention is to double acting forging hammers and,

more particularly, to forging hammers actuated by pressurized gas and/or hydraulic fluid.

Accordingly, there is a need for double-acting forging hammer which utilizes pneumatic

and/or hydraulic hammer driving systems, yet does not have the energy losses associated

with pneumatic systems or the complex and sophisticated of hydraulic systems.

[3]. Howard Terhune, et.al, invented this project is simply is an improvement of

forging hammers used for industrial purposes. As we aware that in forging operation the

temperature of the metal is so high that manual hammering operation is quite difficult for

this purpose. So in this project they provided control valves which directing the ram up or

down by the steam power.

[4]. Invention relates generally to portable motor-operated and manually

controlled machine tools or implements, and more specifically to an improved hammer

tool and operating mechanism of the reciprocating, rotary cam actuated type, and

designed for interchangeable us as a portable power-operated hammer, wood chisel,

scaling chisel, piercing punch, rock drill, and other similar power tools.

[5]. John I. Kupta et.al, invention herein disclosed relates to steam and air

hammers of the pile driver type and in which, usually, the motive fluid is just admitted to

lift and then released to drop the ram. ‘Operating in this manner such hammers naturally

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are inetiicient the use of steam or air and since gravity is the force relied on for the

striking blow, the ram and other parts have had to be heavy and bulky.

[6]. David A. Giardino, et.al, invention relates to the art of rotary impact wrenches

of a type in which a rotating member is periodically reciprocated into and out of rotary

impacting relation with an anvil portion of torque output shaft.

From the detailed literature review it can be observed that there was not any

simple and compact machine designed. All the research was heavy and complex machine

related. So, we have been trying to modelling a simple power hammer machine to

perform forging operation easily.

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Chapter-3
Construction & Working of Project
3.1 Parts used in the project
 Shaft
 DC Motor
 Hammer
 Mounts & Fixtures
 Supporting Frame
 Joints & Screws

3.2 Diagram of the project

Motor
Power supply

Hammer

Frame Structure

3.3 Working of the project

This project has various different design paths to complete our products while

matting the objectives. these means we will have to implement and compare our different

design to insure the best product on our sat of objectives .this paths have changed as we

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progressed through our project, and there were few fore seen methods that we expand

upon in the design section.

The basic design for automatic hammering machine is to have motor fixed on stand, and

then motor shaft is inserted in center hole of the disc. Disc is connected to the hammer

rod with the link rod when we supply the dc current to the dc motor by using adopter then

the motor shaft start rotating further transmit the spinning motion to the disc by using

shaft the first decision is to create an impact force for the respective operation this will

help to determine product affordability.

A more efficient yet expensive design would be to have battery instead of adopter. There

is bound to be various obstacles and design method to be implemented as projected

progressives and will be observed and recorded as they occur.

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Chapter-4

Design and design consideration of the project

4.1. Design consideration of the project

4.1.1 Introduction:

Project design may be defined as the iterative decision making activity to create a

plan or plans by which the available resources are converted, preferably optimally, into

systems, processes or devices to perform the desired functions and to meet human needs.

In fact project design has been defined in many ways but the simplest ways to define

project design as

“An iterative decision making process to conceive and implement optimum

systems to solve society’s problems and needs.”

Project design is practical in nature and must be concerned with physical

reliability, or economic and financial feasibility Design is essentially a decision-making

process. If we have a problem, we need to design a solution. In other words, to design is

to formulate a plan to satisfy a particular need and to create something with a physical

reality.

4.1.2 Basic concept of project design:

Decision making comes in every stage of design. Consider two cars of different

makes. They may both be reasonable cars and serve the same purpose but the designs are

different. The designers consider different factors and come to certain conclusions

leading to an optimum design. Market survey gives an indication of what people want.

Existing norms play an important role. Once a critical decision is made, the rest of the

design features follow. For example, once we decide the engine capacity, the shape and

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size, then the subsequent course of the design would follow. A bad decision leads to a

bad design and a bad product.

