APROJECT REPORTON

SUBMITTED BY-------------------------------------------------------------------

PRINCIPAL HOD PROJ. GUIDE -------------- PROF. --------------------- PROF. -------------

DEPARTMENT OF ------------------ ENGINEERING

POLYTECHNICYEAR 2007-2008

ACKNOWLEDGEMENT

It is the incidence of great pleasure in submitting this project work. We take this opportunity to express our sincere gratitude to ------------------- for his valuable guidance in this undertaking, without which the project report would not have been completed .We are very much grateful to him for his untiring assistance in this project and he has been encouraging us in eliminating the errors .The project has been developed as a result of valuable advice .We are also grateful for the co-operation, valuable suggestion rendered by Prof. ------------------ ,as a head of department and all other teaching staff of the Production department.Finally we are greatly indebted to management of our college ---------------------, and express appreciation and thanks of our Principal Shri -----------, for coordinating keen interest and providing necessary facilities in completing the project and report.

THANKS ---------------------

INDEX

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Name of the topicPage No.

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CHAPTER NO1ABSTRACTREGENERATIVE SHOCK ABSORBER

In the past decade, regenerative braking systems have become increasinglyPopular, recovering energy that would otherwise be lost through braking. However, another energy recovery mechanism that is still in the research stages is regenerative suspension systems. This technology has the ability to continuously recover a vehicle's vibration energy dissipation that occurs due to road irregularities, vehicle acceleration, and braking, and use the energy to reduce fuel consumption.A regenerative shock absorber is a type of shock absorber that converts parasitic intermittent linear motion and vibration into useful energy, such as electricity. Conventional shock absorbers simply dissipate this energy as heat.When used in an electric vehicle or hybrid electric vehicle the electricity generated by the shock absorber can be diverted to its power train to increase battery life. In non-electric vehicles the electricity can be used to power accessories such as air conditioning. Several different systems have been developed recently, though they are still in stages of development and not installed on production vehicles.This could be used on electric or hybrid vehicles (or normal vehicles) to capture energy which would otherwise be absorbed and wasted, and then convert it into electricity. The regenerative shock absorbers can harvest the power in a continuous way. On the smooth highway road, the regenerative shock absorbers can improve the fuel efficiency by 2%, and on bumpy roads up to 10% increase can be expected.

Bike front suspensionRackshaftFree wheelHandlePinionSupportBasecolumn

CHAPTER-02THE SCOPE FOR PROJECT

In our country due to increased paying capacity, advanced lifestyle and rapidly growing industrialization, the need & demand of transportation is increasing day- by- day. The number of vehicles rolling on the road is increasing daily. Hence chances of accidents are increasing while crossing the road especially by the children and old persons. So it became necessary to install the speed breakers (in true sense speed reducers) at the school building or Hospital building- side road or highway. If these speed breakers Yes! In true sense it is speed and ultimately breaker the opposing impact energy supplied by the hard speed breaker will apply massive thrust impact on the suspension system of the vehicle. This impact force can be use for power generation using regenerative method and use to charge battery and release load of alternator or dynamo from engine.Here on working this group task we over-come our following needs:- We became able to have market survey Doped capability of designing a system by collecting necessary data. Learnt actual practical fabrication processes of the sub-components of the system. Planning the cost estimation and budget. Duties of a technician or an Engineer.

CHAPTER-03SELECTION OF PROJECT

We the group of young engineers found that, there is an impending need to make much more forays to make Non Conventional energy attain popular acclaim. This is also very essential to preserve the conventional sources of energy and explore viable alternatives like sustainable energy (the energy which we are already utilizing but for some safety of other uses we are suddenly wasting it, that can be reutilized), solar, wind and biomass that can enhance sustainable growth. What is more, such alternatives are environment friendly and easily replenish able. Therefore, they need to be thoroughly exploited with a functionally expedient, energy matrix mix.

A engineer is always focused towards challenges of bringing ideas and concepts to life. Therefore, sophisticated machines and modern techniques have to be constantly developed and implemented for economical manufacturing of products. At the same time, we should take care that there has been no compromise made with quality and accuracy.In the age of automation machine become an integral part of human being. By the use of automation machine prove it self that it gives high production rate than manual production rate. In competition market every one wants to increase their production & make there machine multipurpose.

