CHAPTER 1 INTRODUCTION

1.1 Hydraulic Multipurpose Machine

1.2 History

1.3 Basic Principle

1.4 Advantages of the Machine

1.5 Applications of the Machine

1.1 HYDRAULIC MULTIPURPOSE MACHINE

Hydraulic machines are machinery and tools that use liquid fluid power to do simple

work. Heavy equipment is a common example. In this type of machine, hydraulic fluid is

transmitted throughout the machine to various hydraulic motors and hydraulic

cylinders and which becomes pressurized according to the resistance present. The fluid is

controlled directly or automatically by control valves and distributed through hoses and

tubes.

The popularity of hydraulic machinery is due to the very large amount of power that can

be transferred through small tubes and flexible hoses, and the high power density and

wide array of actuators that can make use of this power. Hydraulic machinery is operated

by the use of hydraulics, where a liquid is the powering medium.

As the name suggests that it is a multipurpose machine actuated by means of hydraulic

fluid as water. In this machine a turbine is used which is rotated by the help of water

coming out of the nozzle and forced by the pump. Water forced by pump passes through

the nozzle and strikes on the blade of the turbine due to which runner of the turbine also

starts to rotate. Power available on the runner is feed to the machine through the gear

arrangement where operations on the work piece are performed.

1.2 HISTORY

The history of hydraulic systems takes us into the world of technology and construction.

This is one of those Innovative methods of making work easier and more efficient by

compressing fluids that are locked inside a channel or compartment. This compression is

an applied force or torque and supplies leverage to a workload. Thus the work load is

lessened or made easier. The power steering in cars is a good example of the use of

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hydraulic systems. There are countless other hydraulic systems that have come about

since the first use of such systems was invented.

1.2.1 INVENTION

In 1785 and Englander named Joseph Bramah was working on a press. William Georges

Armstrong (sir - 1st Baron) a contemporary of Bramah, was an industrialist and the

founder of Armstrong Whitworth. Sir Armstrong is said to have found inspiration in a

water wheel for his later engineering work while he was out on a fishing expedition. He

noted that while the water wheel was doing much work it was still allowing much

potential to be lost. This lost potential, he reasoned, could be harnessed somehow. He first

designed a rotary engine from the concept but later moved it to a hydraulic piston type of

design that could move a crane.

At a time when the scientific field of hydraulics engineering was not yet recognized

Armstrong and Bramah were applying Pascal's laws to their inventions. Joseph Bramah

got a patent for his invention of the hydraulic press in 1795.

1.2.2 HYDRAULIC SYSTEMS AFTER BRAMAH AND ARMSTRONG.

While arguments could be made that would place the use of hydraulic engineering at a

much earlier period in history such as a claim that in the 14th century Somali tribes used

water forces in agriculture or that even thousands of years ago seafarers used oars as

contraptions or lever to exert force on water, or that in the Greek Hellenic period writers

were describing machines that made use of leveraged fluids in force pumps. But history

has a well marked beginning with Bramah and Sir Armstrong. 

Since 1795 several engineers and inventors have added their contribution to this scientific

field of science that deals with the subject of forces exerted on fluids or fluid dynamics. 

The history of hydraulic systems is found in dam design and engineering. It is found in

the field of automobile, aviation, bicycles, and rail.

It is found in military applications and space exploration and in other disciplines where

fluid circuitry is used such as turbines, pumps, and hydropower.

The history of hydraulic systems is found in the current development of the computer

where computational fluid dynamics is a buzz term. 

This history is found wherever hydraulic machinery and hydraulic cylinders are located.

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1.3 BASIC PRINCIPLE

The basic principle of this machine is to use the hydraulic energy of water and convert it

into the mechanical energy with the help of the turbine. The mechanical energy obtained

on turbine rotor is feed through the gear arrangement to the machine where operations are

performed on work piece.

