Klassic Wheel Trimming Machine

Savitribai Phule Pune University, (2015 pattern)
A PROJECT STAGE – I
REPORT ON
“MODIFICATION OF TRIMMING
MACHINE”
Submitted By:
Mr. JADHAV SAURABH NANASAHEB 91
Mr. MAGAR SHUBHAM VIKRAM 114
Mr. SOLUNKE RAHUL KAILASRAO 153
Mr. ZAWARE DINESH SHASHIKANT 169
Under the Guidance of
Prof. Suryawanshi A.V.
Department of Mechanical Engineering
Dr. Vithalrao Vikhe Patil College of

Engineering, Ahmednagar.
[2019-2020]
Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 1

CERTIFICATE
This is to certify that the following students:
1. Mr. JADHAV SAURABH NANASAHEB

2. Mr. MAGAR SHUBHAM VIKRAM
3. Mr. SOLUNKE RAHUL KAILASRAO
4. Mr. ZAWARE DINESH SHASHIKANT
have successfully completed the project stage-I work entitled

“MODIFICATION OF TRIMMING MACHINE” under
my Supervision in the partial fulfilment of Bachelor of Engineering
– Mechanical Engineering of Savitribai Phule Pune University,
during academic year 2019-20.
Date:
Place: Ahmednagar
Prof. A.V. Suryawanshi Dr. K.B. KALE
(Seminar Guide) (Head of Department)
Dr. U.P. NAIK
(External Examiner) (Principal)

ACKNOWLEDGEMENT
Every orientation work has imprint of many people and this work is no different. This
work gives us an opportunity to express deep gratitude for the same. While preparing
this project report received endless help from number of people. This report would be
incomplete if we don’t convey our sincere thanks to all those who were in involved.
First and foremost, we would like to thank our respected guide Prof. A. V.
Suryawanshi (seminar guide) & Prof. K. B. Kale (H.O.D) for giving us an
opportunity to present this project and his indispensable support, priceless suggestions
and valuable time. Finally, we wish to thanks our friends and our families for being
supportive of us, without whom this seminar would not have seen the light of day.
Every work is an outcome of full-proof planning, continuous hard work and

organized effort. This work is a combination of all the three put together sincerely.
1) Mr. JADHAV SAURABH NANASAHEB
2) Mr. MAGAR SHUBHAM VIKRAM
3) Mr. SOLUNKE RAHUL KAILASRAO
4) Mr. ZAWARE DINESH SHASHIKANT
INDEX

Sr No. Name of figure Page No.

1 PROFILE & HISTORY 1
2 ABSTRACT 5
3 INTRODUCTION 6
3.1 Main purpose and

application
3.2 Operating condition

and environment of the
welding machine:
3.3 Specification and

technical parameters
3.4 Structural explanation
3.5 Pneumatic and

lubrication system
3.6 Operation safety notice
4 PROBLEM STAEMENT 19
5 OBJECTIVE 19
6 FUTURE SCOPE 19
7 METHODOLOGY 20
8 LITERATURE REVIEW 21
9 REFEREACES 22

Klassic Wheel Pvt. Ltd. Ahmednagar, Maharashtra India
PROFILE:
Founded in 1994, Klassic Wheels Ltd is a global Automotive Steel Rim

Manufacturer with leading position in India holding capacity of 11 million + wheel
rim per annum having world class manufacturing facilities across pan India with 500+
employees.
The company manufactures steel rim for two wheelers, three wheelers, four
wheelers. Our state-of-the-art integrated manufacturing unit are equipped with the
specialised machineries that can fulfil all the requirements of the clients, with
precision. We understand our responsibilities towards our customers as a reliable
partner in delivering products as per the international quality standers. Klassic offers
based solutions that give customers a competitive edge in their markets.

1. HISTORY:
Founded in 1994, Klassic Wheels Ltd is a global Automotive Steel Rim

Manufacturer with leading position in India holding capacity of 11 million + wheel
rim per annum having world class manufacturing facilities across pan India with 500+
employees.
The company manufactures steel rim for two wheelers, three wheelers, four
wheelers. Our state-of-the-art integrated manufacturing unit are equipped with the
specialised machineries that can fulfil all the requirements of the clients, with
precision. We understand our responsibilities towards our customers as a reliable
partner in delivering products as per the international quality standers. Klassic offers
based solutions that give customers a competitive edge in their markets.

