PENUMATIC CONTROLLED JOLTING MACHINE

FABRICATION OF JOLTING MACHINE

Submitted in the partial fulfillment of the requirement for the award DIPLOMA IN MECHANICAL ENEINEERINGSUBMITTED BY: 1. P.M. MANIGANDAN 4. R. GANESH

2. R. BALAMURALI

5. T. SARANRAJ

3. R. BADRI NARAYANAN

Under guidance of

MR. RAMUMARCH 2008.DEPARTMENT OF MECHANICAL ENGINERING

ST. MICHAEL POLYTECHNIC COLLEGE

AVADI

ST. MICHAEL POLYTECHNIC COLLEGE

AVADI

BONAFIDE CERTIFICATE

This is to certify that this Project work on

FABRICATION OF JOLTING MACHINE

submitted by . Reg. No.

in partial fulfillment for the award of

DEPARTMENT OF MECHANICAL ENGINEERING

This is the bonafide record of work carried out by him under our supervision during the year 2008Submitted for the Viva-voce exam held on ..

PROJECT GUIDE

INTERNAL EXAMINER

EXTERNAL EXAMINER

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT At the outset, we would like to emphasize our sincere thanks to the Principal Mr.R. KUPPUSAMI encouragement and valuable advice.

We thank our Esquired Head of Department Mr P. SELVAM for presenting his felicitations on us.

We are grateful on our Encourages Mr. RAMU for guiding in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the Mechanical Engineering Department.

Ultimately, we extend our thanks to all who had rendered their co-operation for the success of the project.

CONTENTS

CONTENTS

CHAPTER NO.

TITLE

01 INTRODUCTION

02 SYNOPSIS

03 DESIGN DATA

04 TECHNICAL DATA

05 CONSTRUCTION

06 WORKING PRINCIPLE

07 DRAWINGS

08 ADVANTAGES

09 CONCLUSION

010 COST ESTIMATION

011 BIBILOGRAPHY

012 PHOTO VIEW

INTRODUCTION

INTRODUCTION

This is a self assessment test on the part of the students to assess his competency in creativity.

During the course of study, the student is put on a sound theoretical foundation of various mechanical engineering subjects and of course, to a satisfactory extent. Opportunities are made available to him to work on different kinds of machines, so that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology becomes stronger. He attains a stage of perfection, when he himself is able to design and fabricate a device.

This is the project work. That is the testimony for the strenuous training, which the student had in the institute. This assures that he is no more a student, he is an engineer.

This report discuses the necessity of the project and various aspects of planning , design, selection of materials, fabrication, erection, estimation and testing.

SYNOPSIS

SYNOPSIS

Jolting machine jolting up and down actions. During jolting, the table along with flask and sand in it, is repeatedly lifted by air pressure directed against the piston from the bottom and is then permitted to drop under gravity, because of this sand becomes more compact in the bottom portion of the flask as compared to its upper portion. To get uniform compactness throughout the mould, squeeze is carried out. During squeezing the piston along with jolt table and flask is forced upward to press the sand in the flask by the squeeze board.

The jolt squeeze machine was fabricated by us with M.S. Plate if suit 405mm sq. and a cylinder of outside diameter 76 mm and internal diameter 41.2 mm. The cylinder was turned and bored with a tolerance of + or 0.03 mm and it was tested by air pressure for any leakage. A piston to suit the above cylinder having sliding fit was turned in lathe to give a clearance of 0.02 mm. The clearance was kept to a minimum to avoid any air leakages. The cylinder was welded to the center of base plate. Four guide plate was welded on one side of the jolting plate for positioning the moulding box and the other side of the jolting plate was welded with the

Piston. Inlet and outlet ports were drilled in the cylinder as per dimension given in the sketch. In order to make jolting effective four numbers of 25.4 mm diameters of pipe and length 310 mm were welded in the corners of the base plate which supports jolting plate and also forms the guide for squeeze plate. In the squeeze plate, a squeeze board is attached suitable to the moulding box used. Squeezing takes place when jolting plate is lifted along with moulding flask and sand, at the same time the movement of the squeeze plate is arrested by inserting four bolts into the support pipe, which houses the pipe attached to the squeeze plate.