The engineer is constantly conformed to the challenges of bringing ideas and design into reality. New machines and techniques are being developed continuously to manufacture various products at cheaper rates and high quality.

Growing economies, especially of Asia are gifted with sufficient resource base and non-conventional energy technologies are consistent both for grid linked energy generation and transmission in out of the way locales that are islanded from the grid. Adaptation of technology and employing them should be pursued right from this moment to have a head start, be informed of the barriers in technology applications of the renewable variety and synergizing them with the existing, traditional power production technology and T&D networks. It is known that in coming times, wind energy will be the most cost-effective renewable resource. Yet, it is doubtful if any individual technology would hold centre-stage. Thus we selected kinetic generator means the Energy in motion when it is suddenly applied with a sort of obstacle, then according to Newtons law for every action there is an equal and opposite reaction. Utilization of this reaction is the basic reason behind the selection of this project work.

AVAILABLE ENERGY OF THE MOVING VEHICLE TO APPLY IMPACT FORCE ON THE SPEED BREAKERTRAIN OF GEAR AND PULLEYS AND GENERATOR SYSTEMPOWER GENERTAED IN TERMA OF GLOWING BULB OR CHARGING BATTERY

FIG 1: The set up flow diagram

CHAPTER-04INTRODUCTION TO NON CONVENTIONAL ENERGY

The development planning process designs strategies and activities to use, enhance or conserve both natural and economic goods and services. In big modern cities, economic goods and services almost completely replace the natural ones.Energy is the prime source of all socio-economic activities of the human community. The demographic rate of growth globally and the widening spectrum of economic growth would result in demands of energy at an incremental rate of 7 to 8% annually. This can easily support a GDP growth of 8 to 9% per annum. Projections point toward a doubling of global energy demands in the decade starting 2020. There will be a marked shift in patterns of energy consumption whereby developing economies of the world would have a share exceeding two-third of global energy consumption by that period.Fossil fuels' consumption would remain the major source of energy generation and globally employed power generation technologies. The apportionment of renewable energy in the entire energy supply will continue to be marginal in the real sense. The contribution of renewable energy-excepting hydel energy and conventional biomass-as a proportion of global energy output is pegged at a paltry 2%. This scenario in all likelihood is not going to be altered therefore, guaranteeing the possibility of nudging the renewable contribution up to 5% by 2020. The global sources of fossil fuel will have become dearer due to their depletion thereby, making the viability of fossil fuel plants restoring parity with the renewable sources. 60% of the cumulated energy needs world-wide would be met through renewable sources.Growing economies, especially of Asia are gifted with sufficient resource base and non-conventional energy technologies are consistent both for grid linked energy generation and transmission in out of the way locales that are islanded from the grid. Adaptation of technology and employing them should be pursued right from this moment to have a head start, be informed of the barriers in technology applications of the renewable variety and synergizing them with the existing, traditional power production technology and T&D networks. It is known that in coming times, wind energy will be the most cost-effective renewable resource. Yet, it is doubtful if any individual technology would hold centre-stage.It was in the 1970s that the real potential and role of renewable energy sources was sensed and identified in India for sustainable energy growths. During the past quarter of a century, a significant thrust has been given to the development, trial and induction of a variety of renewable energy technologies for use in different sectors. The activities cover all major renewable energy sources, such as biogas, biomass, solar energy, wind energy, small hydropower and other emerging technologies.India has presently among the world's plentiful agenda on renewable energy. in the 8th Plan, vis--vis a proposal of 600 MW generation, close to 1050 MW of power generating capacity fastened to renewable energy sources was added. About 1500 MW of the total grid capacity in the country is now based on renewable energy sources. India is rated fourth in the world with a wind power capacity of 1000-1100 MW. Small hydel power generation, which is especially ideal for remote, hilly regions, presently not exploited but holds a potential of 500 MW in today's scenario. India has an extensive cane sugar production and we are implementing the world's biggest biogases based cogeneration programmed in agglomeration with sugar mills. There is substantial leverage as regards to deducing energy from urban and industrial wastes. The National Programmed lays special emphasis on supplying energy to rural areas. Close to 2.75 million biogas plants and over 28 million upgraded wood-stoves are also in use in the country.In the sphere of solar energy use, solar photovoltaic and solar thermal technologies are gaining immediate reception for a host of industrial and commercial applications, as well as in Non Electrified and Rural Zones (NERZ). The country has the world's largest assemblage of solar photovoltaic, consisting of about 500,000 PV systems totaling to 39 MW, and encompassing over 30 variegated operations.There is an added emphasis on venturing into grid quality power generation Programmed oriented on solar thermal and solar photovoltaic technologies. A 140 MW Integrated Solar Combined Cycle (ISCC) Power Project is being accorded conclusive shape to be established at Mathania near Jodhpur in Rajasthan. This will be the first of its kind, and the largest such project in the world.To give a fillip to power generation from renewable energy, State Governments and utilities provide remunerative power purchase agreements and arrangements for wheeling, banking and buy back of power. 12 States have so far announced policies for non-conventional energy based power generation. The Indian Renewable Energy Development Agency (IREDA), the corporate financing arm of the Ministry, is the only Agency of its kind in the world dedicated to financing of renewable energy projects. Interest rates vary from 0% to 16%, with special rates being offered for projects.There is an impending need to make much more forays to make Non Conventional energy attain popular acclaim. This is also very essential to preserve the conventional sources of energy and explore viable alternatives like solar, wind and biomass that can enhance sustainable growth. What is more, such alternatives are environment friendly and easily replenish able. Therefore, they need to be thoroughly exploited with a functionally expedient, energy matrix mix.A revolutionary step would be the advent of renewable energy co-operatives for power vending, installation and servicing of renewable energy systems in pockets like NERZs. With a view to take a long-term perspective, and to actualize the entire scope of Non-Conventional energy sources, it is incumbent to draw up a capacious Renewable Energy Policy involving all players in the field, together with the active participation of consumers as wellIn the Ninth Plan (1997-02), the accent is on according commercialization and development of entrepreneurship in all Renewable and Non Conventional Energy Schemes and Plans. An extra power generating capacity from Renewable and Non Conventional Energy sources of about 1500 MW is envisaged. The immediate challenge is to reconcile the reduced budgetary allocations in the 9th Plan due to fiscal control. The Ministry of Non Conventional Energy has stated objective of propping up 24,000 MW from Renewable and Non Conventional Energy by the year 2012.The need is however to have adequate policy framework to be in place with an aim to provide impetus through streamlining the structure of Renewable and Non Conventional Energy. The high potential is what should spur maximum efforts. The bottlenecks are that although there are good plans, we often fall short in measuring up to meet the desired levels of optimization of our potential. If there is a strict regiment by which Renewable and Non Conventional EnergySources are utilized, India is sure to have adequate measure of success. The Numero Uno position in Renewable and Non Conventional Energy is well within reach with a little bit of concerted effort.