Company Overview:
Klassic Wheels Limited is an unlisted public company. It was incorporated on 09

August, 1994 and is located in Ahmednagar, Maharashtra. It is classified as a public
limited company. The company has 11 directors Sanjay Chopda, Neeraj Amrutlal
Munton and others
 Description: The company manufactures motor vehicle parts and accessories. It

offers wheels and other products.
 Products & Services: Split wheel, drop centre for 2, 3, 4-wheeler
 Category: Manufacturer
Klassic Wheels Limited's operating revenues range is INR 100 Cr - 500 Cr for the
financial year ending on 31 March, 2017. It's EBITDA has increased by 32.23
% over the previous year. At the same time, it's book net worth has increased by
38.55 %.
 The registered office of the company is at "HIRKESH", Near Keshar Gulab Mangal
Karyalay, behind ADCC Bank, Station road, Ahmednagar Maharashtra.
 The total paid-up capital is INR 9.49 cr. The last reported AGM (Annual General
Meeting) of the company, per our records, was held on 05 October, 2018. Also, as
per our records, its last balance sheet was prepared for the period ending on 31
March, 2018.
Klassic Journey:
Late Shree. Nemichandaji K. Munot is the founder of the munod group of companies.
The family owned business is spread across India various verticals successfully run by
the group where
 Trading of commodities (like cotton processing, sugar and wheat).

 Real Estate Development and Construction.

 Education Institute and

 Various Automobile Components Manufacturing Units.
 Year 1994 Manufacturing Units at Ahmednagar, Maharashtra-India

 Year 2003 Services Unit at Manesar, Haryana-India
 Year 2005 Additional Manufacturing Unit at Ahmednagar, Maharashtra-India
 Year 2005 Services Unit at Tapukara, Rajasthan-India
 Year 2012 Additional Manufacturing Unit at Ahmednagar, Maharashtra-India
LOCATIONS:
The company’s manufacturing plants in India are located at Pune and

Ahmednagar, Maharashtra.
ENVIRONMENTAL POLICIES:
 Both plants have certification of ISO 14001.

 Recycle the waste, less emission of carbon dioxide, pollution prevention; less
energy consumption and minimum environmental impact are some key targets
of Klassic Wheel Pvt. Ltd.
 The company’s activities in environment protection include soil and water
conservation programs and extensive tree plantation drives.

2. ABSTRACT:
A trimming machine which remove excess material attached to moulded, forged, cast
or butt-welded product, which must usually removed. In this the work piece is fixed
and trimming tool is along the work piece to give inform shape. The cutting die are
precisely designed to remove the flash from a particular part.
In the presence work the proper selection of linear bearing with a linear guide to be
mounted on upper and lower slide. Reduce the rate of wear and tear of brass strips due
to hard job burrs. Also, the job variations must be reduced. Avoid the collection of
burrs on the fixed and moving slide. For these achievements we have to dismantle the
moving slide box of the machine. Also design of two slides has linear motion guide
ways and bearings. According to load on the trimming machine there must be the
selection of linear motion guide ways and bearing. After that we have to go for cad
drawing preparation and machining on slides. After this procedure the fixing of liner
motion guide ways in trimming machine is done and the linear bearing is mounted on
it. Then assembly of different parts is done. In which mounting of cylinder and
assembly of linkage between cylinder and slide is done. Then there is connection of
machine with three phase power supply with five wire system having power supply
about 415V is carried out. And different trials is taken on the trimming machine.