Fig 1.1 Schematic diagram of Hydraulic multipurpose machine

1. 4 ADVANTTAGES OF THE MACHINE:-

1. No need of line layout.

2. Many operations can be performed on a single machine.

3. Time Reduction in tool handling.

4. Productivity increases.

5. Efficient utilization of machines and other resources

1.5 APPLICATIONS OF THE MACHINE:-

1. In industries producing different verities of the products.

2. In Batch production industries.

3. Small scale industries.

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CHAPTER 2: MAIN COMPONENTS OF MACHINE

2.1 Water tank

2.2 Hydraulic pump

2.3 Nozzle

2.4 Pipe line

2.5 Turbine

2.6 Machine (drilling machine)

2.1 WATER TANK:-

Water tank parameters include the general design of the tank, choice of materials of

construction, as well as the following.

Location of the water tank (indoors, outdoors, above ground or underground)

determines color and construction characteristics.

Volume of water tank will need to hold to meet design requirements.

Purpose for which the water will be used, human consumption or industrial

determines concerns for materials that do not have side effects for humans.

Temperature of area where water will be stored may create concern for freezing

and delivery of offsetting heat.

Delivery pressure requirements, domestic pressures range from 35-60 PSI, the

demand for a given gpm (gallons per minute) of delivered flow requirements.

How is the water to be delivered to the point of use, into and out of the water tank

i.e. Pumps, gravity or reservoir?

Wind and Earthquake design considerations allow a design of water tank

parameters to survive seismic and high wind events.

Back flow prevention, are check valve mechanisms to allow single direction of

water flow,

Chemical injection systems for algae, bacteria and virus control to allow long term

storage of water.

Algae in water tanks can be mitigated by removing sunlight from access to the

water being stored. Fire Water Tank Horizontal truck or trailer mounted water

tank designed to deliver water to remote fires, where fire hydrant may not be

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available and a stationary tank provides standby water to fight the same type of

remote fires.

2.2 HYDRAULIC PUMP:-

A pump is a device used to move fluids (liquids or gases) or sometimes slurries by

mechanical action. Pumps can be classified into three major groups according to the

method they use to move the fluid: direct lift, displacement, and gravity pumps.

Pumps must have a mechanism which operates them, and consume energy to

perform mechanical work by moving the fluid. The activating mechanism is

often reciprocating or rotary. Pumps may be operated in many ways, including manual

operation, electricity, a combustion engine of some type, and wind action.

In our project we use a hydraulic centrifugal pump.

2.2.1 CENTRIFUGAL PUMP:-

A centrifugal pump is a rotodynamic pump that uses a rotating impeller to increase the

pressure and flow rate of a fluid. Centrifugal pumps are the most common type of pump

used to move liquids through a piping system. The fluid enters the pump impeller along

or near to the rotating axis and is accelerated by the impeller, flowing radically outward

or axially into a diffuser or volute chamber, from where it exits into the downstream

piping system. Centrifugal pumps are typically used for large discharge through smaller

heads.

Centrifugal pumps are most often associated with the radial flow type. However, the term

"centrifugal pump" can be used to describe all impeller type rotodynamic

pumps including the radial, axial and mixed flow variations.

Fig 2.1 Flow dia. of Centrifugal pump

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2.3 NOZZLE:-

A nozzle is a device designed to control the direction or characteristics of a fluid flow

(especially to increase velocity) as it exits (or enters) an enclosed chamber or pipe via

an orifice.

A nozzle is often a pipe or tube of varying cross sectional area and it can be used to direct

or modify the flow of a fluid (liquid or gas). Nozzles are frequently used to control the

rate of flow, speed, direction, mass, shape, and/or the pressure of the stream that emerges

from them.

Fig 2.2 Water nozzle

2.4 PIPE LINE:-

Pipeline transport is the transportation of goods through a pipe. Most commonly, liquids

and gases are sent, but pneumatic tubes using compressed air can also transport solid

capsules.

As for gases and liquids, any chemically stable substance can be sent through a pipeline.

Therefore sewage, slurry, water, or even beer pipelines exist; but arguably the most

valuable are those transporting fuels: oil (oleo duct), natural gas (gas grid), and biofuels.

