Download - Mandava Institute of Engineering and Technology`s

DESIGN AND FABRICATION OF
LOW COST SURFACE GRINDING
MACHINE
SUBMITED BY
•
•
•
•
•
K.NAGA BHUPATHI
A.NAVEEN
G.SAI KUMAR VARMA
P.DILEEP KUMAR
R.NARESH
14FF5A0306
13FF1A0301
13FF1A0317
13FF1A0332
14FF5A0308
ABSTRACT
• The main aim of this project is manufacture and
fabricate the low cost surface grinding machine by
using the scrap material and we will design that low
cost surface grinding machine by using the CATIA
software for design reference and we had taken part
dimensions as our manufacturing process and
producing the low cost surface grinding machine.
Finally we will done the project success fully with
low cost for comparing the standard surface grinding
machine.
INTRODUCTION
• Grinding is a manufacturing process in this process good
surface finish and dimensional accuracy are complementary,
and can be obtained by grinding. It is a process of removing
metal in small quantities of using an abrasive wheel, called
grinding wheel. It is regarded as a finishing process for
obtaining desired surface finish, accuracy in size and
geometrical configuration of the product.
• The grinding machine consists of a bed with a fixture to
guide and hold the work piece, and a power-driven grinding
wheel spinning at the required speed. The speed is
determined by the wheel’s diameter and manufacturer’s
rating. The grinding head can travel across a fixed work
piece, or the work piece can be moved while the grind head
stays in a fixed position.
TYPES OF GRINDING MACHINES
•
•
•
•
•
•
•
Belt grinder
Bench grinder
Cylindrical grinder
Surface grinder
Tool cutter grinder
Jig grinder
Gear grinder
SURFACE GRINDING MACHINE
• Surface grinding is used to produce a smooth finish on flat surfaces. It is a
widely used abrasive machining process in which a spinning wheel covered
in rough particles (grinding wheel) cuts chips of metallic or non-metallic
substance from a work piece, making a face of it flat or smooth.
TYPES OF SURFACE GRINDING
MACHINES
1. HORIZONTAL SURFACE GRINDING
MACHINE
2. VERTICL SURFACE GRINDING
MACHINE
PROCESS OF SURFCE GRINDING
MACHINE
• Surface grinding is the most common of the grinding
operations. It is a finishing process that uses a rotating
abrasive wheel to smooth the flat surface of metallic or nonmetallic materials to give them a more refined look or to attain
a desired surface for a functional purpose.
GRINDING WHEELS
• Grinding wheel is widely used in grinding machines. These wheels
are expendable wheels composing of an abrasive compound. These
grinding wheels are formed out of an aluminium disc or solid steel
by way of attaching the particles to the exterior surface. In general,
this grinding wheel is normally prepared using the mould of hardpressed coarse particles matrix that are allied together to make a
firm circular shape. Based on the planned use of the wheel, various
profiles and cross sections are also obtainable.
CHARECTERSTICS:
• There are five characteristics of a cutting wheel: material, grain size, wheel
grade, grain spacing, and bond type. They are indicated by codes on the
wheel's label.
Abrasive grain:
The abrasive aggregate is selected according to the hardness of the material
being cut.
• Aluminum oxide(A)
• Silicon carbides (S)
• Ceramic (C)
• Diamond (D)
• Cubic boron nitride (CBN)
• Grinding wheels with diamond or CBN grains are called super abrasives.
Grinding wheels with aluminum oxide (corundum), silicon carbide, or
ceramic grains are called conventional abrasives.
GRINDING WHEEL SPECIFICATIONS:
•
•
•
•
Diameter of grinding wheel 200 mm.
Thickness of grinding wheel 20 mm.
Bore diameter of grinding wheel 31.5 mm.
Maximum speed of grinding wheel 3150 RPM.
Grain size:
From 8 (coarsest) to 1200 (finest), determines the average physical
size of the abrasive grains in the wheel. A larger grain will cut freely,
allowing fast cutting but poor surface finish. Ultra-fine grain sizes are for
precision finish work.
Coarse
Medium
Fine
Very fine
8
10
12
14
16
20
24
30
36
46
54
60
70
80
100
120
150
180
220
240
280
320
400
500
600
Wheel Grade:
The term grade as applied to a grinding wheel refers to the tenacity
with which the bond holds the abrasive grains in place, and does not refer to
the hardness of the abrasive. A wheel from which the grains are released
rapidly during the grinding operation is called soft grade, whereas wheel that
retains the grains more securely is called hard grade.
Soft
Medium
Hard
A
B
C
D
E
F
G
H
I
J
K
L
M
N
O
P
Q
R
S
T
U
V
W
X
Z
Abrasive material properties and uses :
Abrasive
material
Year of
discovery
Hard ness
(K noop)
Temperature Properties and
of
Uses
Decomposition
in oxygen
Silicon carbide
1891
2200-2800
1500-2000
Used for brass,
bronze,
aluminum
stainless steel
and cast iron.
Aluminium
oxide
1893
1600-2100
1700-2400
Softer and
tougher than
SiC, used on
steel,
malleability
cast iron, tough
bronze.
Grinding wheel properties :
The properties of grinding wheels determine the
productivity of the grinding process and the achievable grinding
quality.
•
•
•
•
•
Type of abrasive grain material.
The size of the grit.
The bond material.
The properties of abrasive and bond.
Porosity.
MANUFACTURING OF LOW COST
SURFACE GRINDING MACHINE
FRAME :
First of all, the frame is constructed. We are taking the
MS angular rods and then cutting as per the our dimensions and
bends in required places bending machine and hammer. Then the
angular rods are to be welded.
