n

HOSTING COMPANY: HIBRET MANUFACTURING

AND
MACHINE BUILDING INDUSTRY
(FEB 28 - JUNE 28)

PREPARED BY: WUBEGZHER DILNESAW

FST/URO252/2000
COMPANY ADVISER- SERGE SOLOMON
UNIVERSITY ADVISER-ABRHA G (M.TECH)

SUBMITTION DATE- OCT/10/2011

ACKNOWLEDGEMENT

1
It is my great pleasure to thank those individuals who helped me in preparing this project work. I
heartily thank company adviser left Solomon and university adviser abrha who guide my work
and made the necessary correction.

I would also like to express my deepest gratitude to: Corp. Kassahun, Ato Abay, Corp. Belay and
Corp. Kibru, for their cooperative in teaching catia v5 software, giving an advice, and providing
computers for this project.

Finally, I would like to thank my friends, the machinist and librarian for everything that they
have done for me.

ABSTRACT

2
The report is mainly composed of an overall four month report and a project on heat treatment.
The four month report generally deals with the activities done in five main factories,
(conventional manufacturing factory, precision manufacturing factory, mechanical subsystem
production, machine building factory and material treatment engineering factory), and including
the background of the organization, product and services, and the general work flow of the
factory.

The project generally aims in developing a continuous flow from furnace to quenching media
especially for bulk material and to regulate the temperature of the room. Since in the heat
treatment shop, tongs are used to handle the material which is not suitable and there is a
formation of high temperature which risks workers safety condition. Therefore, it is important to
regulate the flow of the material and the room temperature for safe working conditions. So a
chain roller and a pushing piston mechanism are used for material handling and to regulate the
room temperature, an automatic switch is used.

Moreover, the manufacturing process and detail drawing of each part is including in this project.

LIST OF TABLES

3
TABLE 1—Number of teeth on the gear sprocket

TABLE 2—Power rating of simple roller chain

TABLE 3—Characterstics of roller chains

TABLE 4—Factor of safety (n)

TABLE 5—Material list

TABLE 6—Recommended values for Km and Kt

TABLE 7—Proportional of standard parallel key

TABLE 8—Standard thrust roller bearing

TABLE 9—Standard cylinders

LIST OF FIGURES

4
FIGURE 1—Speed reduction

FIGURE 2—Roller shaft

FIGURE 3— Thrust roller bearing

FIGURE 4—Circuit designs to move a piston at a nearly constant speed

FIGURE 5—Standard cylinder

FIGURE 6—Square flanged cylinder joint

FIGURE 7— Bolt

FIGURE 8—Logarithemic amplifier

FIGURE 9—Inverting amplifier

FIGURE 10—A/D converter

FIGURE 11—D/A converter

FIGURE 12—relay

TABLE OF CONTENT

5
 ACKNOWLEDGEMENT -----------------------------------------------------------------------i
ABESTRACT --------------------------------------------------------------------------------------ii
LIST OF TABLE ---------------------------------------------------------------------------------iii
LIST OF FIGURES-------------------------------------------------------------------------------iv

CHAPTER ONE- INTRODUCTION

1.1 Background of organization---------------------------------------------------------------------1

1.2 The main products and services-----------------------------------------------------------------3
1.3 The main customers ------------------------------------------------------------------------------4
1.4 General procedures--------------------------------------------------------------------------------5
1.5 Over all intern report------------------------------------------------------------------------------9

CHAPTER TWO- PROBLEM IN HEAT TREATMENT

2.1Introduction----------------------------------------------------------------------------------------15
2.2 Problem statement -------------------------------------------------------------------------------15
2.2 Objective------------------------------------------------------------------------------------------16
2.3 Methodology -------------------------------------------------------------------------------------16
2.4 Result----------------------------------------------------------------------------------------------17

CHAPTER THREE-ANALYSIS FOR MATERIAL HANDLING

3.1 Design of roller chain---------------------------------------------------------------------------18

3.2 Design of roller shaft----------------------------------------------------------------------------24
3.3 Bearing selection---------------------------------------------------------------------------------30
3.4 Cylinder and piston selection-------------------------------------------------------------------31
3.5 Design of square flanged cylinder joint-------------------------------------------------------35

CHAPTER FOUR-ANALYSIS FOR TEMPERATURE REGULATION

6
 4.1 Selection of sensor ----------------------------------------------------------------------------38
4.2 selection of signal conditioning--------------------------------------------------------------40
4.3 controlling mechanism------------------------------------------------------------------------43
4.4 Microprocessor---------------------------------------------------------------------------------46
4.5 Actuator-----------------------------------------------------------------------------------------49

CHAPTER FIVE-MANUFACTURING PROCEDURES AND DETAIL DRAWINGS

CHAPTER SIX-CONCLUSION & RECOMMENDATION

REFERENCES

CHAPTER-ONE

7
 1. INTRODUCTION

1.1 BACKGROUND OF THE ORGANIZATION

The company is located in Addis Ababa, Lideta Kifle-Ketema, Kebele 07, around Mexico square
and it covers an area of 92,979 square meters. This company was established between the
agreement of our country and the Czechoslovakian government at Addis in 1945 E.C at an
estimated cost of birr 2,000,000 and invested capital of birr 2,000,000. It was expanded in 1977
E.C with the expense of birr 82,000,000. The main objective was to produce different types of
ammunition of simple bullet, woodwork and metal work, medal and badge, and tools and spare
parts.

Before the current name given as Hibret Manufacturing & Machine Building Industry
(HMMBI), it was described by different names at different time frame by different groups. The
names of the company were: His Majestic H/Silassie Ammunition Factory, Addis Machine Tools
Factory, Addis Metal Pressing Enterprise, Tools and Spare Parts of Design and Manufacturing
Centers, and Engineering Center, respectively.

This organization passed through different situation of administration, Addis Metal pressing
Enterprise was established by the council of ministers Regulation No. 38/1990 in June 19, 1990
E.C by authorized capital Birr 111,216,000.00 and paid capital of Birr 76,216,000.00 and
administered under the development of government organization according to proclamation
No.25/1984.

The council ministers of the federal Democratic Republic of Ethiopia government 101 th regular
meeting held decision number 2/ms101w284/1996 the Addis Metal Pressing completely
restructure, and the rights and obligation of the organization will shifted to Defense Ministry of
the country. This was provoked by the federal Negarit Gazeta 11 th year No.39 under the heading
council of Ministry Regulations No.102/1996. By using this power Defense takes corrective
measure and ordered to transfer the ammunition factory to ‘Hormat Engineering Factory’ and
according to this order the main body of the factory i.e. ammunition products equipment,
machine, etc. were transferring to Hormat Engineering Factory. Thus the remaining workshops
in the organization are Tools and Spare parts, Medal and Badges and metal and product
packaging workshops.