CHAPTER -05WORKING OF PROJECT

Regenerative suspension basically new concept of non-conventional energy generation. It is electro-mechanical energy generating machine. This machine converts reciprocating motion in to rotary motion. The rotational power is stored in flywheel & flywheel rotates dynamo, which generates electricity.

Here first important point is how we get reciprocating motion, which is prime input in the system. For that we use weight of moving vehicles that run on roads. We put our mechanism on bike suspension, the head of rack with pinion. When vehicles move on speed breaker rack will be reciprocate. The rack is attached with pinion that rotates in one direction only. The rack & pinion arrangement convert reciprocating motion in to rotary motion.This rotary motion is further magnified using chain drive. The output of free wheel is attached with flywheel which stores kinetic energy and transfer to dynamo which generate electricity with zero cost.A "generator" and "motor" is essentially the same thing: what you call it depends on whether electricity is going into the unit or coming out of it. A generator produces electricity. In a generator, something causes the shaft and armature to spin. An electric current is generated, as shown in the picture (lightning bolt).Lots of things can be used to make a shaft spin - a pinwheel, a crank, a bicycle, a water wheel, a diesel engine, or even a jet engine. They're of different sizes but it's the same general idea. It doesn't matter what's used to spin the shaft - the electricity that's produced is the same.