Welding :
Welding is a fabrication or sculptural process that joins
materials, usually metals or thermoplastics, by causing coalescence.
This is often done by melting the work pieces and adding a filler
material to form a pool of molten material (the weld pool) that
cools to become a strong joint, with pressure sometimes used in
conjunction with heat, or by itself, to produce the weld.
Mechanical properties :
•
•
•
•
•
•
•
•
•
Strength
Hard ness
Tough ness
Malleability
Ductility
Elasticity
Plasticity
Durability
Brittle ness
Properties of cast iron and mild steel :
Type of metal
Properties
1 . Cast iron
Brittle ness, hard ness, fusibility, and non
malleability. Which means that is can not
be stretched. Its has a crystalline structure.
2 . Mild steel
Mild steel is tough ness, ductility and
malleability. It has good strength but poor
corrosion resistance. It is mainly used as
an all-purpose engineering material.
COMPARING THE LOW COST SURFACE
GRINDING MACHINE & SURFACE
GRINDING MACHINE
LOW COST SURAFCE
GRINDING MACHINE
•
•
•
•
•
•
This is having less weight.
Low power consumption.
Accuracy is good.
High efficiency.
This is occupies less space.
This is easily to move one place
to another place.
• This machine cost is low.
• The construction of this
machine is very simple.
SURFACE GRINDING MACHINE
•
•
•
•
•
This is having more weight.
High power consumption.
Accuracy is more.
High efficiency.
This is comparing to occupies
more space .
• This is comparing to not easily
to one place to another place.
• This machine cost is very high.
• The construction of this
machine is very complicated.
SPECIFICATIONS OF LOW COST
SURFACE GRINDING MACHINE
PARTS
FRAME
HORIZONTAL
FEED OF
MILLING BED
CROSS
FEED OF
MILLING
BED
ELEVATIN
G SCREW
MECHANICAL
VICE
HAND
LEVER
60.2 CM
100 CM
20.4 CM
50.4 CM
20.6 CM
20.2
CM
40.2 CM
40.2 CM
30.8 CM
_
10.7 CM
0.3 CM
4 MM
10.1 CM
20 CM
_
0.7 CM
2 MM
130 CM
_
_
_
_
_
_
_
_
20 CM
_
_
LENGTH
WIDTH
THICK
NESS
BASE
HEIGHT
DIAMETER
PARTS OF LOW COST SURFACE
GRINDING MACHINE
•
•
•
•
•
•
•
Frame
Motor
Horizontal feed of milling bed
Cross feed of milling bed
Elevating screw
Mechanical vice
Hand lever
LOW COST SURFACE GRINDING
MACHINE
DESIGN IN CATIA V5
INTRODUCTION TO CATIA:
• Computer Graphics-Aided Three-Dimensional Interactive
Application (CATIA) is the world’s leading computer-aided
design (CAD)/computer-aided manufacturing
(CAM)/computer-aided engineering (CAE) package.
• Developed by Desalt systems and marketed worldwide by
IBM, CATIA delivers one of the best Product Lifecycle.
• CATIA started as an in-house development in 1977 by French
aircraft manufacturer Avionics Marcel Desalt, at that time
customer of the CAD/CAM CAD software to develop
Dassault's Mirage fighter jet, and then was adopted in the
aerospace, automotive, shipbuilding, and other industries.
PROCEDURE OF PARTS TO BE
DESIGN
Frame
step 1:STRAT –Mechanical design- sketcher. In the sketcher we have done the
sketcher part of frame.
Step 2: In this frame we are using shell option, pad, and pocket option.
Electric motor
•Step 1: start-mechanical design-sketcher In the sketcher we have done the part of
electric motor
•Step 2: In this sketcher part we are using pad, drafted fillet, multi solid, and
mirror, circles, and holes options.
•Step 3: Then go to the surface design and then selecting the helical option and then
select the slot option then click enter button and then form a screw thread.
Horizontal feed of milling bed
•Step 1:start-mechanical design-sketcher In this sketcher we have to done the
part of horizontal feed of milling bed
•Step 2: In this sketcher part we are using pad, pockets and
mirror, circles, rib, and holes options.
•Step 3: Then go to the surface design and then selecting the helical option and
then select the slot option then click enter button and then form a screw thread.
Cross feed of milling bed
•Step 1:start-mechanical design-sketcher
In this sketcher we have to done the part of cross feed of milling bed
•Step 2: In this sketcher part we are using pad, pockets and
mirror, circles tools in the sketch based features.
•Step 3: For the screw spindle go to the surface design and then select the
helix option and create the height of the screw spindle then go to the part
design select the slot option then click enters button and then form a screw
thread.
Elevating screw
•Step 1: For the elevating screw ,we will just create the helical gear by
using multi section commands.
•Step 2: And later we will just creates the hexagonal nut.
Mechanical vice
•Step 1:bench vice is used for the work piece holding purpose.
•Step 2: by using pad, pocket, helix and the slots options we just created
the mechanical bench vice.
Hand lever
•Step 1: lever is used to move the horizontal and cross feed of milling
beds.
•Step 2: in this we used the draft options and the pad options.
ASSEMBLY OF LOW COST
SURFACE GRINDING MACHINE
DRAFTING OF LOW COST
SURFACE GRINDING MACHINE
CONCLUSION
The low cost surface grinding machine
featuring high accuracy and high rigidity pursued
hand in hand with the technological capability of a
machine tool manufacture. The joint development of
a grinding wheel with a leading tool manufacture
has enabled the use of an optimum grinding wheel
that has a wide application scope and that matches
the user needs.
THANK YOU