8
The organization was working by the name of “Tools and Spare parts of Design and
Manufacturing Center” under the Defense Industry Coordination Office starting from the letter
written by the country Defense Minister of protocol number “m3/st2/t/1094/96” on the day of
April 9, 1997 E.C.

The letter was written from Defense Industries Coordination Office protocol number
“m3/st2/t/357/97”on the day of November 23, 1997 E.C decided the name of the organization to
be called as Addis Engineering Center.

Defense Industries Coordination Office decides, since December, 2000 E.C the company
restructured itself with, Hibret Machine Tool Engineering Complex(HMTEC) add some value to
the ministry of national defense (MOND).

Again, by the council of ministers pursuant to article 5 of the definition of power and duties of
the executive organs of the federal democratic republic of Ethiopia proclamation No.471/2005
and engineering corporation on the day of the June 9,2002 E.C.

Finally, after the council of ministry proclamation Metal and Engineering Corporation decides,
since June, 2002 E.C re-structure itself with a new name, Hibret Manufacturing & Machine
Building Industry (HMMBI), by applying new management concepts to add some value to the
countries staggering manufacturing & machine building industry. Currently, HMMBI is coming
out of its past history and it is now becoming relatively profitable.

1.2 THE MAIN PRODUCTS AND SERVICES

1.2.1 PRECISION AND CONVNTIONAL MANUFACTURING FACTORY

9
 PRODUCTS

 Industrial Machinery parts

 Construction Machinery parts
 Farm Machinery parts
 Vehicle Machinery parts
 Molds, Dies, punches, Jigs and Fixture

1.2.2 MATERIAL TREATMENT FACTORY

PRODUCT

 Engraving and Pressing products

SERVICES

 Heat treatment
 Surface treatment
 Oxidizing phosphate
 Cadmium plating
 Tin plating
 Silver plating
 Chemical oxidation coloring
 Chrom plating
 Copper plating
 Gold plating
 Laboratory testing
 Metallurgical test
 Chemical test
 Mechanical test
1.2.3 MACHINE BULDING FACTORY

PRODUCTS

10
 Industrial machinery
 Construction machinery
 Farm machinery

SERVICES

 Consultancies
 Training on machine tool building technology
 Machine erection and commissioning
 Upgrading conventional machineries to NC and CNC
1.2.4 MECHANICAL SUB SYSTEM PRODUCTION FACTORY

PRODUCTS

 Torque converters
 Gear box
 Transfer case
 Differential
 Control rods

1.3 THE MAIN CUSTOMERS

Hibret Manufacturing and Machine Building Industry have many customers because many
different tools can be manufactured but to name the main customers:

 All sugar factories

 All textile factories
 All cement factories
 EPECO
 National defense
 Private and other government company
1.4 GENERAL PROCEDURES

Customer

Needs/requirements
11
 Product design

Procedures

(A)

Process design

Procedures

(B)

Manufacturing
process

And control
procedures

Delivery/feedback

1.4.1 PROCEDURE-(A)

12
 1.4.1.1 PRODUCT DESIGN PROCEDURES

Input Process Output Responsib

ility
Customer Recorded input Marketing &
requirement, Need received data operation
specifications
Delivery date,
price & quantity
Concept design
Material, CAD,CATIA Engg.section
geometry, model, real
machine- time
Embodiment
element, control simulation
element design relevance &
database conformance
Detail design standard

Design Analyzed Engg.section

specification design
Analyzing, specification
synthesizing,
Analyzed design N and Finalized Engg.section
specification product
specification,
Y Prototyping
design
Design document, document
transferring
Finalized Documentation Engg.section
product GO TO (B) for production
specification

1.4.2 PROCEDURE-(B)

13
 1.4.2.1 PROCESS DESIGN PROCEDURES

Input Process output Responsi

bility
Received product Record Process
design input data designer

Selected process Process Process

design plan designer

Process design
Quantities & due Quantities PPC
date & due date
Production planning &
scheduling
Approved capacity Capacity & PPC
approved
N Capacity
requiremen
Y t planning
Breakdown work Work PPC
scheduling break
Detailed schedule

BOD, job order & Revised PPC

revised schedule Y schedules
Revise
the
Process sheet, N schedule Withdrawn PPC
drawing, schedule material
Withdraw required
material

Process sheet, Job order PPC

drawing, schedule, & master
due date & production
withdrawn schedule &
material input
material

14
 1.4.3 PROCEDURE-(C)
1.4.3.1 MANUFACTURING PROCESS AND CONTROL PROCEDURES

Input Process output Responsi

bility
Job order & master Job order Shop manager
production schedule Job order document & documents & input
input material input material received material received

Job order document Completely Shop

to start production reviewed job order manager/team
Job order document document & input leader/inspect
review & input material to start or
material check production

Reviewed N Detail document & Shop manager

document to start Does it job order received
production comply? Y & action plan

Preparing work order &

dispatch
Material, drawing, Approved sample Team leader
utilization & work
instruction Sample production &
test N
Approved sample CAP Conformed Team leader
OK
product & quality
inspection
Continue mass
production
Inspection & Y Product Quality
testing plan Inspection accept/reject inspector

N
OK
Confirmed product Finished/semi PPC
Y
finished products
Store/next process

15
 1.5 OVER ALL INTERN REPORT

There are five departments in Hibret Manufacturing and Machine Building Industry these are,

1. Conventional manufacturing factory

2. Precision manufacturing factory
3. Mechanical subsystem production factory
4. Machine building factory
5. Material treatment and engineering factory

1. CONVENTIONAL MANUFACTURING FACTORY

This section contains different machines to mention some of them, lathe machine, milling
machine, heavy duty machine and shaper machine. This factory contains other two factories,

1.1 Cutting tool shop

In cutting tool shop, there are different cutting tools but the most commonly applied to their
works are;

 Slab mills (shell cutter) - For heavy cutting of large and flat surface.
 Side and face cutter (splaying cutter) - This type of cutter has cutting edge on the
peripheral and side of the teeth for cutting shoulder and slot.
 Slitting saw - For cutting deep slots or for parting off.

But horizontal milling cutter are specified by the name, the material, the width, the diameter and
the hub size of the cutter such as,

 End mill -Commonly used for facing, slotting and profile milling.
 Rough cut end mills -For rapid metal removal.
 Slot drills -For producing pockets without drilling a hole beforehand.
 Face milling cutter -For heavy cutting

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 1.2 Medal and batch

In this section, there are different press machines that are used for cutting, stamping, and bending
medals. Electroplating is also included in this section and it contains different chemical such as
hydrochloric acid, nitric acid, and Sulfuric acid. The overall process in this section is first the
medals are produced in press machine, then to make them pure in color and to have a shiny
property, they will insert to the mixed chemical. Since the chemical are strong acid, the medals
will insert in water.