2.4.1 Pipe line for water:-

Two millennia ago the ancient Romans made use of large aqueducts to transport water

from higher elevations by building the aqueducts in graduated segments that

allowed gravity to push the water along until it reached its destination. Hundreds of these

were built throughout Europe and elsewhere, and along with flour mills were considered

the lifeline of the Roman Empire. The ancient Chinese also made use of channels and

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pipe systems for public works. The famous Han Dynasty court eunuch Zhang Rang (d.

189 AD) once ordered the engineer Bi LAN to construct a series of square-pallet chain

pumps outside the capital city of Luoyang. These chain pumps serviced the

imperial palaces and living quarters of the capital city as the water lifted by the chain

pumps was brought in by a stoneware pipe system.

Pipelines are useful for transporting water for drinking or irrigation over long distances

when it needs to move over hills, or where canals or channels are poor choices due to

considerations of evaporation, pollution, or environmental impact.

The 530 km (330 mi) Goldfields Water Supply Scheme in Western Australia using

750 mm (30 inch) pipe and completed in 1903 was the largest water supply scheme of its

time.

Examples of significant water pipelines in South Australia are the Morgan-

Whyalla (completed 1944) and Mannum-Adelaide (completed 1955) pipelines.

2.5 TURBINE:-

A turbine is a rotary mechanical device that extracts energy from a fluid flow and

converts it into useful work.

The simplest turbines have one moving part, a rotor assembly, which is a shaft or drum

with blades attached. Moving fluid acts on the blades, or the blades react to the flow, so

that they move and impart rotational energy to the rotor. Early turbine examples

are windmills and water wheels.

Gas, steam, and water turbines usually have a casing around the blades that contains and

controls the working fluid. Credit for invention of the steam turbine is given both to the

British engineer Sir Charles Parsons (1854–1931), for invention of the reaction and to

Swedish engineer Gustaf de Laval (1845–1913), for invention of the impulse turbine.

Modern steam turbines frequently employ both reaction and impulse in the same unit,

typically varying the degree of reaction and impulse from the blade root to its periphery.

Theory of operation:- A working fluid contains potential energy (pressure head)

and kinetic energy (velocity head). The fluid may be compressible or incompressible.

Several physical principles are employed by turbines to collect this energy:

Impulse turbines change the direction of flow of a high velocity fluid or gas jet. The

resulting impulse spins the turbine and leaves the fluid flow with diminished kinetic

energy. There is no pressure change of the fluid or gas in the turbine blades (the moving

blades), as in the case of a steam or gas turbine; the entire pressure drop takes place in the

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stationary blades (the nozzles). Before reaching the turbine, the fluid's pressure head is

changed to velocity head by accelerating the fluid with a nozzle. Pelton wheels and de

Laval turbines use this process exclusively. Impulse turbines do not require a pressure

casement around the rotor since the fluid jet is created by the nozzle prior to reaching the

blading on the rotor. Newton's second law describes the transfer of energy for impulse

turbines.

Reaction turbines develop torque by reacting to the gas or fluid's pressure or mass. The

pressure of the gas or fluid changes as it passes through the turbine rotor blades. A

pressure casement is needed to contain the working fluid as it acts on the turbine stage(s)

or the turbine must be fully immersed in the fluid flow (such as with wind turbines). The

casing contains and directs the working fluid and, for water

Fig.2.3 Schematic of impulse and reaction turbines, where the rotor is the rotating part

and the   stator   is the stationary part of the machine.

Turbines, maintains the suction imparted by the draft tube. Francis turbines and

most steam turbines use this concept. For compressible working fluids, multiple turbine

stages are usually used to harness the expanding gas efficiently. Newton's third

law describes the transfer of energy for reaction turbines.

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In the case of steam turbines, such as would be used for marine applications or for land-

based electricity generation, a Parsons Type reaction turbine would require approximately

double the number of blade rows as a de Laval type impulse turbine, for the same degree

of thermal energy conversion. Whilst this makes the Parsons turbine much longer and

heavier, the overall efficiency of a reaction turbine is slightly higher than the equivalent

impulse turbine for the same thermal energy conversion.