Design may be for different products and with the present specialization and

knowledge bank, we have a long list of design disciplines e.g. ship design, building

design, process design, bridge design, clothing or fashion design and so

4.1.3 Types of project design:

There may be several types of design such as

1. Adaptive design

This is based on existing design, for example, standard products or systems

adopted for a new application. Conveyor belts, control system of projects and

mechanisms or haulage systems are some of the examples where existing design systems

are adapted for a particular use.

2. Developmental designs

Here we start with an existing design but finally a modified design is obtained. A

new model of a car is a typical example of a developmental design .

3. New design

This type of design is an entirely new one but based on existing scientific

principles. No scientific invention is involved but requires creative thinking to solve a

problem. Examples of this type of design may include designing a small vehicle for

transportation of men and material on board a ship or in a desert. Some research activity

may be necessary.

 Types of design based on methods

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4. Rational design:

This is based on determining the stresses and strains of components and thereby

deciding their dimensions.

5. Empirical design:

This is based on empirical formulae which in turn are based on experience and

experiments. For example, when we tighten a nut on a bolt the force exerted or the

stresses induced cannot be determined exactly but experience shows that the tightening

force may be given by P=284d where, d is the bolt diameter in mm and P is the applied

force in kg. There is no mathematical backing of this equation but it is based on

observations and experience.

6. Industrial design:

These are based on industrial considerations and norms viz. market survey,

external look, production facilities, low cost, use of existing standard products.

4.1.4 Factors to be considered in project design

There are many factors to be considered while attacking a design problem. In many

cases these are a common sense approach to solving a problem. Some of these factors are

as follows:

(a) What device or mechanism to be used? This would decide the relative

arrangement of the constituent elements.

(b) Material

(c) Forces on the elements

(d) Size, shape and space requirements. The final weight of the product is also a

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major concern.

(e) The method of manufacturing the components and their assembly.

(f) How will it operate?

(g) Reliability and safety aspects

(h) Inspectibility

(i) Maintenance, cost and aesthetics of the designed product.

 What device or mechanism to be used:

This is best judged by understanding the problem thoroughly. Sometimes a

particular function can be achieved by a number of means or by using different

mechanisms and the designer has to decide which one is most effective under the

circumstances. A rough design or layout diagram may be made to crystallize the thoughts

regarding the relative arrangement of the elements.

1. Material:

This is a very important aspect of any design. A wrong choice of material may

lead to failure, over or undersized product or expensive items. The choice of materials is

thus dependent on suitable properties of the material for each component, their suitability

of fabrication or manufacture and the cost.

2. Load:

The external loads cause internal stresses in the elements and these stresses must be

determined accurately since these will be used in determining the component size.

Loading may be due to:

i) Energy transmission by a project member.

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ii) Dead weight.

iii) Inertial forces.

iv) Thermal effects.

v) Frictional forces.

4.1.5. Steps in project design

Project Design or mechanical design is primarily concerned with the systems by

which the energy is converted into useful mechanical forms and of mechanisms required

to convert the output of the project to the desired form. The design may lead to an

entirely new project or an improvement on an existing one. Thus project design is the

production or creation of the right combination of correctly proportioned moving and

stationary components so constructed and joined as to enable the liberation,

transformation, and utilization of energy.

The basic procedure of project design (Mechanical Project Design) consists of a

step by step approach from given specifications of functional requirement of a product to

the complete description in the form of blue prints of the final product. The following

steps are involved:

First Step:

In the very first step a complete list of specifications for the functional

requirement of the product is to be prepared. The requirement may include, for example:

(a) Output capacity;

(b) Service life;

(c) Cost;

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(d) Reliability; etc.

In consumer products, in addition appearance, noiseless operation, and simplicity in

control are important requirements. Depending upon the type of product, various

requirements are given Weight age and a priority list of specifications is prepared.