If the medals are needed to be painted such as flag paint or other similar like that, it goes to
painting room and it will be painted by using glaze and tenor.

Some of the products that are mostly produce in mass in the medal and batch section are;

 Fastener 1,2(small, big)

 Bottle opener
 Chest pin
 Gift article
 Key holder
 Medal(fixed, rotary)
 End clip(small, big)
 Bag
 Engraving of word on brass sheet

1.2.1 Die design room

This room is found in medal and batch, initially the customer order the medals and badges by
sample or drawing then the order go to the architectural designer, and the die designed in two
dimensionally or three dimensionally by using a machine called pantograph. After the die is
designed, it will go to the heat treatment shop in order to get enough hardness.

17
 2. PRECISION MANUFACTURING FACTORY

This is the other factory that found in Hibret Manufacturing and Machine Building Industry. This
factory contains,

 CNC machine that works in two, three, four, and five axis having better surface finish,
 Vertical and horizontal g-boring machine that works different process such as turning,
drilling and facing for big material and
 Internal and external grinding machines for finishing purpose.
 Gear hobbing machine; these machines help to make worm gear, helical gear, bevel gear, and
spur gear from that spur gear is mostly produced.

But the difference between the gear those are produced in milling machine that are found in
conventional and in this section is that index is used in convectional but in gear hobbing machine
only the arrangement of gear (teeth) is used.

 Plasma cutting machine

This plasma cutting is the only non-traditional manufacturing process within the industry
according to cutting capacity. It performs its work with the help of software like Master Cam and
AutoCAD by using these software different irregular shapes were loaded.

It has both advantage and disadvantage. The advantage is capable of cutting many irregular
shapes and there is no creation of chip. The disadvantage is create some dimensional in accuracy
and due to the development of temperature a piece get undesirable hardness.

☞ In this shop, there are two types of cutting technologies:

1. Acetylene (oxygen)
2. Plasma (flow of electron)
☞ The main difference is their cutting capacity
 Acetylene (oxygen)- can cut up to 150 mm
 Plasma cutters- can cut up to 250 mm

18
So, in general in this section most precise, accurate and complex shape products are made.

3. MECHANICAL SUBSYSTEM PRODUCTION FACTORY

This department is not working properly because of a lack of material. But at this time, this
department works maintenance for machines that works for a long period of time up to 30 years.
The problem is either mechanical or electrical so by checking the machine it rebuilt again.

4. MACHINE BUILDING FACTORY

This department is also not working properly even there is no activity is done because of lack of
equipment but after all equipment are available, this department works that when one machine
comes, it disassemble each component and redesign again and manufacturing process will
proceed then these all be assemble together. This helps to rebuilt many heavy duty machines in
our country.

5. MATERIAL TREATMENT & ENGINEERING FACTORY

In this section there are furnaces, quenching media (water, oil and air) and salt bath. When some
material (piece) needs to be heat treated, first it inserted into the furnace at required temperature
500˚c. After reaching to its own temperature, it will move to the quenching media that is water,
oil or air depending up on the material property for some minutes.

But in some heavy duty material (piece) especially that carries a load such as gear, shafts and
other will be inserted in salt bath at a given temperature and quenched by water to have the
required strength.

But sometime during hardening, a piece could have maximum HRS level so if it has higher HRS
level from required level, it is minimized by further process called annealing and this helps for to
reduce its hardness.

And also a piece could have a lower HRS level so if it has lower HRS level from required level,
it is maximized by carburization. This helps to increase the carbon content. The main agent in
this process is charcoal and sodium carbonate. This sodium carbonate helps to facilitate burning
then it quenched by air but for further hardness it goes to heat treatment and quenched by oil.

19
In this section blanking is also done. It helps giving color for corrosion resistance and then
quenched by oil or water.

 The main problem in this section is that;

 There is a formation of high temperature
 There is also a formation of high smoke during quenching.
 The material handling is not safe(use tong for big material)

This industry uses two software catia and master cam. This software helps to do objects in 3D, to
make an assembly, to do animation and analysis.

 The equipments that are found in heat treatment shop;

FURNACE

Because heating always is involved in heat treating, numerous type of heating equipment have
been developed in a range of sizes. A basic classification of furnace is whether they are of the
batch or continuous type. From those batch types of furnace is available in heat treatment.

Batch type furnace is those in which the work piece remains stationary during their time it is in
the furnace. Batch furnace may be either horizontal or vertical.

 Horizontal batch type furnace--- is often called box furnaces, because they
resemble a rectangular box. A door is provided in one end to permit the work to be
put in and remove, either air or electricity is used as a heat source.

And they are relatively;

 Easy to construct in any size

 Are easily insulated and thermally efficient
 Vertical furnace of the pit type ---- these are cylindrical chamber sunk into the floor
with a door on the top that can be permitting the work to be lowered and suspended in
the furnace. Suspended in this manner, long work piece are less likely to warp. This

20
 type of furnace also is used to heat batches of small parts, which are loaded in to
baskets and lowered in to the furnaces.
QUENCHING MEDIA

Quenching media are varying in their effectiveness. The variation being best understood by
considering the three stage of quenching. When a piece of hot metal is first inserted in to a tank
of liquid quench ant that adjacent to the metal vaporizes and forms a gaseous layer separating the
metal and liquid.

Cooling is slow in this vapor-jacket stage (first stage) since all heat transport now must be
through a gas. This stage occurs when the metal is above the boiling point of the quench ant.
Soon bubbles nucleate and remove the gas, liquid contacts the metal, vaporizes (removing its
heat of vaporization from the metal), form a bubble, and the process continues.

The second stage of quenching provides rapid cooling as a result of the large quantities of heat
removed by the mechanism. When the metal cools below the boiling point of the quench ant a
cross the solid-liquid interface, aided by conventional within the quench ant, this is the third
stage.

Some of the quenching media that are available in the heat treatment factory is;

 Water-is a fairly good quenching media because of its high heat of vaporization and also is
cheap, but the clinging tendency of the bubbles may cause soft spots in the metal.
 When a slower cooling rate is desired, oil quenches are often used. Various oils are available
that have high flash point and different degree of quenching effectiveness. Cooling often is
entire by conduction.
 Molten salt baths also are used as quench media and similarly possess the property of going
directly to the third stage.
 Still lower cooling can be obtained by cooling in still air.

In general, when attempting to understand the heat treatment of steel several key effects must be
understood the effect of carbon, the effect of alloy addition and the effect of various quenching
condition. The first two related to the material and the third top the process.