The air pressured used is above 3 kg. /cm.sq. This gives uniform compactness.

DESIGN CALCULATION

DESIGN CALCULATION

THE LIMITING CAPACITY OF THE JOLTING IS GIVEN BY:

P = AIR LINE PRESSURE = 2.5 Kg/Cm2D = DIAMETER OF PISTON

W = WEIGHT OF SAND, MOULDING FLASK,

PATTERN ETC. 30 KG

TECHNICAL DATA

TECHNICAL DATA

WORKING PRESSURE RANGE (JOLTING)

.. 3 to 10 kg/cm sq.

JOLTING STROKE

.. 15 MM

HT. BETWEEN SQUEEZE PLATE AND JOLTING

TABLE

.. 110 MM

JOLTING TABLE HEIGHT FROM FLOOR

.. 310 MM

SQUEEZE PRESSURE

.. 10 MM

CYLINDER

OUTSIDE DIAMETER

.. 76 MM

TOTAL HEIGHT

.. 210 MM

BORE DIAMETER

41.25 MM

BORE DEPTH

.. 120 MM

HEIGHT BETWEEN OUTLET HOLE AND

TOP SURFACE

.. 35 MM

HEIGHT BETWEEN INLET & OUTLET HOLE

.. 45 MM

INLET HOLE DIAMETER

.. 9 MM

NUMBER FOR INLET HOLES

.. 1

OUTLET HOLE DIAMETER

.. 9 MM

NUMBER OF OUTLET HOLES

..4PISTONDIAMETER

41.2 MM

LENGTH

.. 85 MM

PISTON HEAD DIAMETER

69 MM

LENGTH

.. 50 MM

BASE PLATE

SIZE

.. 405 MM. SQ.

THICKNESS

8 MM

CENTRE TO CENTRE

.. 370 MM

JOLTING PLATE:SIZE

.. 400 MM. SQ.

THICKNESS

6 MM.

CENTRE TO CENTRE

.. 370 MM

SQUEEZE PLATE:SIZE

.. 400 MM SQ.

THICKNESS

.. 6 MM

CENTRE TO CENTRE

.. 370 MMPIPE I:SIZE

.. 25.4 MM. DIA

NUMBER OF PIPES

.. 4DISTANCE BET. KEYHOLE FROM TOP SURFACE

.. 50 MM

KEY HOLE DIA

.. 9 MMPIPE I:SIZE

.. 19 MM.DIA

NUMBER OF PIPES

.. 4

DISTANCE BET. KEYHOLE FROM TOP SURFACE

.. 186 MM

KEY HOLE DIA

.. 9 MM

CONSTRUCTION

CONSTRUCTION

First we selected 8 mm thick plate as our Base Plate. We purchased a plate of size approximately 410 mm sq. The edges of the plate was reduced by using grinding machine. The finished size of plate is 405 x 405 mm size of the plate are checked withy try square for squareness. Then on the surface of the plate oil was applied and the surface is rubbed with blue paste. The plate is then rubbed against the surface plate. The distribution of the blue colour is unioform on our base plate and surface plate. This indicates the correctness in the flatness of the base plate. 28.00 mm diameter hole is made on the four corners of the 370.00 mm sq. marked.

For cylinder a 76.20 mm diameter rod with length of 220.00 mm was purchased. The internal diameter of the cylinder was finished 41.20 mm using boring tool. The cylinder was subjected to pressure test for any leakage by supplying air at 30 kg/cm.sq. And maintained at this pressure for 45 minutes. Since there is no pressure drop the cylinder was leak proof. An inlet hole of 9.00 mm diameter was made at a distance of 35.00 mm from

The top face of the cylinder and four exhaust hole was made at a distance of 45.00 mm from inlet hole.

Four pipes of 320.00 mm height and 25.4 mm diameter was finished to a size of 310.00 mm and a through hole of 6.00 mm diameter was made at a distance of 50.00 mm from the top face of the pipe.

A 70.00 diameter rod with a height of 150.00 mm was purchased to make piston. It was turned to sliding fit to above said cylinder to give a clearance of 0.02 mm to height of 85.00 mm. The clearance was kept to minimum to avoid air leakages. The piston head was turned to 69.20 mm diameter with a height of 50.00 mm.