Second Step:

After a careful study of the requirements the designer prepares rough sketches of

different possible mechanisms of project and depending upon the cost competitiveness,

availability of raw material, and manufacturing facilities, the possible mechanisms are

compared with each other and the designer selects the best possible mechanism for the

product

Third Step:

In the third step of the design procedure a block diagram is to be prepared which

showing the general layout of the selected configuration. In this step designer specifies

the joining methods, such as riveting, bolting, and welding to connect the individual

components. Rough sketches of shapes of individual parts are prepared.

Fourth Step:

 After selecting the required or deciding the configuration of mechanism / project

in third step above. The design of individual components of the selected

configuration is to be done in this step. It consists of the following stages:

 Determine the forces acting on each component;

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 Selecting the proper material for the component depending upon the functional

requirement, such as strength, wear, rigidity, hardness and bearing properties etc.

 Determine the likely mode of failure & select the criterion of failure like, yield

strength, ultimate strength, deflection etc.

 Determine the geometric dimensions of the components using suitable factor of

safety and modify the dimensions from manufacturing considerations. This stage

involves the detailed stress analysis.

Fifth Step:

The last stage in design process is to prepare the blue prints of assembly and

individual component. On these drawings, the material of the components, dimensions

and tolerances, surface finish and machining methods are specified.

The designer prepare two separate lists of components

 Standard components to be purchased directly from the market;

 Special components to be projects in the factory;

Thus the project design or mechanical design process is a systematic step-by-step

approach from known specification to unknown solution

4.1.6. Planning for project design

Project design is the chronological vertical structure of the various phases or steps

together from the project analysis to the retirement of the product. Thus Project of design

includes the following steps:

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(i) Feasibility Study:

The aim is to produce a number of feasible and useful solutions. Here the

alternatives are assessed in stages. The first stage is made on the basis of common sense.

Many of the broad solutions may not be worth consideration. Considering technical

feasibility some of the solutions can be eliminated. The last stage is the economic

assessment. Systematic technical, economic, social and legal considerations provide a

rapid convergence towards the useful solutions.

(ii) Preliminary Design:

Feasibility study yields a set of useful solutions. The aim in this phase is to choose

the optimal solution. To do this, criterion of optimization must be explicitly delineated.

The chosen alternative is then tested and predictions are made concerning its

performance.

(iii) Detailed Design:

The purpose of the detailed design is to produce a complete project description of

a tested and producible design for manufacture. A detailed design includes manufacturing

drawings with tolerances. Planning for Manufacturing- A procedure sheet is to be made

which contains a sequence of manufacturing operations that must be performed on the

component. It specifies clearly the tooling, fixtures and production projects. This phase

may include planning, and inventory control, quality control system, the fixing of

standard time and labor cost for each operation.

(iv) Planning for Distribution, Use of the Product:

The success of a design depends on the skill exercised in marketing the product.

Also the user-oriented concern such as reliability, ease of maintenance, product safety,

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and convenience in use, aesthetic appeal, economy and durability must meet. The product

life considering actual wear or deterioration, and technological obsolescence must be

planned.

4.2 Design of the project

4.2.1 Selection of power supply

An electric power supply is a device consisting of one or more electrochemical

cells that convert stored chemical energy into electrical energy. Each cell contains a

positive terminal, or cathode, and a negative terminal, or anode. Electrolytes allow ions to

move between the electrodes and terminals, which allows current to flow out of the

battery to perform work.

5 Amp Hour 12 Volts power supply

4.2.2 Selection of Motor as battery specification

Motor 12V DC 30 RPM

An electric motor is a machine which converts electric energy into mechanical

energy. Its action is based on the principle that when a current carrying conductor is

placed in magnetic field, it experiences a mechanical force whose direction is given

Fleming’s Left Hand Rule.

4.2.3 Design of the Motor

We know,

Specification of the DC motor,

Toque (T) = 5 N-m

Speed (N) = 30 rpm

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We know,

Power (P) = 2πNT/60

= (2×3.14×30×5)/60

= 15.7 watt

Power of the motor (P) = 15.7 watt.