21
 CHAPTER-TWO

PROBLEM IN HEAT TREATMENT

2.1 INTRODUCTION
There are a lot of material handling mechanism from these chains are one of them. They are
mostly used to transmit motion and power from one shaft to another. The chains may also be
used for long center distance of up to 8 meters. The chains are used for velocity up to 25 m/s and
for power up to 110 Kw.
The power transmitting are three types, roller chain is one of them. It is extremely strong and
simple in construction. There is a little noise with this chain which is due to impact of the roller
on the sprocket wheel teeth. This chain may be used where there is a little lubrication. When one
of these chains elongates slightly due to wear and stretching of the parts, then the extended chain
is of greater pitch than the pitch of the sprocket wheel teeth. The roller then fit unequally into the
cavities of the wheel. The result is that the total load falls on one tooth or a few teeth. The
stretching of the parts increase wears of the surface of the roller and of the sprocket wheel teeth.

2.2 PROBLEM STATEMENT

Materials are heat treated to increase their strength and also to reduce its hardness. But when this
process is done, it has some problem.
Especially the materials that is inserted in the furnace after attaining its required temperature, it
will be inserted to a quenching media. To do this activity they use tongs as a material handling.
But it is difficult to use it for bulk materials.
When they insert the material (piece) in the quenching media, there is also the formation of bad
smell and this all affect the workers so to avoid these two problems we need to regulate the
temperature and we need another material handling mechanism.

22
 2.2 OBJECTIVE

The main objective of this project is to regulate the formation of high temperature in the room
and to make the material handling mechanism safe to the workers. When we do this, we can
protect the smoke and bad smell b/c it helps to avoid a direct contact b/n the workers and the
material (piece) that is inserted to the quenching media.

In general, we need to prevent time wastage and make it suitable for workers so we can create a
good working atmosphere.

Basket Quenching
Media

Tong

2.3 METHODOLOGY

In order to solve this problem, we must consider the following:

Material handling mechanism

The material handling mechanism in the heat treatment shop is not suitable. Tongs only used for
small material. So to make suitable for both small and bulk material, I select another material
mechanism called roller chain.
In this condition, we need to consider:
 Roller shaft design

23
  Bearing selection
 Pushing piston design
 Roller chain design
 Square flanged cylinder joint design
Controlling the temperature
In the heat treatment shop, there are furnaces and quenching media so these furnaces eject some
heat to the room and when the material is inserted in to the quenching media, there is also the
formation of heat.
So in order to solve this, we need a temperature regulator that works automatic switch on/off
when it decreases/increases from the limited temperature. To solve this I include
 Proper selection of sensor
 Selection of actuator and signal conditioning
 Controlling mechanism
 Logical network design

2.4 RESULT
After finishing this project, it will help to have a continuous flow from a furnace to a quenching
media and we can regulate the temperature this all helps the workers to work their work properly
without affecting their health.
And also especially for bulk material it is helpful and there will be a mass production and
prevent time wastage. When we add all these things, it will increase a company profit.

24
 CHAPTER-THREE
ANALYSIS FOR MATERIAL HANDLING

3.1 DESIGN OF ROLLER CHAIN

I select for the material handling for bulk material is a roller chain because of:-

 It used for both long as well as short distance

 It gives high transmission efficiency (up to 98%)
 It gives less load on the shaft
 It has the ability to transmit motion to several shaft by one chain only

GENERAL SPECIFICATION

 Rated power =2kw

 Electric motor running=600rpm

ANALYSIS

To reduce the speed for the roller shaft speed reduction let’s take the gear ratio 1:3

The speed is reduce from gear 1 to gear 2 i.e. from 600 rpm to 200 rpm and then to 66.67 rpm
with gear 3.

25
 Fig 1.speed reduction

We need a shaft to rotate at a constant speed and small revolution that operated 16 hours per day.
So N1=N2

From speed reduction, I get N1 =66.67rpm so,

 The velocity ratio of a chain drive

N 1 66.67
V.R= N 2 = 66.67 =1

TABLE 1.Number of teeth on the gear sprocket

Number of teeth at velocity ratio

Type of chain
1 2 3 4 5 6

Roller 31 27 25 23 21 17

Source:-Material Handling Equipments

Jose M.Dominguez E

From table 1, we find that for the roller chain, the number of teeth on the sprocket (T 1) for a
velocity ratio 1 is 31.

I.e. Number of teeth (T1) =31

26
 Number of teeth (T2) =31

∴ Number of teeth on the larger sprocket or gear:-

N1 1000
T2=T1* N 2 =31* 1000

T2=31

It is known that;

Design power = rated power * service factor (Ks)

The service factor (Ks) is the product of various factors K 1, K2 and K3. The values of these
factors are taken as;

Load factor (k1) for variable load with heavy shock and continuous operation =1.5

Lubrication factor (K2) for drop lubrication =1

Rating factor (K3) for 16 hours per day =1.25

∴ Service factor, K3=K1*K2*K3

=1.5*1*1.25

=1.875

And design power = 2*1.875=3.75 Kw

TABLE 2- power rating (in Kw) of simple roller chain

Speed of sprocket Power(Kw)

(rpm) 06B 08B 10B 12B 16B

27
 66.67 0.16 0.46 0.84 1.43 3.46

100 0.25 0.64 1.18 2.01 4.83

200 0.47 1.18 2.19 3.75 8.94

300 0.61 1.70 3.15 5.43 13.06

500 1.09 2.72 5.01 8.53 20.57

⋮ ⋮ ⋮ ⋮ ⋮ ⋮

Source: - Material Handling Equipments

Jose M.Dominguez E

From table 2, we find that corresponding to a pinion speed of 66.67 rpm the power transmitted
for chain number 16 is 3.46 Kw per strand. Therefore, a chain number 16 with two strands can
be used to transmit the required power.

Table 3- characteristics of roller chains

ISO Pitch (p) Roller dia Width b/n Transverse Breaking load (KN) min
chain No. mm (d1)mm inner pitch(p1)mm
max plates
(b1)mm Simplex duplex Triplex
min

⋮ ⋮ ⋮ ⋮ ⋮ ⋮ ⋮ ⋮

08B 12.70 8.51 7.75 13.92 17.8 31.1 44.5

10B 15.875 10.16 9.65 16.59 22.2 44.5 66.7

12B 19.05 12.07 11.68 19.46 28.9 57.8 86.7

16B 25.4 15.88 17.02 31.88 42.3 84.5 126.8

⋮ ⋮ ⋮ ⋮ ⋮ ⋮ ⋮ ⋮

SOURCE: - Material Handling Equipments

28
 Jose M.Dominguez E

From table 3, we find out

 Pitch, p=25.4
 Roller diameter, d1 =15.88
 Minimum width of roller, W=17.02
 Breaking load, WB =84.5

The pitch circle diameter of the gear:-

180 180
D1=p*csc ( T 1 ¿ )¿ =25.4* csc( 31 ¿ )¿ mm

D1=251 mm

Since they have equal number of teeth

D1=D2=251 mm=0.251 mm

 Pitch line velocity of the sprocket

π D 1 N 1 π∗0.251∗66.67
V1= 60
= 60

V1=0.876 m/s

 Load on the chain

rated power 2
W= pitch line velocity = 0.55

W=2.283 KN

Now let’s calculate the factor of safety. This value of factor of safety should be greater than the
value given in table 4

Table 4.Factor of safety (n)

29
 Type of Pitch of Speed of the sprocket pinion in rpm
chain Chain(mm 50 200 400 600 800 1000 1200 1600 2000
)
12-15 7 7.8 8.55 9.35 10.2 11 11.7 13.2 14.8
Roller
chain 20-25 7 8.2 9.35 10.3 11.7 12.9 14 16.3 --

30-35 7 8.55 10.2 13.2 14.8 16.3 19.5 -- --

SOURCE: - Material Handling Equipments
Jose M.Dominguez E
3
WB 84.5∗10
Factor of safety = W = 3 = 37.01
2.283∗10

∴ This value is more than the value given in table 4, which is equal to 7.