In practice, modern turbine designs use both reaction and impulse concepts to varying

degrees whenever possible. Wind turbines use an airfoil to generate a reaction lift from

the moving fluid and impart it to the rotor. Wind turbines also gain some energy from the

impulse of the wind, by deflecting it at an angle. Cross flow turbines are designed as an

impulse machine, with a nozzle, but in low head applications maintain some efficiency

through reaction, like a traditional water wheel. Turbines with multiple stages may utilize

either reaction or impulse blading at high pressure. Steam turbines were traditionally

more impulse but continue to move towards reaction designs similar to those used in gas

turbines. At low pressure the operating fluid medium expands in volume for small

reductions in pressure. Under these conditions, blading becomes strictly a reaction type

design with the base of the blade solely impulse. The reason is due to the effect of the

rotation speed for each blade. As the volume increases, the blade height increases, and the

base of the blade spins at a slower speed relative to the tip. This change in speed forces a

designer to change from impulse at the base, to a high reaction style tip.

2.5.1 PELTON TURBINE:-

The Pelton wheel is an impulse turbine which is among the most efficient types of water

turbines. It was invented by Lester Allan Peltonin the 1870s. The Pelton wheel extracts

energy from the impulse (momentum) of moving water, as opposed to its weight like

traditional overshot water wheel. Although many variations of impulse turbines existed

prior to Pelton's design, they were less efficient than Pelton's design; the water leaving

these wheels typically still had high speed, and carried away much of the energy. Pelton's

paddle geometry was designed so that when the rim runs at ½ the speed of the water jet,

the water leaves the wheel with very little speed, extracting almost all of its energy, and

allowing for a very efficient turbine.

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Fig.2.4 Pelton's original patent (October 1880)

2.5.1.1 APPLICATION OF PELTON TURBINE:-

Pelton wheels are the preferred turbine for hydro-power, when the available water source

has relatively high hydraulic head at low flow rates. Pelton wheels are made in all sizes.

There exist multi-ton Pelton wheels mounted on vertical oil pad bearings in hydroelectric

plants. The largest units can be up to 200 megawatts. The smallest Pelton wheels are only

a few inches across, and can be used to tap power from mountain streams having flows of

a few gallons per minute. Some of these systems utilize household plumbing fixtures for

water delivery. These small units are recommended for use with thirty meters or more of

head, in order to generate significant power levels. Depending on water flow and design,

Pelton wheels operate best with heads from 15 meters to 1,800 meters, although there is

no theoretical limit.

The Pelton wheel is most efficient in high head applications (see the "Design Rules"

section). Thus, more power can be extracted from a water source with high-pressure and

low-flow than from a source with low-pressure and high-flow, even when the two flows

theoretically contain the same power. Also a comparable amount of pipe material is

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required for each of the two sources, one requiring a long thin pipe, and the other a short

wide pipe.

2.6 Machine Tool: -

A machine tool is a machine for shaping or machining metal or other rigid materials,

usually by cutting, boring, grinding, shearing or other forms of deformation. Machine

tools employ some sort of tool that does the cutting or shaping. All machine tools have

some means of constraining the work piece and provide a guided movement of the parts

of the machine. Thus the relative movement between the work piece and the cutting

tool (which is called the tool path) is controlled or constrained by the machine to at least

some extent, rather than being entirely "offhand" or "freehand".

Today machine tools are typically powered other than by human muscle (e.g., electrically,

hydraulically, or via line shaft), used to make manufactured parts (components) in various

ways that include cutting or certain other kinds of deformation.

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CHAPTER 3: OPERATIONS FERFORMED ON MACHINE

3.1 Drilling

3.2 Reaming

3.3 Grinding

3.4 Buffing

3.1 DRILLING:-

Drilling is a cutting process that uses a drill bit to cut or enlarge a hole in solid materials.

The drill bit is a multipoint, end cutting tool. It cuts by applying pressure and rotation to

the work piece, which forms chips at the cutting edge.

Drilled holes are characterized by their sharp edge on the entrance side and the presence

of burrs on the exit side (unless they have been removed). Also, the inside of the hole

usually has helical feed marks.