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Chapter-5

Manufacturing process of the project

5.1Introduction

Manufacturing is the backbone of any industrialized nation. Manufacturing and

technical staff in industry must know the various manufacturing processes, materials

being processed, tools and equipment’s for manufacturing different components or

products with optimal process plan using proper precautions and specified safety rules to

avoid accidents. Beside above, all kinds of the future engineers must know the basic

requirements of workshop activities in term of man, machine, material, methods, money

and other infrastructure facilities needed to be positioned properly for optimal shop

layouts or plant layout and other support services effectively adjusted or located in the

industry or plant within a well-planned manufacturing organization.

The complete understanding of basic manufacturing processes and workshop

technology is highly difficult for anyone to claim expertise over it. The study deals with

several aspects of workshops practices also for imparting the basic working knowledge of

the different engineering materials, tools, equipment’s, manufacturing processes, basic

concepts of electro-mechanical controls of machine tools, production criteria’s,

characteristics and uses of various testing instruments and measuring or inspecting

devices for checking components or products manufactured in various manufacturing

shops in an industrial environment. It also describes and demonstrates the use of different

hand tools (measuring, marking, holding and supporting tools, cutting etc.), equipment’s,

machinery and various methods of manufacturing that facilitate shaping or forming the

different existing raw materials into suitable usable forms. It deals with the study of

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industrial environment which involves the practical knowledge in the area of ferrous and

nonferrous materials, their properties and uses. It should provide the knowledge of basic

workshop processes namely bench work and fitting, sheet metal, carpentry, pattern

making, moulds making, foundry, smithy, forging, metal working and heat treatment,

welding, fastening, machine shop, surface finishing and coatings, assembling inspection

and quality control. It emphasizes on basic knowledge regarding composition, properties

and uses of different raw materials, various production processes, replacement of or

improvement over a large number of old processes, new and compact designs, better

accuracy in dimensions, quicker methods of production, better surface finishes, more

alternatives to the existing materials and tooling systems, automatic and numerical

control systems, higher mechanization and greater output.

Manufacturing is derived from the Latin word manufactus, means made by hand.

In modern context it involves making products from raw material by using various

processes, by making use of hand tools, machinery or even computers. It is therefore a

study of the processes required to make parts and to assemble them in machines. Process

Engineering, in its application to engineering industries, shows how the different

problems related to development of various machines may be solved by a study of

physical, chemical and other laws governing the manufacturing process. The study of

manufacturing reveals those parameters which can be most efficiently being influenced to

increase production and raise its accuracy.

5.2.Manufacturing Process

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Manufacturing process is that part of the production process which is directly

concerned with the change of form or dimensions of the part being produced. It does not

include the transportation, handling or storage of parts, as they are not directly concerned

with the changes into the form or dimensions of the part produced.

5.2.1. Classification of Manufacturing Processes

In the manufacturing processes used in manufacturing concern for changing the

ingots into usable products may be classified into six major groups as primary shaping

processes, secondary machining processes, metal forming processes, joining processes,

surface finishing processes and processes effecting change in properties. These are

discussed as under.

1. Primary Shaping Processes

Primary shaping processes are manufacturing of a product from an amorphous

material. Some processes produces finish products or articles into its usual form whereas

others do not, and require further working to finish component to the desired shape and

size. Castings need re-melting of scrap and defective ingots in cupola or in some other

melting furnace and then pouring of the molten metal into sand or metallic moulds to

obtain the castings. The parts produced through these processes may or may not require

undergoing further operations.

Some of the important primary shaping processes is:

(1) Casting, (2) Powder metallurgy, (3) Plastic technology, (4) Gas cutting, (5) Bending

and (6) Forging.

2. Secondary or Machining Processes

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As large number of components require further processing after the primary

processes. These components are subjected to one or more number of machining

operations in machine shops, to obtain the desired shape and dimensional accuracy on flat

and cylindrical jobs. Thus, the jobs undergoing these operations are the roughly finished

products received through primary shaping processes. The process of removing the

undesired or unwanted material from the workpiece or job or component to produce a

required shape using a cutting tool is known as machining. This can be done by a manual

process or by using a machine called machine tool (traditional machines namely lathe,

milling machine, drilling, shaper, planner, slotter). In many cases these operations are

performed on rods, bars and flat surfaces in machine shops.