 Fix the center distance b/n the sprockets

The minimum center distance b/n the two sprockets should be 30 to 50 times.

Let’s take it as 50 times the pitch=50*P = 50*25.4

=1270
In order to accommodate initial sag in the chain, the value of center distance is reduced by 2 to 5
mm.

∴ Correct center distance

X=1270-4=1266 mm
Determine the length of the chain
The number of chain links
T 1+T 2 2 X T 2−T 1 2 P
K= + + ( ¿
2 P 2π X
31+ 31 2∗266 31−31 2 25.4
= + +( ¿*
2 25.4 2π 1266
= 31+ 99.685
= 130.685
∴ Length of chain

30
 L=k*p=130.685*25.4
= 3320 mm

3.2 DESIGNS FOR ROLLER SHAFT

GENERAL SPECIFICATION

 The shafts carry a gear and supporting in two bearings.

 Central load 500 N (we need to carry this amount of load)
 Bearing support 700 mm apart depend up on furnace opening
 Gear located 100 mm
 From roller chain design
 The shaft transmits 2kw at 66.67rpm

31
  Material selection
Table 5:- material list

Steel tensile Yield stress Min % Uses

strength N elongation
(min) 2
(min) mm

Fe 490 490 290 21 Steel for making key, shaft

Fe E 370 490 370 21 spindle, sheet piling.
Fe 540 540 320 20 Steel for locomotion, carriage,
Fe E 400 540 400 20 wagon bolts & welded tubes.

Source: - HMMBI material list

The material selected is steel Fe 490

Tensile strength = 490 Mpa

Yield stress (σ y) = 290 Mpa

Assumption
 F.S = 1.5 to 2 for well known material under reasonably constant environment condition
subjected to load and stress that can be easily determined.

Since it is subjected to gradual applied loads, I select F.S=2

σy 290
τ y= = 2 = 145Mpa
F .S

σt 490
σ t= = 2 = 245 Mpa
F .S
32
 Fig 2-Roller shaft

ANALYSIS

The torque transmitted by the shaft:-

3
p∗60 2∗10 ∗60
T= 2 πN = = 286.46*103 N-mm
2 π∗66.67

Assuming that the torque on the gear A is the same as that of the shaft, therefore the tangential
force acting vertical downward on the gear A

T 286.46∗10
3
251
Ft= R = Where RA = 2 = 125.5 mm
A 125.5

Ft=2282.5 N

Now let’s find the reaction at the bearing B and C. Let R B and RC be the reaction at B and C
respectively

Taking a moment at C,

RB*700+2282.5*45=500*350

RB*700+102,712.5=175,000

RB=103.2 N

For the equilibrium of the shaft,

33
 RB+RC=500+2282.5

103.2+RC=2782.5

RC=2679.3N

Since it is a support, the bending moment at B and C =0

Bending moment of simple support shaft carrying a central load,

W∗L 500 N∗700 mm
M=
4
= 4
M=350*103 N-mm
The bending moment at A =2282.2 N*45 mm = 102.7*103 N-mm

∴Bending moment is maximum at central load;

Maximum B.M = M=MC=350*103N-mm

Table 6:- recommended values for km and kt

Nature of load km kt

Rotating shaft

(a)gradually applied or steady load 1.5 1.0

(b)suddenly applied load with minor shocks only 1.5 to 2.0 1.5 to 2.0

(c) suddenly applied load with heavy shocks 2.0 to 3.0 1.5 to 3.0

SOURCE: - Material Handling Equipments

Jose M.Dominguez E

From table 6, for rotating shaft with gradually applied loads Km=1.5 and kt=1

34
  The equivalent twisting moment

Te =√ ¿ ¿

=√ ¿ ¿

= 598.067*103 N-mm

The equivalent twisting moment is equal to,

π
598.067*103= 16 τ d3

π
598.067*103= *145*d3
16

d=27.6 mm

 The equivalent bending moment

1
Me= 2 (km*M+√ ¿ ¿ )

1
= (1.5*350*103+ √ 598.067∗103 ¿
2

=561.54*103N-mm

The equivalent bending moment is equal to

π
561.54*103= 32 * σ b*d3

π
561.54*103 = *245*d3
32

d=28.6 say 30mm

∴Taking the largest of the two values,

d= 30mm

35
 Designing rectangular key

 Shaft dia = 30 mm

 σ y =290 Mpa -----for material Fe 490 in table 5

Table 7:- proportional of standard parallel key

Shaft dia (mm) up to & Key cross-section

including
Width (mm) Thickness (mm)

17 6 6

22 8 7

30 10 8

38 12 8

SOURCE: - Material Handling Equipments

Jose M.Dominguez E

From table 7, for shaft of 30mm dia,

 Width of key, w=10mm

 Thickness of key, t=8mm

The length of the key is obtained by considering the key in shearing and crushing.

Let l=length of key.

 According to maximum shear stress theory, the maximum shear stress for the shaft,
σy 290
τ max = = 2∗2 = 72.5 N/mm2
2∗F . S
 Maximum shear stress for key the key,

σy 290
τK = = = 72.5 N/mm2
2∗F . S 2∗2

The maximum torque transmitted by the shaft and key,

36
 π π
T= * τ max *d3 = * 72.5* 303 = 384,354.2N-mm
16 16

Let’s consider the failure of key due to shearing, maximum torque transmitted (T),

d 30
384,354.2=l*w*τ k * =l*10*72.5* = 10875 l
2 2

384,354.2
∴ l= 10875
= 35.34 mm

Now consider the failure of key due to crushing, we know that the maximum torque transmitted
by the shaft and key (T),

σy 290
σ ck= = 2 = 145N/mm2
F .S

t d 8 30
384,354.2=l * * σ ck* = l* *145* = 8700 l
2 2 2 2

384,354.2
∴ l= = 44.17 mm
8700

Taking the larger of the two values, length of key,

l=44.17 say 45mm

3.3 BEARING SELECTION

THRUST BEARING: - Is selected for the design b/c thrust bearing can support axial load but
radial bearing can support only radial load.