3. INTRODUCTION:
WHAT IS TRIMMING MACHINE?
It is a machine which remove excess material attached to molded, forged, cast or

butt-welded product, which must usually remove. In this the work piece is fixed
and trimming tool is along the work piece to give inform shape. The cutting die are
precisely designed to remove the flash from a particular part.
One of the most common defects of welds is flash, which is mainly made by
softened or melted material extruded outward from the interface between work
pieces. The size and shape of flashes strongly depend on the processing
parameters. Without proper treatment or design, flashes on the surface may cause
significant problems of stress concentration, corrosion, and surface finish.
Sahin (2004) developed a finite element program to simulate the friction

welding process. The results indicated that the flash formation has strongly
dependence on the axial load, dwelling time, rotational speed, and upset length.
Hasan et al. (2007) studied the fatigue failure of flash butt welds on high-pressure

gas pipelines after 15-20 years of service. The micrographs showed that the fatigue
cracks mainly emanate from the remaining weld flashes due to stress concentration
and corrosion. For friction stir welding, the flash is the excessive material
extruded by the tilted welding tool and accumulated along the sides of the weld.
Kainuma et al. (2008) investigated the fatigue behaviour of friction stir butt-
welded joints for aluminium alloys. They found that the flash provides a notch
structure on the surface with high stress concentration; therefore, fatigue cracks
prefer to emanate from/near the flash. In order to avoid these problems, flashes
should be completely removed by machining processes after welding, such as
trimming, grinding, and polishing.
3.1 Main purpose and application:
Steel ring
Operating condition and environment of the welding machine:
This machine should be operated under the following condition
I. Compressed air
a. Compressed air supply pressure 0.5-0.6 MPa (at the equipment inlet)
b. Flow rate >15m/h
c. Assigned air compressor >10PH
d. Air quality should comply with industrial compressed air standard
II. Power supply
415V+-10%50Hz+-2 % Three -phase five wire system
III. Cooling medium

a. inlet cooling water temperature should be in the range between +5C~+30C
b. ambient air temperature not higher than 40C
IV. Cooling water
a. pressure 0.15~0.3MPa (when meet the rated flow capacity)

b. flow rate >1200L/h

c. PH value 7~8
d. Water quality should comply with industrial water standard
V. Relative humidity
The maximum average relative humidity is 90% for the most humid month, while the
average lowest temperature not higher than 25 C.
VI. The operation site should have nothing that will severely affect the equipment,
such as gas steam, chemical deposition, dust, mold and other explosive or corrosive
medium.
VII. The operation site should have no severe vibration and bumps / vibration and
bump.
3.2 Specification and technical parameters:
Maximum width of the welding line to be slag shaved :5 mm
Maximum height of the welding line to be slag shaved :5mm
Number of planer tool :3
Width of the planer tool :20mm
Diameter of the clamping roller :102mm
Air source pressure :0.6MPa
Motor power of hydraulic system :37KW
Maximum operating pressure of hydraulic system :16MPa
Equipment outer dimension (L x W x H) : 2830 x 1150 x 1940

Equipment weight around 3600kg
Equipment with PLC control cabinet
Slag planer characteristics:
I. This slag planer user hydraulic oil cylinder to apply force for the slag
planning, with the simple structure and stable working condition. The planer
tool can be adjusted.
II. The planer tool guide mechanism is composed of slider with copper billet and
fixed guiding rail the fixed guiding rail has been high frequency surface
quench and precisely grounded, so it has the characteristics of high guiding
precision and good abrasion resistance.
III. The planer tool uses a fast switching mechanism.
3.3 Main structure of the product:

I. Structure component:
This machine is composed of the following components and systems:
1) Clamping
2) Pneumatic system
3) Lubrication system
4) Flexible arm
5) Fixed arm
6) Control system
7) Gas tank
II. Operating procedures:
First, according to the working piece diameter, adjust the height the floating rank tray
and opening of the supporting roller;
1) Manually put the welded steel ring on the try of the floating rack, and push
the working piece into the planner tool opening;
2) Step on the foot pedal to start (entering automatic planning procedure);
3) Flexible arm presses down to clamp the steel ring;
4) The slider between the fixed arm and the flexible arm moves forward to
plane the steel ring;
5) The flexible arm losses the steel ring;
6) The slider between the fixed arm and the flexible arm moves back, at the
same time it blows air automatically;
7) Pull the working piece out of the planer tool opening, manually takes out
the working piece;