CHAPTER-06METHODOLOGY

Here following method is adopted to generate the electricity:- The set up is designed. Its subcomponents are manufactured The sub components are assembled together The set up is tested for checking whether it performing its intended task or not. Under this method the fly wheel is the key component for energy transformation.FlywheelIntroductionFlywheel is a device to smoothen the cyclic fluctuation of speed change when delivering constant output power from the engine. It has no influence on the mere speed of the prime mover. It has no influence on the varying load demand on the prime mover or the delivered power from the prime mover. In is the forgoing discussion, it is observed that turning moment diagrams for the cycle show period during which torque is in excess of the mean torque responsible for the constant power output and also periods during which the torque is less than the mean torque. Thus the speed of the flywheel would increase during period of excess of torque during the cycle and the speed will fall during the period of the deficit torque during the cycle. Thus a flywheel stores energy and releases energy during the cycle without affecting mean energy output. Thus a properly designed flywheel has to ensure the cyclic fluctuations of speed within prescribed limits preferably as small as possible.Definition of the flywheel:- A flywheel used in machine serves as a reservoir which stores energy during the period when the supply of energy is more than the requirement and releases it during the period when the requirement of energy is more than the supply.Working of the flywheel:-The excess energy is developed during power stroke is absorbed by flywheel and releases it to the crankshaft during the other stroke in which no energy is developed, thus rotating the crankshaft at a uniform speed. A little consideration will show that when the flywheel absorbs energy, its speed increases and when it releases energy, the speed decreases. Hence a flywheel does not maintain a constant speed; it simply reduces the fluctuation of speed. In other words, a flywheel controls the speed variations caused by the fluctuation of the engine turning moment during each cycle of operation.

Application:-Flywheel are mostly used in machine where the operation is intermitted like punching machines, shearing machines, riveting machines, crushers etc, the flywheel stores energy from the power source during the greater portion of the operating cycle and gives it up during a small period of the cycle. Thus the energy from power source to the machines is supplied practically at a constant rate throughout the operation.

Bike front suspensionRackshaftFree wheelHandlePinionSupportBasecolumn

CHAPTER-07LITERATURE SURVEY

WHAT IS ELECTRICITY?Electricity is a form of energy.Electricity is the flow of electrons.All matter is made up of atoms, and an atom has a center, called a nucleus. The nucleus contains positively charged particles called protons and uncharged particles called neutrons. The nucleus of an atom is surrounded by negatively charged particles called electrons. The negative charge of an electron is equal to the positive charge of a proton, and the number of electrons in an atom is usually equal to the number of protons.When the balancing force between protons and electrons is upset by an outside force, an atom may gain or lose an electron. When electrons are "lost" from an atom, the free movement of these electrons constitutes an electric current.Electricity is a basic part of nature and it is one of our most widely used forms of energy. We get electricity, which is a secondary energy source, from the conversion of other sources of energy, like coal, natural gas, oil, nuclear power and other natural sources, which are called primary sources. Many cities and towns were built alongside waterfalls (a primary source of mechanical energy) that turned water wheels to perform work. Before electricity generation began slightly over 100 years ago, houses were lit with kerosene lamps, food was cooled in iceboxes, and rooms were warmed by wood-burning or coal-burning stoves. Beginning with Benjamin Franklin's experiment with a kite one stormy night in Philadelphia, the principles of electricity gradually became understood. In the mid-1800s, Thomas Edison changed everyone's life -- he perfected his invention -- the electric light bulb. Prior to 1879, electricity had been used in arc lights for outdoor lighting. Edison's invention used electricity to bring indoor lighting to our homes.HOW ELECTRICITY IS MADE?Electricity can be made or generated by moving a wire (conductor) through a magnetic field.

FIG 4:- Magnetism.A bar magnet has a north and South Pole. If it is placed under a sheet of paper and iron filings are sprinkled over the top of the paper, these iron filings will arrange themselves into a pattern of lines that link the north pole with the south pole of the magnet (see diagram 1). These lines show the magnetic field around the magnet.

FIG 5(a):- Making Electricity. If a coil of wire is moved within a magnetic field so that it passes through the magnetic field, electrons in the wire are made to move (as in diagram 2). When the coil of wire is connected into an electric circuit (at the terminals A and a) the electrons are under pressure to move in a certain direction and a current will flow. This electrical pressure is called voltage.The amount of pressure or voltage depends on the strength and position of the magnetic field relative to the coil, as well as the speed at which the coil is turning. As the amount of electricity changes so does its voltage.