37
 Fig 3- Thrust roller bearing

Table 8: -standard thrust roller bearings

bearing no. d(mm) d2(mm) D(mm) H(mm)

51104 20 20.2 35 10

51104 25 25.2 42 11

51105 30 30.2 50 12

⋮ ⋮ ⋮ ⋮ ⋮

Source: - engineering drawing and design

Cecil Jensen & jay d.helsel

Bearing selected for my design is

 Since the shaft diameter is 30 mm,
Bearing no.51105
d=30mm
d2=30.2mm
D=50mm
H=12mm

3.4 CYLINDER AND PISTON SELECTION

3.4.1 GENERAL SPECIFICATION

38
 This piston helps to push the basket that holds the pieces and it has a brick at the tip to
resist high temperature since it makes a direct contact with the basket. Therefore this
piston pushes the basket that is found in the furnace to the roller chain.
Its stroke length is depends on the width of the furnace.
The weight of the basket that holds the pieces let’s take
Max weight=500N
SELECTION
 For directional control valve,
Four way directional control valve is selected b/c,
 They are capable of controlling double acting cylinder and bi-directional motor.
 For pressure control value,
Pressure relief valves is selected b/c,
 It limits the maximum pressure in the hydraulic circuit by providing an alternate path
for fluid flow when the pressure reaches a present level.

Fig 4-Schematic dia a circuit designed to move a piston at nearly constant speed

3.4.2 COMPONENTS

39
  Directional valve with three positions, four connectional
and an arrangement that close the value when in the central position.

 Manual shut off valve operated by either hand or foot.

 Electric motor

 Filter – remove dirt and foreign matter from the system

 A fixed displacement pump

 Double acting cylinder, single rod end

 Pressure gauge – for indicating either oil or air pressure

 Pilot operated relief valve

 A line to the reservoir, entering the reservoir below the fluid level in the

reservoir or tank.

A circuit design to move an object A from position X to position Y at a nearly constant speed is
shown in fig. it may be noted in this circuit that it is necessary to show the power source. The
operator loads the object A at position X and shifts the handle of the three position open center
four way valve C, & oil under pressure, is directed from the power unit E through the inlet port
of valve C to part 1 and them to port 3 of cylinder D.

As oil pressure forced the piston forward, oil is exhausted from port 4 to port 2 of valve C and
then to the reservoir of the unit E. The piston and piston rod of cylinder D cause the object to
move to position Y. Then the operator shifts the handle of valve C to the extreme opposite
position and oil, under pressure, is directed from the inlet of valve C to port 2 and then onward to
port 4 of the cylinder D.

40
The piston of the cylinder begins to retract, and oil is exhausted through port 3 to port 1 of valve
C and through the exhaust port to the reservoir of the unit E. The piston rod of cylinder D retracts
to position X.

The operator shifts the handle to the neutral or central position, and the cycle is completed. By
placing the handle in neutral position, the oil is directed to the reservoir at no pressure during the
stand by period; this keeps heat from building up in the system. If a two-position valve, rather
than a three position valve were used, the oil, under pressure, would spill through to the
exhaust of the relief valve during the stand by period, thus creating heat.

3.4.3 STANDARD FOR CYLINDER SELECTION

Fig 5- standard cylinder

Table 9: - standard cylinders

Type Bore O.Dia Rod Max A 1.5 B C D

barrel dia stroke

40M 40 50 22 300 122 55 11 ¼

50M 50 60 28 480 134 60 22 ¼

60M 60 73 36 650 146 65 27 3/8

70M 70 80 40 750 155 70 27 3/8

80M 80 92 45 820 177 82 32 3/8

90M 90 105 50 900 190 88 32 --

100M 100 115 56 1005 210 90 32 --

41
 Source: - Standards of HMMBI

Since the furnace width (w) = 870mm

∴ The rod should fully extend up to this mm so:-
 Type-90M
 Bore-90mm
 Outer dia barrel-105mm
 Rod dia-50mm
 Max stroke-900mm is selected.
3.4.4 PUMP SELECTION
Assumption
 No leakage through the cylinder i.e. positive displacement
Sliding velocity=0.25m/s
The volume leaving the pump is equal to the volumetric displacement of a piston.
Q=V.A
Dia rod =50mm=0.05mm
Weight =500N
 The pressure
500
F
P= A = π (0.05)2 = 254.648*103 N/m2 or 0.26Mpa
4
 The flow rate
Q=V.A
2
π (0.05)
Q=0.25*
4
Q=4.91*10−4 m3/s

 By using the value P=0.26 Mpa and Q=4.91*10−4 m3 /s, we can select an appropriate pump.

42
 3.5 DESIGN OF SQUARE FLANGED CYLINDER JOINT

GENERAL SPECIFICATION
 I get external diameter of barrel = 105 mm
 Fluid pressure = 0.26Mpa
 Maximum tensile stress in the bolt
Material selected is St 540--------from table 5
σ t = 540Mp

The total force (the external loads) acting on the cylinder head i.e. on 4 bolts,

2 2
πd π (105)
F= p= *0.26
4 4

= 2251.3 N

∴External loads on the cylinder head per bolt,

F 2251.3
P2= 4 = 4
= 563 N

Let d=nominal diameter of bolt, and

dc= core diameter of the bolt

→The soft gasket, the minimum value of k=0.5

∴ Resultant axial load on the

P= p1+ k*p2

→The initial tension due to tightening of bolt,

P1= 2840d N

∴P=2840d + 0.5*563N

43
 P=2840d+281.5

The load on the bolt,

π 2 π
2840d+281.5= d c σ t = (0.84d) 2*540
4 4

2840d+281.5=299.26d2

299.26d2 - 2840d - 281.5=0

d2 - 9.49 d-0.94=0

9.40 ± √(9.49) +4 (0.94 )

2
d=
2

9.49 ± 9.746
d= ---------------------- (taking +ve sign)
2

d=9.588mm say 10mm

A bolt size=M10

∴Minimum length of a diagonal for this square

Fig 6-square flange cylinder joint

L=outside dia of cylinder + 2*dia of bolt+2t

L=105+2*10+2*30

44
 L=189mm

Side of square,

L 189
L1= = = 134mm
√2 √2

The side of the flange must be of sufficient length to accommodate the bolts heads without
overhangs.

The length L2 may be kept as (L1+2d) i.e.