Four pipes of 250.00 mm height and 21.00 mm diameter was finished to a size of 240 mm and 19.00 mm respectively a through hole of 6.00 mm diameter was made at a distance of 186.00 mm from the top face of the pipe.

For jolting table, we purchased a plate of 6.00 mm thick and 405 mm sq. The sides of the plate are checked with try square for squareness. Then on this surface plate oil was applied on the surface is rubbed with blue paste. The plate is then rubbed against the surface plate the distribution is blue colour is uniform on our jolting plate. This indicates

Correctness in the flatness of the jolting plate. 21.5 mm diameter hole is made in the corners of 370.00 mm sq. marked.

For squeeze plate, we purchased a plate of 6.00 mm thick and 405 mm sq. The sides of the plate are checked with try square for squareness. Then on this surface plate oil was applied on the surface is rubbed with blue paste. The plate is then rubbed against the surface plate the distribution is blue colour is uniform on our jolting plate. This indicates correctness in the flatness of the jolting plate. This indicates correctness in the flatness of the jolting plate. 21.5 mm diameter hole is made in the corners of 370.00 mm sq. marked. Four 6.0 mm hole is made in the corners of 200.00 mm sq. marked.

A wooden squeeze board of size 280 x 280 mm with 12.00 mm thick was made and four 6.00 mm hole was made in the four corners of 200.00 mm sq. marked. Over it 12.00 mm diameter hole was made to a depth of 5.00 mm. A wooden board of 355.00 mm. Sq. was attached to the squeeze board.

A cylinder was placed on the center of base plate and it was welded. Before welding perpendicularity was checked using try square. Now the base plate is placed on the support pieces to a height of 22.00 mm from the floor. Using spirit level of the plate was checked. The Pipe is then inserted into the drill hole at the corners, using try square it was kept perpendicularly to the base plate and was welded like wise, the other pipes were welded to the base plate. The piston was welded on one side of the Jolting plate and on the other side for guide plates was welded for positioning the moulding box. Four 19.009 mm pipe was inserted into base plate pipes and bolted together. Support pieces of 110.00 mm was placed on the Jolting plate on which squeeze plate is placed. The pipes protrude to the height of 6.00 mm from the squeeze plate and it was welded. The squeeze board was bolted to the squeeze plate.

WORKING PRINCIPLE

WORKING PRINCIPLE

First the moulding box with pattern is place don the jolting table and parting agent are applied over it. Sand is filled in the box. The compressed air is to be allowed to pass through inlet hole via brass tube, the air lifts the piston until the bottom of the piston clears the outlet port, so the piston along with the moulding box falls suddenly. This is done repeatedly until the required mould density is achieved. Now the squeezer attachment is placed over the jolting table by inerting its pipe into the base plate pipes and bolted together. Now air pressure of above 3 Kg./cm sq,. is applied, the squeezer board squeezes the mould. The squeezer attachment is removed and the moulding is ready.

CONCLUSION

CONCLUSION

By doing this project JOLTING MACHINE we

have gained experience in fabrication and we have gathered

practical experience by welding the structures .we did this project

to our entire satisfaction.

We faced many problems whether it is a small one

or big ones by which we feel to solve any set of hurdles that may

come in future in carrying over a project.

COST ESTIMATION

COST ESTIMATION

1. CYLINDER

-

1,000.00

2.BASE PLATE

-

1,000.00

3.SQUEEZE PLATE

-

1,000.00

4.JOLT PLATE

-

1,000.00

5.PIPE I

-

500.00

6.PIPE II

- 500.00

7. FINSIHING AND PAINTING-

500.00

6.PROJECT REPORT

-

500.00

-------------

6000.00

-------------

BIBILOGRAPHY

BIBILOGRAPHY

1.Foundry Technology

-O.P. Khanna

2. Machine Design

-R.S. Khurumi

3.Manufacturing Processes

-S.S. Manian & Rajagopal

PHOTO VIEW

Photo view EMBED Equation.3

EMBED Equation.3

EMBED Equation.3

EMBED Equation.3

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