FIG 5(b) & 5(c)

FIG 5(d)

FIG 5(e)In the diagram above, the coil of wire is rotating in a clockwise direction. When the coil of wire is in the horizontal position 1the voltage is greatest (diagram 4) because the coil is passing through the strongest part of the magnetic field. At this stage the current flows from 1 to 2 to 3 to 4, out through terminal A, through the globe and back into terminal a. When the coil of wire is in the vertical position (2), no electricity is produced because the coil does not cut the magnetic field, and no current flows. When the coil of wire is in the horizontal position again 3 the voltage is at its maximum (3), however the current flows in the opposite direction 4 to 3 to 2 to 1, out through terminal a, through the globe, and back into terminal A.The current produced changes direction every half turn (180 degrees). This is called alternating current or AC. The generators at large power stations produce nearly all the electricity we use in this way.

IMPORTANCE OF SYSTEMThis system very suitable for our country because we have wide range of road.State/UTTotal Road LengthAreaPopulationRoad Length (km)

(km)(sq.km)(million)(per 100(per 1 million

sq.km)of population)

A & N Islands122482490153497

Andhra Pradesh17266927506873632354

Arunachal Pradesh10240837431129394

Assam680797843825872693

Bihar855651738779549898

Chandigarh1723114115112127

D & N Haveli51849101053047

Delhi2658214831317922132

Goa7457381421965108

Gujarat13385019602446682883

Haryana279074421219631467

Himachal Pradesh29610556736534753

J & K13042222236961408

Karnataka14275419179150742839

Kerala14185638863323654509

Madhya Pradesh19893644344676452617

Maharashtra359262307690881174070

Manipur10760223272484678

Meghalaya8391224292373780

Mizoram6910210811337943

Nagaland13732165792838975

Orissa210238155707351356015

Pondicherry234349514732320

Punjab5815150362231152550

Rajasthan13463234223951392638

Sikkim183470961263596

Tamil Nadu205706130058601583412

Tripura147261048641404256

Uttar Pradesh237358294411161811477

West Bengal775798875276871019

CHAPTER 8MATERIAL SELECTION

The proper selection of material for the different part of a machine is the main objective in the fabrication of machine. For a design engineer it is must that he be familiar with the effect, which the manufacturing process and heat treatment have on the properties of materials. The Choice of material for engineering purposes depends upon the following factors:1. Availability of the materials.2. Suitability of materials for the working condition in service.3. The cost of materials.4. Physical and chemical properties of material.5. Mechanical properties of material.The mechanical properties of the metals are those, which are associated with the ability of the material to resist mechanical forces and load. We shall now discuss these properties as follows:1. Strength : It is the ability of a material to resist the externally applied forces 2. Stress: Without breaking or yielding. The internal resistance offered by a part to an externally applied force is called stress.3. Stiffness: It is the ability of material to resist deformation under stresses. The modules of elasticity of the measure of stiffness.4. Elasticity: It is the property of a material to regain its original shape after deformation when the external forces are removed. This property is desirable for material used in tools and machines. It may be noted that steel is more elastic than rubber.5. Plasticity: It is the property of a material, which retain the deformation produced under load permanently. This property of material is necessary for forging, in stamping images on coins and in ornamental work.6. Ductility: It is the property of a material enabling it to be drawn into wire with the application of a tensile force. A ductile material must be both strong and plastic. The ductility is usually measured by the terms, percentage elongation and percent reduction in area. The ductile materials commonly used in engineering practice are mild steel, copper, aluminum, nickel, zinc, tin and lead.7. Brittleness: It is the property of material opposite to ductile. It is the Property of breaking of a material with little permanent distortion. Brittle materials when subjected to tensile loads snap off without giving any sensible elongation. Cast iron is a brittle material.8. Malleability: It is a special case of ductility, which permits material to be rolled or hammered into thin sheets, a malleable material should be plastic but it is not essential to be so strong. The malleable materials commonly used in engineering practice are lead, soft steel, wrought iron, copper and aluminum.9. Toughness: It is the property of a material to resist the fracture due to high impact loads like hammer blows. The toughness of the material decreases when it is heated. It is measured by the amount of absorbed after being stressed up to the point of fracture. This property is desirable in parts subjected to shock an impact loads.10. Resilience: It is the property of a material to absorb energy and to resist rock and impact loads. It is measured by amount of energy absorbed per unit volume within elastic limit. This property is essential for spring material.11. Creep: When a part is subjected to a constant stress at high temperature for long period of time, it will undergo a slow and permanent deformation called creep. This property is considered in designing internal combustion engines, boilers and turbines.12. Hardness: It is a very important property of the metals and has a wide verity of meanings. It embraces many different properties such as resistance to wear scratching, deformation and mach inability etc. It also means the ability of the metal to cut another metal. The hardness is usually expressed in numbers, which are dependent on the method of making the test. The hardness of a metal may be determined by the following test.0. Brinell hardness test0. Rockwell hardness test0. Vickers hardness (also called diamond pyramid) test and0. Share scaleroscope.The science of the metal is a specialized and although it overflows in to realms of knowledge it tends to shut away from the general reader. The knowledge of materials and their properties is of great significance for a design engineer. The machine elements should be made of such a material which has properties suitable for the conditions of operations. In addition to this a design engineer must be familiar with the manufacturing processes and the heat treatments have on the properties of the materials. In designing the various part of the machine it is necessary to know how the material will function in service. For this certain characteristics or mechanical properties mostly used in mechanical engineering practice are commonly determined from standard tensile tests. In engineering practice, the machine parts are subjected to various forces, which may be due to either one or more of the following.