L2=L1+2d

=134+2*10

=154mm

For M10

Fig 6- Bolt

Nominal Thread Minor Ø Width Width Height of

size thread pitch of thread across across flat head, H
dia, D corner A/C A/F

M10 1.5 8.1 19.5 17 8

45
 CHAPTER-FOUR
ANALYSIS FOR TEMPRATURE REGULATION

4.1SELECTION OF SENSOR
Sensor is an element in mechatronics system which acquires a physical parameter and changes it
in to signal that can be process by the system and used to produce a varying signal according to
the quantity being measured.

Factors that need to be considered in selecting sensor for particular applications are;

 The nature of the measurement that is required.

 The nature of the output required for the sensor.
 Specific properties of sensors such as range, accuracy, maintainability.

There are different types of sensor but from these thermal sensors is one of them. So for the
design purpose thermister is selected as a sensor which has the following criteria;

 Thermister are in expensive

 Easily obtained
 Have reasonable output voltage

Thermister are temperature sensitive resistors. All resistors vary with temperature, but thermister
is constructed of semiconductor material with a resistivity of that is especially sensitive to
temperature. However, unlike most other resistive devices the resistance of a thermister
decreases with increasing temperature.

Since the thermister give in resistor this resistor must changed to voltage therefore we use wheat
stone bridge.

46
 4.1.1WHEAT STONE BRIDGE

Wheat stone bridge is a signal conditioning element which converts the resistance change of the
thermister to voltage change for a corresponding temperature change. It needs an extra supply
voltage to give an output voltage.

 The change in temperature from T 1 to T1+ ΔT is replaced by the corresponding change in

resistance of from R1 to R1+ΔR which also yields voltage change from V 1 to V1+ΔV in
the signal conditioning element wheat stone bridge.

 Since the resistance in wheat stone bridge is much greater than the change in resistance,
or the change in voltage due to the corresponding increasing in temperature can be simply
defined by

Dr
dv = vs. ( ) where vs. is the external supply voltage
R1+ R 2

The change in the output voltage is thus proportional to the resistance R 1 of the sensor which
varies in corresponding to temperature change. Finally the output voltage goes directly to the
logarithmic amplifier to linearize.

4.1.2 LOGARITHEMIC AMPLIFIER

Since the output resistance from the thermister, thus the output voltage from the wheat stone
bridge is not linear it should be linearize by an amplified which is the logarithmic amplifier.

Logarithmic amplifier is an operational amplifier, which is used to linearize the output voltage
from the wheat stone bridge before it is amplified and preceded to the microprocessor.

47
 4.2 SELECTION OF SIGNAL CONDITIONING

Signal condition elements are amplifying the signal to the right level;

 protect the current , voltage and wrong polarity

 avoid interference
 make it linear of some variable

4.2.1 INVERTING AMPLIFIER

Since the output voltage from the logarithmic amplifier is so small that it must be amplified by
the use of this inverted amplifier.

The input signal to the inverting amplifier is b/n 0.0001 and -0.0001, but it can be magnified up
to± 10 v .

The output voltage & the out voltage for inverting amplifier can be related by;
V out Rf Rf
= - Where - is the gain G, the magnification factor to amplify the given input
V¿ R1 R1
voltage to the output voltage.

THE OVER ALL FLOW

Thermister Wheat stone bridge Logarithmic op amp Filter

ON/OFF switch (correction element) inverting amplifier

48
 Relay (ACTUATOR) Zener diode

D/A converter Microprocessor A/D converter

4.2.2 PROTECTION

The microprocessor is (the CPU of the hole system) that contains many programs, so that the
voltage entering to the microprocessor from the op-amp (inverting) must be corrected, if it has
high current or high voltage.

A high current in the input can be protected against by incorporation in the input line a series
resistor to limit the current to an acceptable level and a fuse to break if the current does exceed a
safe level.

The high voltage and wrong polarity may be protected against by the use of a zener diode circuit.

Since zener diode have a low resistance for the current in one direction through it and a high
resistance for the opposite direction it provides protection against the wrong polarity.

4.2.3ANALOG TO DIGITAL CONVERTER

The microprocessor needs an input signal which is in a digital form, the on/off or the operation is
low if it is OFF since the signal from the inverting amplifier are in analog form thus we have to
use signal conditioner which converts the analog signal to digital signal.

The analog to digital converter that we used for our problem is the parallel encoder that uses a set
of voltage comparators and a service of resistors to simultaneously compare an analog input
signal to a set of reference voltage.

When the analog voltage is applied to this ADC all these comparators for which the analog
voltage is greater than the reference voltage of a comparator will give a high output. The

49
resulting outputs are feed in parallel to a logical gate system which translates them in to a digital
word.

4.2.4 DIGITAL TO ANALOG COVERTER

Since the signal output from the microprocessor is in the digital form and the actuation system
needs an analog signal there must be a converter system thus we use a summing amplifier to
form the weighted sum of all the non-zero bits in the input word, having a reference voltage.

It has an input signal (digital) form the microprocessor (Y1) and the output voltage (analog).

50
 4.3 CONTROLLING ELEMENT
4.3.1 MICROPROCESSOR AND LOGICAL NETWORK

LOGICAL NETWORK DESIGN

To design the logical function for controlling the working temperature of the room the logic
network is for an automatic control of the temperature that is when the temperature of the room
above 30℃ there will be a cooler is switched on to control this activity and if the temperature of
the room is below 30℃ then the cooler is switched off. And also if the system is unable to
control this temperature, there is an alarm that gives a signal sound and the worker will take
action after getting this alarm.

STATEMENTS

State 1- cooler OFF when the temperature of the room is below 30℃ .

State 2- cooler ON when the temperature of the room is above 30℃ .

State 3- cooler ON but cannot control the temperature and the temperature of the room exceed
highly then the alarm become ON and give sound.

DEFINE THE BOOLEAN VARIABLE

A-when the temperature is below 30℃

B-when the temperature is above 30℃

C-when the temperature is not controlled

Y1-(output variable) regulated temperature

Y2-(output variable) Alarm

D-switch D

E-switch E

Switch 00 state 1

DE = 10 state 2

51
 01 state 3

CONDITION STATEMENTS

i. If temperature is below 30℃ and DE=0 0 is high then the cooler will OFF
ii. If temperature is above 30℃ and DE=1 0 is high then the cooler will ON
iii. If temperature is exceed above 30℃ and DE=0 1 is high or cooler not control the
temperature and DE= 1 0 is high then the alarm will ON

Write the quasi logic statement in variable

 Y1 is high when
B is high and DE=1 0 is high
Or
C is high and DE=0 1 is high
 Y2 is high when
B is high and DE=0 1 is high
Or
C is high and DE=1 0 is high
 Y1 is low when
A is high and DE=0 0 is high
Or
B is low and DE=1 0 is low
 Y2 is low when
A is high and DE=0 0 is high
Or
B is high and DE=1 0 is high

EQUATION OF STATEMENT

DE = 1 0 state 2

DE = 0 1 state 3

 DE is at 1 0 or high
DE= D.E⎺=1
 DE is at 0 1 or high
DE=D⎺.E=1
Y1= (B.D.E⎺) + (C.D⎺.E)

52
 Y2= (B.D⎺.E) + (C.D.E⎺)
Simplify the equation

D E D.E⎺ D⎺.E

0 0 0 0
1 0 1 0
0 1 0 1

The above table shown us;

D.E⎺ = D
D⎺.E = E
∴The simplified equation of the statement will be;
Y1= (B.D) + (C.E)
Y2= (B.E) + (C.D)

DRAW CIRCUIT DIAGRAM

53
 4.4 MICROPROCESSOR
4.4.1 SELECTION OF MICROPROCESSOR

PIC16F84 microcontroller is selected since it has the following properties;

 Low cost
 Easy for programming language
 High speed of response

It has four input ports and two output ports.