These secondary processes are mainly required for achieving dimensional

accuracy and a very high degree of surface finish. The secondary processes require the

use of one or more machine tools, various single or multi-point cutting tools (cutters), job

holding devices, marking and measuring instruments, testing devices and gauges etc. for

getting desired dimensional control and required degree of surface finish on the

workpieces. The example of parts produced by machining processes includes hand tools

machine tools instruments, automobile parts, nuts, bolts and gears etc. Lot of material is

wasted as scrap in the secondary or machining process. Some of the common secondary

or machining processes are:

(1) Turning, (2) Threading, (3) Knurling, (4) Milling, (5) Drilling, (6) Boring, (7)

Planning, (8) Shaping, (9) Slotting, (10) Sawing, (11) Broaching, (12) Hobbing, (13)

Grinding, (14) Gear cutting, (15) Thread cutting and (16) Unconventional machining

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processes namely machining with Numerical Control (NC) machines tools or Computer

Numerical Control (CNC) machines tools using ECM, LBM, AJM, USM setups etc.

3. Joining Processes

Many products observed in day-to-day life, are commonly made by putting many

parts together may be in subassembly. For example, the ball pen consists of a body, refill,

barrel, cap, and refill operating mechanism. All these parts are put together to form the

product as a pen.

More than 800 parts are put together to make various subassemblies and final

assembly of car or aero-plane. A complete machine tool may also require to assemble

more than 100 parts in various sub assemble or final assembly. The process of putting the

parts together to form the product, which performs the desired function, is called

assembly. An assemblage of parts may require some parts to be joined together using

various joining processes. But assembly should not be confused with the joining process.

Most of the products cannot be manufactured as single unit they are manufactured as

different components using one or more of the above manufacturing processes, and these

components are assembled to get the desired product.

Joining processes are widely used in fabrication and assembly work. In these

process two or more pieces of metal parts are joined together to produce desired shape

and size of the product. The joining processes are carried out by fusing, pressing,

rubbing, riveting, screwing or any other means of assembling. These processes are used

for assembling metal parts and in general fabrication work. Such requirements usually

occur when several pieces are to be joined together to fabricate a desired structure of

products. These processes are used developing steam or water-tight joints. Temporary,

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semi-permanent or permanent type of fastening to make a good joint is generally created

by these processes. Temporary joining of components can be achieved by use of nuts,

screws and bolts. Adhesives are also used to make temporary joints. Some of the

important and common joining processes are:

(1) Welding (plastic or fusion), (2) Brazing, (3) Soldering, (4) Riveting, (5)

Screwing, (6) Press fitting, (7) Sintering, (8) Adhesive bonding, (9) Shrink fitting, (10)

Explosive welding, (11) Diffusion welding, (12) Keys and cotters joints, (13) Coupling

and (14) Nut and bolt joints.

4. Surface Finishing Processes

Surface finishing processes are utilized for imparting intended surface finish on

the surface of a job. By imparting a surface finishing process, dimension of part is not

changed functionally; a very negligible amount of material is removed from the certain

material is added to the surface of the job. These processes should not be misunderstood

as metal removing processes in any case as they are primarily intended to provide a good

surface finish or a decorative or protective coating on to the metal surface. Surface

cleaning process also called as a surface finishing process. Some of the commonly used

surface finishing processes are: (1) Honing, (2) Lapping, (3) Super finishing, (4) Belt

grinding, (5) Polishing, (6) Tumbling, (7) Organic finishes, (8) Sanding, (9) Debarring,

(10) Electroplating, (11) Buffing, (12) Metal spraying, (13) Painting, (14) Inorganic

coating, (15) Anodizing, (16) Sheradising, (17) Parkerizing, (18) Galvanizing, (19)

Plastic coating, (20) Metallic coating, (21) Anodizing and (22) Sand blasting.