Note: when the manual or automatic button on operating box is at the manual state,
every button or operating box can work separately, in order to be able to carry out
feeling status adjustment.
3.4 Structural explanation
I. Clamping mechanism:
1) Pneumatic lubricant pump;

2) Pump switching valve;
3) Service unit;
4) Slag blowing valve;
5) Planner tool arm put out position sensor switch;

6) Lubrication points;
7) Hydraulic station oiling port.
II. The pneumatic system of the equipment is divided into two part; one for blowing
slag, and the other for the pneumatic lubrication pump. The pressure of the
compressed air is both controlled by the pressure regulator in the service unit. Adjust
the pressure regulator to change the gas pressure, rotate clockwise to increase the
pressure and counter clockwise to reduce the pressure periodically check whether oil
pressure and pneumatic system is normal. periodically release the water from
distributor and air filter in the service unit; check the oil level of the automizer, the oil
level should not be lower than half the oil cup.
III. Hydraulic system
During operating the clamping cylinder pressure is set to be 5-7Mpa, and the pushing
cylinder pressure 5-8Mpa.
Note: when disassembling the cylinder oil tube, open the two ball valves on the
equipment inlet and outlet pipeline. Connect the inlet and outlet pipeline to relieve the
oil pressure in piston rod cavity to prevent spraying hydraulic oil from hurting
personnel.
During the normal operation, in order to reduce the planner tool recoil distance, moves
forward the planner tool retract position sensor switch to reduce the retraction
distance.
IV. During equipment operation, if the upper and lower planner tool are
misaligned adjust the forward and backward position of the upper planner tool
arm. When the upper planer tool is protruding the lower planer tool, back out
the right screw and screw in left one; otherwise back out the left screw and
screw in the right one.

As shown in fig:
1) Cylinder;
2) Adjustable connecting rod;
3) Cylinder upper position limit sensor switch;
4) Clamping sensor switch of clamping arm;
5) Slag blowing gas tube;
6) Slag collecting slot;
7) Adjustable positioning block at working piece side
Note- during operation when the clamping arm fail to clamp the working piece.
Solutions:

1) Move the clamping sensor switch of clamping arm downward;

2) If steel fail to clamp, then the working distance of the cylinder is use up
and the connecting rod should be adjusted to move down the clamping arm.
During the normal operation, if need to shrink the clamping arm lifting opening, move
down the cylinder upper position limit switch.
When the width of the working piece changes, adjust the adjustable positioning block.
3.5 Pneumatic and lubrication system
1) Right screw

2) Adjustment plat
3) Left screw
5. During the equipment operation, if the flexible arm is unparallel to the fixed arm,
adjust the position of the eccentric shaft at the back of the flexible arm. Move the
swing stem to the right, if there is gap at the front side of the flexible arm, move the
wing stem to the left.
6. Planer tool height adjustment
1) Planer tool
2) Adjustment screw
3) Wedge block
4) Adjustment nut
5) Clamping roller

The opening of the planer tool group A,B,C should decrease in turn, and the height
difference should be less than height of welding slag .the planner tool and planner
holder are welded together by silver brazing adjust the planner tool height ,first move
flexible arm up and fill in would blocking between arm .Loosen the adjustment nut to
move down the wedge block, take out of the planer tool and planer tool holder. Screw
down the adjustment screw t the lower planer tool height, unscrew the adjustable
screw to increases the planner tool holder firmly.
The height of the upper clamping roller can be adjustment through the clamping roller
seat nut During the operation, worn and damaged planner tool should be replaced in
time.
6.Transportation and storage
The equipment should be packed before transporting. Cover the equipment main body
with the plastic mantle. The packaging material is wood board. The box should have a
should have a strong enough base, whose structure should be suited to forklift and
crane if with steel cable. The equipment is fixed to the base using four M27 bolt. The
controller should be packaged in separated box. The inside of the box should nail
bitumen carpet.
The equipment type, gross weight, dimension should be indicated outside the
packaging box, and sign like don’t put upside down handle with the care lifting
direction etc. Should be posted. When storing before opening the package, care must
be taken that button of the package box must be flat, do not put any linear underneath.
The storage site should be rain proof, moisture proof, corrosive medium proof and
insect proof.
7. Installation and commissioning
1. Installation of equipment
This machine should be inspected carefully before installation. Check all the screw
connection, and tighten all loosen bolts and nuts