For the Boolean function; Y1= (B.D) + (C.E)

Y2= (B.E) + (C.D)

Define the variables and deceleration of variable;

A var portB4

B var port B0

C var port B2

Y1 var port A1

Y2 var port A2

D var port B1

54
E var port B3

DEFINE CONSTANTS

High con 1

Low con 0

ON con 1

OFF con 0

If ((D=0 and E=0)) ' normal temperature

Then

If(A=High)
low Y1

If ((D=1 and E=0))

Then

If (B=High)

High Y1

Else

Low Y1

If ((D=0 and E=1))

Then

If (C=high)

High Y1

55
 Else

Low Y1

If ((D=0 and E=1))

Then

If (B=high)

High Y2

Else

Low Y2

If ((D=1 and E=0))

Then

If (C=high)

High Y2

Else

Low Y2

End if

Else

Low Y1

Low Y2

end

end

end

56
 end

4.5 ACTUATORS
Actuators are correction elements produces a change in the process to correct or the controlled
condition. They are elements of control system which are responsible for transforming the output
of a microprocessor or control system into a controlling action on a device.

There are many types of actuators such as pneumatic, hydraulic, mechanical and electrical
actuators. The actuator that I used in my problem for actuating the power supply of the boiler is
an electrical actuator which is the relay which actuates the power supply by close or opens the
switch of the power supply in corresponding to the temperature of the boiler.

RELAY

Relay are electrically operated switches in which changing a current in one electrical circuit
switches a current on/off in another circuit.

The principle is when a current flows though the coil of the wire a magnetic field is produced.
This pulls a movable armature that are two sets of contacts with one being opened and the other
closed by the action.

When the temperature is above, the microprocessor will have a high output and a current coming
to the relay so that there is an action to the power supply to switch off.

57
The one set of the contact is being attached to the power supply. If no current to the relay, set 1
which is in contact now is connected to power supply. If there is current in the coil of the relay,
the contact (set 1) will open and thus the power supply will open.

CHAPTER-FIVE
MANUFACTURING PROCEDURES AND DETAIL DRAWINGS

5.1 INTRODUCTION
This manufacturing process is take place in different section and in different machine that
available in the industry such as;

 lathe (L),
 Milling (M),
 Slotting (S),
 Heat treatment (HT),
 Plasma cutting machine (EDM),
 Internal Grinder (GRI),
 External Grinder(GRS),
 In gear hobbing (GH) machine.

The first process is to shape the blank material in the required dimension in lathe machine. Then
it goes to either milling or slotting depending upon the shape that we required and if we want to
make teeth for the gear, it directly goes to the gear hobbing machine and then before grinding
any material; if it is needed to be hard, it goes to the heat treatment and finally grinding process
is takes place at required dimension.

But sometimes if we required rectangular or circular and their dimension is very large and also if
it is difficult to do them using lathe or milling machine, it is advisable to use a plasma cutting
machine (EDM). But if you want to make holes, you can’t drill by using a drill bit b/c this
plasma cutting machine increase its strength so, to drill first the material must heat treated to
make soft by a process called annealing then we can drill the material easily.

58
Cylinder can be manufacturing by machining in the precision shop using CNC lath and milling
but other components such as control valves, pump, filter, lines are bought from the market by
the specified parameters.

CHAPTER-SIX

CONCLUSION AND RECOMMENDATION

CONCLUSION

Generally in this four month I gain more knowledge especially when we see in terms of
improving my personal skills, I can easily see the difference between theory and practical work.
When you do practical work, you can easily see each and individual thing so this make better to
improve my personal skills.

And when we see in terms of upgrading my theoretical knowledge, the knowledge that we know
in theory only is not enough but when you see the theory in practical, it is unforgettable so this
makes to upgrade your theoretical knowledge and when you look in terms of work ethics you
learn to be punctual and to work your work properly.

The activities done on each factory helps to see and to know different things because a lot of
activities are done in each day on each factory and I develop my software knowledge by
knowing a software called catia, this helps to do part, assembly, and draft and so on I think it is
helpful to know this in the future.

This mini project helps me to know more things and to read different books so this helps in the
future to take large projects.

Future work

The work that I have not finish is to change it to real product. So the remaining is to manufacture
each part and make them assemble. Since I have done the manufacturing process and detail
drawings of each part, this all makes easy to manufacture.

59
 RECOMMENDATION

HMMBI produces many different machine parts but there are some problems and some of my
recommendations for these problems are;

 Minimize material wastage

When some product ordered to produced, very large diameter material (piece) is used. This
makes a material to waste b/c to make smaller diameter, we need to remove some material from
it. So if we need to have a small diameter piece, we must use small diameter piece.

 Reuse waste materials

The most waste material in this industry is chip. These chips are not recycled, it’s just thrown
away and expose to temperature and weather but if we recycle them, we can save a lot of things.

 Avoid tool wear

During machining heat is generated at the cutting point. This heat generated is shared by the
chip, cutting tool and the blank. This causes rapid tool wear which reduces tool life. So to solve
this, we must avoid continuous chip formation by using chip breaker.

 Use coolant

The basic purpose of cutting fluid application is cooling of the job and the tool to reduce the
detrimental effects of cutting temperature on the job and the tool. But the machinists don’t use
coolant and there is a formation of fire due to the high contact b/n the tool and job. So coolants
are very important and consider it to increase the tool life.

 Maintenance

60
The failure of the machine is due to carelessness or unskilled labor and also improper material or
tool usage due to these and other some machines are stop working so they need to be maintained
and we can increase our profit.

REFERENCES

 Josely Dominguez E, Machine element & Design.

 Harry L.stewart, practical guide to fluid power new edition.
 Paul H.Black, Machine Design third edition, page 514-521.
 R.S Khurmi and K.Gupta, a text book of machine design.
 Cecil Jensen & Jay d.helsel, Engineering drawing and design.
 Hibret Manufacturing and Machine Building Industry, written documents and material list.
 W.bolton, Mechatronics second edition
 Different Web sites.

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