5.3. Product development process

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A product development has to go through the following concepts of product

engineering which are given as under.

 Product functions

 Product specifications

 Conceptual design

 Ergonomics and aesthetics

 Standards

 Detailed design

 Prototype development

 Testing

 Simulation

 Design for manufacture

 Design for assembly

 Drafting

5.4 Manufacturing process of the project

1. Measurement of the material required dimension:

Measurement is the foundation of scientific inquiry. In order to test our

hypotheses, we must observe our theoretical concepts at the operational level. In simple

words, we must measure what we have defined. But there are different levels of

measurement, which provide differing amounts of information about the theoretical

construct. There are also some basic issues about the adequacy of measurement which we

must address.

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2. Cutting operation as per dimension:

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 workpiece 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 operations 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.

3. Machining operation on required parts:

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Turning is a cutting operation in which the part is rotated as the tool is held

against it on a machine called a lathe. The raw stock that is used on a lathe is usually

cylindrical, and the parts that are machined on it are rotational parts – mathematically,

each surface machined on a lathe is a surface of revolution. Machining is an essential

process of finishing by which work pieces are produced to the desired dimensions and

surface finish by gradually removing the excess material from the preformed blank in the

form of chips with the help of cutting tool(s) moved past the work surface(s).Most of the

engineering components such as gears, bearings, clutches, tools, screws and nuts etc.

need dimensional and form accuracy and good surface finish for serving their purposes.

Performing like casting, forging etc. generally cannot provide the desired accuracy and

finish. For that such preformed parts, called blanks, need semi-finishing and finishing and

it is done by machining and grinding.

 Grinding is also basically a machining process.

 Machining to high accuracy and finish essentially enables a product:

 Fulfill its functional requirements.

 Improve its performance.

 Prolong its service

3. Drilling and tapping the material as per dimension:

These four methods all produce holes of different types. Drilling produces round

holes of different types; reaming is used to improve the dimensional tolerance on a drilled

hole; boring uses a special machine operating like a lathe, to cut high precision holes; and

tapping creates screw-threads in drilled holes. Drilling: The geometry of the common

twist drill tool (called drill bit) is complex; it has straight cutting teeth at the bottom –

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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 workpieces;

 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

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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;

 large and deep holes are made by spade drills;

 Countersink/counter bore drills have multiple diameters – they make a

chamfered/stepped hole, which is useful for inserting screws/bolts – the larger

diameter part of the hole accommodates the screw/bolt head;

 Internal threads can be cut into holes that mate with screws/bolts. These are cut by

using tapping tools.

4. Welding the material as per dimension:

Welding is a process for joining two similar or dissimilar metals by fusion. It

joins different metals/alloys, with or without the application of pressure and with or

without the use of filler metal. The fusion of metal takes place by means of heat. The heat

may be generated either from combustion of gases, electric arc, electric resistance or by

chemical reaction. During some type of welding processes, pressure may also be

employed, but this is not an essential requirement for all welding processes. Welding

provides a permanent joint but it normally affects the metallurgy of the components. It is

therefore usually accompanied by post weld heat treatment for most of the critical

components. The welding is widely used as a fabrication and repairing process in

industries. Some of the typical applications of welding include the fabrication of ships,

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pressure vessels, automobile bodies, off-shore platform, bridges, welded pipes, sealing of

nuclear fuel and explosives, etc. Most of the metals and alloys can be welded by one type

of welding process or the other.

However, some are easier to weld than others. To compare this ease in welding term

 ‘Weld ability’ is often used. The weld ability may be defined as property of a

metal which indicates the ease with which it can be welded with other similar or

dissimilar metals.

 Weld ability of a material depends upon various factors like the metallurgical

changes that occur due to welding, changes in hardness in and around the weld,

gas evolution and absorption, extent of oxidation, and the effect on cracking

tendency of the joint. Plain low carbon steel has the best weld ability amongst

metals. Generally it is seen that the materials with high cast ability usually have

low weld ability.