Compressed air is connected through the oxygen tube with inner diameter at 10 mm to
the position at the backside of the equipment with a gas inlet sign and secure the
connection with hose clamp
After installation, check all gas connection for leakage.
Cooling water is connected by hard pipes to the cooler inlet and outlet of the hydraulic
station, and connected to the factory drainage system
2.Commissioning of the equipment
Necessary test and adjustment must be carried out before operation after installation
are stopping using for a long time
1)Connect the compress air and check the condition of pneumatic system If there is
leakage or jam, do identify the reason and fixing time
2) Check the condition of the oil system. If there is oil leakage jam, do identify the
reason and fix in time.
3) Start up the cooling system, check whether there is water leakage or jam do identify
the reason and fix in time.
4) Lubricate the guiding rail and the guiding rod of the clamping cylinder.
5) Check whether the height and position of the planner tool are correct, make
adjustment if necessary.
6) Switch on the power.
7) When the controller is the automatic state, operate the machine. Step down the foot
pedal to check whether all part of the equipment are running normally.
8) If all the about testing shows that the equipment is normal, start operation.

8. Use and Maintenance:
1) If machines stop working for a long time, grease the unpainted moving part to
prevent rusting.
2) Bolts connection should be check periodically and tighten any loose once.
Replace sealing ring in the time if there is any distinctive worn out.
3) Clean the slag collecting slot regularly, replace severely warn planer tool in
time.
4) Periodically check whether the oil pressure and pneumatic system or normal.
Periodically release the water from the distributor and air filter in the service
unit; check the oil level of the oil atomizer and the oil level should not be
lower than half the oil cup.
5) Adjust the pressure regulator in service unit to change the gas pressure. Rotate
clockwise in increase the pressure and counter clockwise to reduce the
pressure.
3.6 Operation safety notice
Warning
Please take care of the safety of yourself and others. Before the equipment installation,
operation and maintenance, please carefully read and understand the instruction
manual.
The installation, operation and maintenance personnel must be qualified professionals.
 Beware of electric shock.

 Beware of pressure equipment and moving parts
1) During the operation, the doors the controller should be closed secured.
2) When hands are near the working table, don't press any buttons to
prevent damage.
3) During the operation, keep hands, hair, clothes and tools away from
pneumatic exclusion components and moving parts, and beware of
hydraulic and pneumatic pressure parts to prevent damage.

4. PROBLEM STATEMENT:
 The aim of the project is to modify and development of trimming machine for
removing the excess material on component.
 Wear and tear of the brass strips due to hard job burr.
 Size variation in job tapper.
 Tapper cutting on the flash of butted rim
 Excessive burr in fixed and moving slide.
5. OBJECTIVES:
1) To minimize the gap between the slider and outer casing.
2) To create the pockets on bottom plate of the slider.
3) To apply the proper linear bearing.
4) To apply the cover plate over the outer casing if required.
6. FUTURE SCOPE:
1) Currently we are going to finishing by trimming. In future we can developed
another some ideas such as automatic finishing.
2) For removal flash particle we can use various advance flash removers such as
(magnetic flash removers).

7. METHODOLOGY:
1. First, we select the project topic.
2. Then survey the company.
3. Understand all machines in line layout of company.
4. Get information of all the types of trimming machines.
5. Then get information about Shanghai Mountain trimming machine.
6. Studied different major and minor parts of the trimming machine.
7. Checking the defective parts of the trimming machine.
8. Applying the corrections on the defective parts.
9. Purchased raw material for producing the new parts.
10. Parts are produced by the production department.
11. Assemble the required parts.
12. Inspection and running of machine.
13. Ready for production.

