Design and Fabrication of m10 Hexagonal Nut Deburring

8/14/2019 Design and Fabrication of m10 Hexagonal Nut Deburring

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LOW COST AUTOMATION OFM10 HEXAGONAL NUTDEBURRING MACHINE

Project GuideMr.P.Mohanavelu M.E

Lecturer

Mechanical engineering

Panimalar engg,coll

Project venue

TVS SFL

Padi

Project Members

Goutham. S

Gobinath. K

Karthikeyan.k Diwakaran. U


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CONTENTS

ABSTRACT

INTRODUCTION

NEED FOR DEBURRING OPERATION PHASES OF THE PROJECT

PHOTOS


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ABSTRACT Nut deburring is used to remove burrs in the work. When the job is machined

burrs are produced due to various reasons in the work and this may reduce theaesthetic value of the product.

The main objective of the operation is to get good surface finish. Machining at any

scale usually produces burrs on surfaces;

The deburring operation is performed by mounting the head of the machine withan inclination for the gravity feed of the work. The work is allowed through the

guide ways and the work is clamped and separated with the help of pneumatic

cylinders.

The expected benefits of the project are the low cost automation which is done

with the help of PLC which reduces the time involved and the fatigue. This will

also increase the production and decreases the amounts spend on the quality.


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INTRODUCTION

A burr is a raised edge or small pieces of material

remaining attached to a work piece after a modification

process. It may be present in the form of a fine wire on

the edge of a freshly sharpened tool or as a raised

portion on a surface, after being struck a blow from an

equally hard or heavy object. A normal burr from well-

maintained tools is usually less than 10% of material

thickness. If burrs are not acceptable (burr-freerequirement), then deburring needs to be done.


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NEED FOR DEBURRINGOPERATION

Deburring is important for quality, aesthetics,functionality and smooth operation of workingparts. It is also important for safety.

Even a small notch can cause moving parts to

catch, creating the potential for accident, injuryor unnecessary delay in production. Rough edges can also cause injury when

individuals are required to handle blanks. Each of these preventable problems can cost

companies a great deal of money.


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PHASES OF THE PROJECT

MECHANICAL

ELECTRICAL AND ELECTRONICS

PNEUMATICS


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MECHANICALThe mechanical part of our project actually consists of the following

steps. Setting up a suitable guide arrangement for the drill head. Arranging a work piece guiding setup. Fixing the two guide plates with the base.

Aligning the centre point of the tool with that of the work centre. Placing the cylinders to full fill the sequence. Making the guide ways according to the requirement.

OPERATIONS Milling the base plate . Brazing the end effecters of the cylinders. Grinding the extra metal in the end effecters. Drilling the plates for fastening.


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FABRICATION PROCESS The machine is made using a dismantled drill head attachment of a US

machine.

The head is given with an inclination of 35 degree for gravity feed;

The guide ways is bolted to the guide plate. The pneumatic cylinders are alsomounted to the guide plate.

Both the tool head and the guide plate are given some inclination and isattached to the base.

Two single acting and two double acting cylinders are used to fulfill theoperation.

The single acting cylinders are used for the tool feeding and for the stopping

action and is controlled by a 5/2 DCV.

The double acting cylinders are used for separating and clamping action andis controlled by a 3/2 DCV.

Pencil cylinder is used to control the mechanical actuator switch in the toolcylinder.


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ELECTRICAL ANDELECTRONICS

Selecting the appropriate motor for the spindle.

Fixing a DOL starter for the main spindle motor.

Wiring the solenoid coil for actuation

PLC.


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PNEUMATICS

The pneumatic section consists of the following steps.

Selecting the cylinder based upon the maximumpressure.

Selecting the directional control valve based upon

the cylinders used. Placing the FRL unit and silencers.

Fitting the tubes to the entire setup.

Clamping at the areas at which two tubes are

connected.


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PNEUMATICCOMPONENTS

The following are the pneumatic components used to satisfy thesequence.

Pneumatic cylinders 3 nos Clamping cylinder. Separating cylinder. Stopper cylinder.

5/2 directional control valves- 2 nos. 3/2 directional control valves- 2 nos. FRL unit. Air compressor. Silencers. Tubes.


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INSTALLATION OF FRLUNIT

The filter is installed upstream from other conditioning

components. This protects internal moving parts in theregulator from harmful contaminants and avoids foulingthe lubricator reservoir.

Large capacity filters are available to protect a pneumaticnetwork, but it is more common practice to install filter ineach branch. Likewise regulators are installed at eachbranch which requires a specified pressure setting.

Some pressure regulators are designed to be mounted onvalve manifolds.

Lubricators are installed at downstream end of the FRLunit. Just after the regulator and should be placed as closeto the equipment as possible.


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FUNCTIONAL DIAGRAM

CY-4

CY-3

CY-1

CY-2

VALVE-4

VALVE-1

VALVE-3

VALVE-2


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SEQUENCE

CYLINDERS FORWARD STROKE RETURN STROKE

CYLINDER-1 1

3

CYLINDER-2 2

7

CYLINDER-3 4

8

CYLINDER-4 5

6CYLINDER 1 SEPARATOR CYLINDERCYLINDER 2 CLAMPING CYLINDERCYLINDER 3 STOPPER CYLINDERCYLINDER 4 TOOL CYLINDER


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SELFEEDER DEBURRINGUNIT

MODEL SN4U

SPECIFICATIONS

STROKE MAX.: 3.15"

SPINDLE TAPER: JT1

THRUST: 310 LBS.

COLUMN DIAMETER: 2"

MOTOR: HORSEPOWER: 1/2

R.P.M.: 1100

VOLTS: 230/460

AMPS: 1.1/0.55

OVERALL DIMENSIONS: 10" X 5" X 22" TALL


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HYDRO SPEEDREGULATOR

The regulator will control the forward speed of the spindleto any desired rate.

The suitable feed can be set to the work piece. A constant smooth rate of travel is obtained.

The regulator prevents sudden forward surge breakthroughand thus prevents the drill damage. It is a compact and essential unit for precision and

maintenance of accuracy, clean finish and long life. It has also other application as like a shock absorber or a

linear speed regulator.


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PHOTOS AT ZEROTH REVIEW


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PHOTOS FOR THE FIRST

REVIEW


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ENTIRE SET-UP


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GUIDE WAYS FORM10 NUT

CYLINDER


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CYLINDERARRANGEMENT


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CONCLUSION

Thus we have designed the gatewaymechanism and the machine is operatedmanually. The PLC program are yet to be

done to make it perform automatically.


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THINGS TO BE DONE INTHE FUTURE

We are going to make this machinesuitable for components of various sizesby manufacturing a adjustable guide ways

and suitable standards for the tool.This machine is also to be manufactured in

many numbers for the use in productionarea and as a part of its qualityimprovement.


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Documents

Design and Fabrication of m10 Hexagonal Nut Deburring