5. Grinding the project welding joints:

There are several types of grinding machines. The main ones are surface grinders,

grinding wheels, cylindrical grinders and center less grinders. The figure below shows

examples of a few of these. Surface grinders produce flat surfaces. The part is held on the

flat table (steel parts can be held by a magnetic force – this is called magnetic chucking).

The table moves in a reciprocating motion, and the rotating wheel is lowered so that it

just scrapes along the surface.

To improve dimension control on cylindrical parts, center less grinders, which use

long cylindrical wheels, are employed. The axis of the regulating wheel and grinding

wheel are slightly misaligned, causing the part to travel slowly in the axial direction, and

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after some time, the part automatically moves beyond the length of the wheel.

Controlling the angle of misalignment can control the time that the part is subjected to

grinding. If a turned part of complex shape (e.g. stepped shafts) are to be ground, then

cylindrical grinding is used, which employs specially made grinding wheels, whose

profile fits the profile of the part to be ground.

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Chapter-6
Advantages, Disadvantages and Application of the project
6.1. Advantages of the project
Advantages of the project as per following like as:
 No conventional grid electricity required
 Long operating life
 Highly reliable and durable
 Easy to operate and maintain
 Eco-friendly

6.2. Disadvantages of the project

Dis-advantages of the project as per following like as:
 High installation cost
 Operating speed is low
 Maintenance cost high
 Operating cost is high
 Skilled operator required

6.3. Application of the project

Our project should use for following various applications like as:
 To perform smithy operation i.e. upset forging.
 To perform the punching operation.
 To perform filleting operation as torque force produce is sufficient for the
operation.
 To perform riveting operation etc.
 Industrial purpose
 Agricultural purpose
 Domestic purpose
 Commercial purpose
 Automobile application

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Chapter-7
Conclusion
Our project is successfully implemented for we have successfully calculated the

torque force of the motor. For the design the impact velocity and torque force for riveting

of 2 mm rivet is calculated accurately. The entire modelling of the project is done with

fabrication. In this addition to this. The project work has provided us an excellent

opportunity and experience, to use our limited knowledge. We gained a lot of practical

knowledge regarding. Planning, Perching, assembling and machining while doing this

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

institutions and industries. We are proud that we have completed the work with limited

time successfully Automatic hammering machine is working with satisfactory condition.

We have done to our ability and skill making ma work.

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Chapter-9
Reference
A] Book Reference

1) R.S. Khurmi and Gupta, “Machine Design” 14th edition, S. Chand

2) V.B. Bhandari, “Machine Design” 3rd edition, Tata McGraw Hill
3) U. C. Jindal, “Machine Design”.2 reprint edition, Pearson Education India
4) Richard G. Budynas and J. Keith Nisbett “Mechanical Engineering Design” 9th
edition, Tata McGraw Hill
5) Hall, Holowenko, Laughlin “Theory and problems of Machine Design” Reprint
2005 edition, McGraw Hill
6) PSG, “Design Data Book” 8th edition, PSG College of Technology Coimbatore
7) Robert C. Juvinall and Kurt M Marshek, “Fundamentals of Machine Components
Design” 3rd edition, Wiley India Edition
8) K. Ganesh Babu and K. Sridhar “Design of machine elements” Tata McGraw Hill
9) Theraja B. L, “Fundamentals of Electrical and Electronics Engineering” S. Chand
and company LTD
10) K. Sawney, “Electrical and Electronic Measuring Instruments”, Dhanpat Rai and
sons.
11) Thomas Malvino, “Electronic Principles”, Tata McGraw hill Publishing Company
Ltd
12) V. K. Mehta, “Principles of Electrical and Electronics Engineering” S. Chand and
company Ltd.
13) R. Savan Kymar, K.V. Inoth Kumar and V. Jegathesan “Basic Electrical and
Electronics” Wiley Precise publisher

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