Drilling may affect the mechanical properties of the work piece by creating low residual

stresses around the whole opening and a very thin layer of highly stressed and disturbed

material on the newly formed surface. This causes the work piece to become more

susceptible to corrosion at the stressed surface.

For fluted drill bits, any chips are removed via the flutes. Chips may be long spirals or

small flakes, depending on the material, and process parameters. The type of chips

formed can be an indicator of the machinability of the material, with long gummy chips

reducing machinability.

When possible drilled holes should be located perpendicular to the work piece surface.

This minimizes the drill bit's tendency to "walk", that is, to be deflected, which causes the

hole to be misplaced. The higher the length-to-diameter ratio of the drill bit, the higher

the tendency to walk. 

3.2 REAMING:-

Reaming is a process which slightly enlarges a pre-existing hole to a tightly tolerance

diameter. A reamer is similar to a mill bit in that it has several cutting edges arranged

around a central shaft, as shown below. Because of the delicate nature of the operation

and since little material is removed, reaming can be done by hand. Reaming is most

accurate for axially symmetric parts produced and reamed on a lathe.

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Fig.3.1 Reamer specification

Fig.3.2 Detailed Nomenclatures for a Reamer

3.3 GRINDING (ABRASIVE CUTTING):-

Grinding is an abrasive machining process that uses a grinding wheel as the cutting tool.

A wide variety of machines are used for grinding:

Hand-cranked knife-sharpening stones (grindstones)

Handheld power tools such as angle grinders and die grinders

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Various kinds of expensive industrial machine tools called grinding machines

Bench grinders often found in residential garages and basements

Grinding practice is a large and diverse area of manufacturing and tool making. It can

produce very fine finishes and very accurate dimensions; yet in mass production contexts

it can also rough out large volumes of metal quite rapidly. It is usually better suited to the

machining of very hard materials than is "regular" machining (that is, cutting larger chips

with cutting tools such as tool bits or milling), and until recent decades it was the only

practical way to machine such materials as hardened steels. Compared to "regular"

machining, it is usually better suited to taking very shallow cuts, such as reducing a

shaft's diameter by half a thousandth of an inch (thou) or 12.7 um.

Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each grain of

abrasive functions as a microscopic single-point cutting edge (although of high

negative rake angle), and shears a tiny chip that is analogous to what would

conventionally be called a "cut" chip (turning, milling, drilling, tapping, etc.). However,

among people who work in the machining fields, the term cutting is often understood to

refer to the macroscopic cutting operations, and grinding is often mentally categorized as

a "separate" process. This is why the terms are usually used in contradistinction in shop-

floor practice, even though, strictly speaking, grinding is a subset of cutting.

Similar abrasive cutting processes are lapping and sanding.

Fig.3.3 Grinding Process

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3.3.1 GRINDING WHEEL:-

A grinding wheel is an expendable wheel used for various grinding and abrasive

machining operations. It is generally made from a matrix of coarse abrasive particles

pressed and bonded together to form a solid, circular shape, various profiles and cross

sections are available depending on the intended usage for the wheel. Grinding wheels

may also be made from a solid steel or aluminum disc with particles bonded to the

surface.

The use of fluids in a grinding process is necessary to cool and lubricate the wheel and

work piece as well as remove the chips produced in the grinding process. The most

common grinding fluids are water-soluble chemical fluids, water-soluble oils, synthetic

oils, and petroleum-based oils. It is imperative that the fluid be applied directly to the

cutting area to prevent the fluid being blown away from the piece due to rapid rotation of

the wheel.

3.4 POLISHING (BUFFING):-

Polishing and buffing are finishing processes for smoothing a work piece’s surface using

an abrasive and a work wheel. Technically polishing refers to processes that use an

abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to

the work wheel Polishing is a more aggressive process while buffing is less harsh, which

leads to a smoother, brighter finish.  A common misconception is that a polished surface

has a mirror bright finish, however most mirror bright finishes are actually buffed.