8. LITERATURE REVIEW:
 K.-W. Zeng, Z.-M. Su, M.-T. Dong, B. Huang (September 2016)
-Removing approach for ﬂashes of friction stir spot welds
 Tony L. Schmitz (March 2017) - Automatic trimming of machining
stability lobes
 Zulquerlain Mallick (June 2017) Optimization of operating parameter of
trimming machine
 Chun Ting Hou(August 2018)TRZI-based trimming for process -machine
improvement : slit-valve innovative redesign

9. REFERANCES
[1] S. Tobias, Machine Tool Vibration, Blackie and Sons Ltd, London, 1965.
[2] S. Tobias, W. Fishwick, Theory of Regenerative Machine Tool Chatter, The

Engineer, February, Vol. 205 (1958).
[3] F. Koenisberger, J. Tlusty, Machine Tool Structures, vol. I: Stability Against

Chatter, Pergamon Press, New York, 1967.
[4] J. Tlusty, M. Polacek, The stability of the machine tool against

self-excited vibration in machining, in: ASME Production Engineering Research
Conference, Pittsburgh, PA (1963).
[5] H. Merritt, Theory of self-excited machine tool chatter, Transactions of ASME

Journal of Engineering for Industry 87 (1965) 447–454.
[6] I. Minis, T. Yanushevsky, R. Tembo, R. Hocken, Analysis of linear and nonlinear

chatter in milling, Annals of the CIRP 39 (1990) 459–462.

Klassic Wheel Trimming Machine

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Klassic Wheel Trimming Machine

Uploaded by

Copyright:

Available Formats

Savitribai Phule Pune University, (2015 pattern)

Mr. JADHAV SAURABH NANASAHEB 91

Mr. MAGAR SHUBHAM VIKRAM 114

Mr. SOLUNKE RAHUL KAILASRAO 153

Mr. ZAWARE DINESH SHASHIKANT 169

Under the Guidance of

Prof. Suryawanshi A.V.

Department of Mechanical Engineering

Dr. Vithalrao Vikhe Patil College of

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 1

1. Mr. JADHAV SAURABH NANASAHEB

have successfully completed the project stage-I work entitled

Prof. A.V. Suryawanshi Dr. K.B. KALE

(Seminar Guide) (Head of Department)

Dr. U.P. NAIK

(External Examiner) (Principal)

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 2

Every work is an outcome of full-proof planning, continuous hard work and

1) Mr. JADHAV SAURABH NANASAHEB

2) Mr. MAGAR SHUBHAM VIKRAM

3) Mr. SOLUNKE RAHUL KAILASRAO

4) Mr. ZAWARE DINESH SHASHIKANT

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 3

Sr No. Name of figure Page No.

3.1 Main purpose and

3.2 Operating condition

3.3 Specification and

3.4 Structural explanation

3.5 Pneumatic and

3.6 Operation safety notice

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 4

Klassic Wheel Pvt. Ltd. Ahmednagar, Maharashtra India

Founded in 1994, Klassic Wheels Ltd is a global Automotive Steel Rim

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 5

Founded in 1994, Klassic Wheels Ltd is a global Automotive Steel Rim

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 6

Klassic Wheels Limited is an unlisted public company. It was incorporated on 09

 Description: The company manufactures motor vehicle parts and accessories. It

 Products & Services: Split wheel, drop centre for 2, 3, 4-wheeler

 Trading of commodities (like cotton processing, sugar and wheat).

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 7

 Education Institute and

 Year 1994 Manufacturing Units at Ahmednagar, Maharashtra-India

The company’s manufacturing plants in India are located at Pune and

 Both plants have certification of ISO 14001.

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 8

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 9

WHAT IS TRIMMING MACHINE?

It is a machine which remove excess material attached to molded, forged, cast or

Sahin (2004) developed a finite element program to simulate the friction

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 10

3.1 Main purpose and application:

Operating condition and environment of the welding machine:

This machine should be operated under the following condition

415V+-10%50Hz+-2 % Three -phase five wire system

III. Cooling medium

IV. Cooling water

a. pressure 0.15~0.3MPa (when meet the rated flow capacity)

Dr. Vitthalrao Vikhe Patil, COE. Ahmednagar Page 11

b. flow rate >1200L/h

3.2 Specification and technical parameters:

Maximum width of the welding line to be slag shaved :5 mm