Polishing is often used to enhance the looks of an item, prevent contamination of

instruments, remove oxidation, create a reflective surface, or prevent corrosion in

pipes. In metallographic and metallurgy, polishing is used to create a flat, defect-free

surface for examination of a metal's microstructure under a microscope. Silicon-based

polishing pads or a diamond solution can be used in the polishing process.

The removal of oxidization (tarnish) from metal objects is accomplished using a metal

polish or tarnish remover; this is also called polishing. To prevent further unwanted

oxidization, polished metal surfaces may be coated with wax, oil, or lacquer. This is of

particular concern for copper alloy products such as brass and bronze.

3.4.1 BUFFING PROCESS:-

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The first stage starts with a rough abrasive and each subsequent stage uses a finer

abrasive until the desired finish is achieved. The rough pass removes surface defects like

pits, nicks, lines and scratches. The finer abrasives leave very thin lines that are not

visible to the naked eye. Lubricants like wax and kerosene may be used as lubricating and

cooling media during these operations, although some polishing materials are specifically

designed to be used "dry." Buffing may be done by hand with a stationary polisher or die

grinder, or it may be automated using specialized equipment.

When buffing there are two types of buffing motions: the cut motion and the color

motion. The cut motion is designed to give a uniform, smooth, semi-bright surface finish.

This is achieved by moving the work piece against the rotation of the buffing wheel,

while using medium to hard pressure. The color motion gives a clean, bright, shiny

surface finish. This is achieved by moving the work piece with the rotation of the buffing

wheel, while using medium to light pressure.

When polishing brass, there are often minute marks in the metal caused by impurities. To

overcome this, the surface is polished with a very fine (600) grit, copper plated, then

buffed to a mirror finish with an airflow mop.

Polishing operations for items such as chisels, hammers, screwdrivers, wrenches, etc., are

given a fine finish but not plated. In order to achieve this finish four operations are

required: roughing, dry fining, greasing, and coloring. Note that roughing is usually done

on a solid grinding wheel and for an extra fine polish the greasing operation may be

broken up into two operations: rough greasing and fine greasing. However, for

inexpensive items money is saved by only performing the first two operations.

Polishing knives and cutlery is known as fine glazing or blue glazing. Sand buffing, when

used on German silver, white metal, etc., is technically a buffing operation because it uses

a loose abrasive, but removes a significant amount of material, like polishing.

3.4.2 EQUIPMENT IN BUFFING:-

Aluminum oxide abrasives are used on high tensile strength metals, such

as carbon and alloy steel, tough iron, and nonferrous alloys. Silicon carbide abrasives are

used on hard and brittle substances, such as grey iron and cemented carbide, and low

tensile strength metals, such as brass, aluminum, and copper.

Polishing wheels come in a wide variety of types to fulfill a wide range of needs. The

most common materials used for polishing wheels are wood, leather, canvas, cotton cloth,

plastic, felt, paper, sheepskin, impregnated rubber, canvas composition, and wool; leather

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and canvas are the most common. Wooden wheels have emery or other abrasives glued

onto them and are used to polish flat surfaces and maintained good edges. There are many

types of cloth wheels. Cloth wheels that are cemented together are very hard and used for

rough work, whereas other cloth wheels that are sewn and glued together are not as

aggressive. There are cloth wheels that are not glued or cemented, instead these are sewed

and have metal side plates for support. Solid felt wheels are popular for fine finishes.

Hard roughing wheels can be made by cementing together strawboard paper disks. Softer

paper wheels are made from felt paper. Most wheels are run at approximately

7500 surface feet per minute (SFM), however muslin, felt and leather wheels are usually

run at 4000 SFM.

Buffing wheels, also known as mops, are either made from cotton or wool cloth and

come bleached or unbleached. Specific types include: sisal, spiral sewn, loose cotton,

canton

flannel, domet flannel, denim, treated spiral sewn, cushion, treated vented, untreated

vented, string buff, finger buff, sisal rope, mushroom, facer, tampered, scrubbing

mushroom, hourglass buff, rag, "B", climax, swans down, airflow, cool air, and bullet.

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CHAPTER 4: DESIGN AND CALCULATION

4.1 Observations from Project

4.2 Design of the Project

4.3 Project Image

4.1 OBSERVATIONS FROM PROJECT

4.1.1 MOTER

Power of the motor (P) = 500W

RPM of the motor =2800rpm

4.1.2 IMPELLER

Dia. at the outlet of the impeller = 6.6 cm.

Dia. at the inlet of the impeller = 1.5 cm.

Discharge from impeller = 1800 ml per 3.12 sec.

= 576.92 ml/sec.

= 576.92 cm3/sec

Suction head for impeller (hs) = 5 cm

Discharge head for impeller (hd) = 54 cm

So manometric head for impeller (Hm) =hd-hs = 54-5= 49 cm

4.1.3 NOZZLE

Outlet dia. of the nozzle = 4 mm

Inlet dia. of the nozzle = 7 cm

Discharge from the nozzle = 1200 ml per 3.89 sec.

= 308.48 ml per sec

= 308.48cm3/sec

4.1.4 TURBINE

Outer dia. of the turbine = 17.5 cm

Blade height of the turbine = 3 cm

So inner dia. of the turbine = 11.5 cm

Width of the blade = 3 cm

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Revolution of the turbine = 10 RPS

= (10*60) = 600 RPM

4.1.5 GEAR

No of teeth’s on the small gear =17 teeth

No of teeth’s on the large gear = 50 teeth

4.1.6 DRILL

Feed of machine = 3cm/120*

Dia. of the Drill = 5mm

Shank length of the drill =4 cm

Flute length of the drill =5.5 cm

4.1.7 REAMER

Dia. of the Reamer = 5.02 mm

Shank length of the Reamer = 4 cm

Flute length of the Reamer = 5.8 cm

Material for drill and reamer = HSS

4.1.8 GRINDING WHEEL

Dia. of the Grinding Wheel =10 cm = 100 mm

Width of the Grinding Wheel =12 mm

Material of grinding Wheel = Quartz stone OR with vitrified or shellac bond

4.1.9 BUFFING WHEEL

Dia. of the Buffing Wheel =100 mm

Width of the Buffing Wheel = 12 mm

Material of the Buffing Wheel = cotton, leather etc.

4.2 DESIGN OF THE PROJECT

4.2.1 Motor Design

Data available:-

Power of the motor = 500 W

RPM of the motor = 2800 rpm

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So torque available on the motor (T) = (P*60)/ 2πN

Torque (T) = 500*60

2*π*2800

= 1.705 N/m

4.2.2 Pump Design

Data available:-

Dia. at the outlet of the impeller (Do) = 6.6 cm.

Dia. at the inlet of the impeller (Di) = 1.5 cm.

Discharge from impeller (Qi) = 1800 ml per 3.12 sec.

= 576.92 ml/sec.

= 576.92 cm3/sec

Suction head for impeller (hs) = 5 cm

Discharge head for impeller (hd) = 54 cm

So manometric head for impeller (Hm) = hd-hs

= 54-5

= 49 cm

Calculations:-

We can find Velocity at the inlet of the impeller by following method =

tan θ = (Vf1)/u1

But u1 = ( π* Di*N)/60

= (π * 1.5 *2800)/60

= 219.91 cm/sec

And let vane angle at inlet (θ) = 10.

So tan 10. = Vf1 /219.91

Vf = 38.78 cm/sec

So overall efficiency of the impeller (ή0) = {(ρ*g*Q*Hm)/1000} S.P.

= (1000*9.81*572.92*49)/1000*1000)

500

ή0 = 0.5546

ή0 = 55.46 %

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At outlet of the impeller

Velocity at outlet of the impeller (uo) = (π* Do*N)/60

= (π * 6.6 *2800)/60

= 976.61 cm/sec

tan φ = (Vf2)/(u2 –Vw2)

But Vf1 =Vf2 = 38.78 cm/sec

Let φ = 45.

So tan 45. = (38.78)/ (976.61-Vw2)

Vw2 = 937.83cm/sec

Now manometric efficiency of the impeller (ήm) = (g*Hm)/Uo *Vw2

= ((9.81*49)*100))/ (9.769*937.83)

= 0.5246

(ήm) = 52.46 %

4.3 Nozzle design

Data available:-

Outlet dia. of the nozzle = 4 cm

Inlet dia. of the nozzle = 7 cm

Discharge from the nozzle (Qn) = 1200 ml per 3.89 sec.

= 308.48 ml per sec

= 308.48 cm3/sec

Calculation:-

We know discharge from nozzle (Qn) = An* v2

308.48 = (π/4)*42* v2

So velocity at outlet of the nozzle (v2) = 24.54 cm/sec

4.4 Design of the turbine

Data available:-

Outer dia. of the turbine = 14.5 cm

Blade height of the turbine = 3 cm

So inner dia.of the turbine = 11.5 cm

Width of the blade = 3 cm

Revolution of the turbine = 10 Revolution/sec

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= 10*60

= 600 rpm

4.5 Gear design =

Data available:-

No of teeth’s on the small gear (T1) = 17 teeth

No of teeth’s on the large gear (T2) = 50 teeth

RPM of the turbine shaft = RPM of the small gear shaft

= 600 rpm

Calculations:-

We know in case of meshed gear

N2/N1 = T1/T2

N2/600 = 17/50

N2 = 204 rpm

So Velocity ratio = (angular velocity of the large gear)/(angular velocity of the small

gear)

= w1 /w2

= (2*π*N2)/ (2*π* N1)

= N2/N1

= 204/600

= 0.34

4.2.6 Drilling parameters calculation:-

Data available:-

Dia. of the Drill = 5mm

Shank length of the drill = 4cm

Flute length of the drill = 5.5cm

Calculations =

We know cutting speed (V) = (π*d*N)/1000

Where d = dia. of the drill

N = rotational speed of the spindle

So V = (π*d*N)/1000

= ((π*(5/1000)*204))/1000

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= 3.204mm/min

Cutting speed also depends upon many factors like:-

Material to be cut

Material of the cutting tool

Type of the finishing required

Type of the coolant used

4.2.6.1 Feed (f): -

Feed is the distance travelled by a drill along its axis into the work piece during its one

revolution. It is usually expressed in mm/rev.

Data available:-

Feed (f) = 3 cm/120.

= (30/120)*360

= 90mm/rev

Calculations:-

Feed in mm/min = (feed in mm/rev)*N

f = 90*204

f = 18360mm/min

OR feed = 18.36m/min

4.2.6.2 Depth of the cut (t):-

It is the distance measured at right angle to the axis of the drill.

So depth of the cut (t) = (Drill Dia.)/2

t = 5/2

t = 2.5mm

4.2.6.3 Machining time(Tm ): -

This can be calculated as follows:-

Tm = L/ (N*f)

Where Tm = Machining time in min

N = speed of the drill in rpm

F = feed in mm/rev

L = length of the axial travel of the drill in mm

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So Tm = (3)/ (204*90)

Tm = 1.6*10-4

Tm = 1.6*10-4*60*60

Tm = 0.588 hours

Tm = 35.29 minutes

Tm = 36 min approx.

4.2.7 Grinding parameters:-

Data available:-

Dia. of the Grinding Wheel = 10cm

= 100mm

Width of the Grinding Wheel = 12mm

Calculations:-

Cutting speed (Vs) = (π*d*N)/1000

Vs = (π*100*204)/1000

Vs = 64.08mm/min

Vs = 64.08/60

Vs = 0.006814 m/s

4.3 PROJECT IMAGE

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Fig.4.1 project image

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REFERENCE:-

1. Fluid mechanics and hydraulic machines by Dr. R. K. Bansal

2. Workshop Technology-1 by Sandeep Bajaj

3. Workshop Technology-П by Sandeep Baja

4. Workshop Technology-Ш by Sandeep Bajaj

5. http://en.wikipedia.org/wiki/Hydraulics

6. http://lennybrioxy.hubpages.com/hub/history-of-hydraulic-systems

7. http://en.wikipedia.org/wiki/Hydraulic_machinery

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