1. Energy transmitted2. Weight of machine3. Frictional resistance4. Inertia of reciprocating parts5. Change of temperature6. Lack of balance of moving partsThe selection of the materials depends upon the various types of stresses that are set up during operation. The material selected should with stand it. Other criteria for selection of metal depend upon the type of load because a machine part resist load more easily than a live load and live load more easily than a shock load.Selection of the material depends upon factor of safety, which in turn depends upon the following factors.1. Reliabilities of properties2. Reliability of applied load3. The certainty as to exact mode of failure4. The extent of simplifying assumptions5. The extent of localized6. The extent of initial stresses set up during manufacturing7. The extent loss of life if failure occurs8. The extent of loss of property if failure occursMaterial usedMild steelReasons:1. Mild steel is readily available in market2. It is economical to use3. It is available in standard sizes4. It has good mechanical properties i.e. it is easily machinable5. It has moderate factor of safety, because factor of safety results in unnecessary wastage of material and heavy selection. Low factor of safety results in unnecessary risk of failure6. It has high tensile strength7. Low co-efficient of thermal expansionPROPERTIES OF MILD STEEL:M.S. has carbon content from 0.15% to 0.30%. They are easily wieldable thus can be hardened only. They are similar to wrought iron in properties. Both ultimate tensile and compressive strength of these steel increases with increasing carbon content. They can be easily gas welded or electric or arc welded. With increase in the carbon percentage weld ability decreases. Mild steel serve the purpose and was hence was selected because of the above purpose

BRIGHT MATERIAL:It is a machine drawned. The main basic difference between mild steel and bright metal is that mild steel plates and bars are forged in the forging machine by means is not forged. But the materials are drawn from the dies in the plastic state. Therefore the material has good surface finish than mild steel and has no carbon deposits on its surface for extrusion and formation of engineering materials thus giving them a good surface finish and though retaining their metallic properties

BILL OF MATERIALSR NOPART NAMEMATERIALQTY

1FRAME MS40kg

2FLYWHEELMS15kg

3SHAFTEN82

4BIG SPROKETMS1

5SMALL SPROKETMS1

6DYNAMOSTD1

7BELT------1

8CHAIN 1

9BIKE SUSPENSION STD1

10RACKMS1

11HANDELMS4

12NUT BOLT WASHERSTD12

13SUPPORTMS1

14FREE WHEELSTD1

15WELDING ROD5 /pcs25

16COLOUR300/lit0.75 lit

CHAPTER 9COST ESTIMATION

The machine tool designer must furnish the management with an idea of how much tooling will cost, and how much money the productions methods save over a specified run. This information is generally furnished in a form of cost worksheets. By referring to the cost worksheets the final cost of machine is calculated.Cost estimation is defined as the process of forecasting expenses that are incurred to manufacture a product. These expenses take into account all expenditure involved in designing and manufacturing with all the related service facilities such as material handling, heat treatment and surface coating, as well as portion of general administrative and selling costs.

NEED OF COST ESTIMATION:-

1. Determine the selling price of a product for a quotation or contract, so as to ensure a reasonable profit to the company.2. Check the quotations supplied by the vendors.3. Decide whether a part or assembly is economical to be manufactured in the plant or is to be purchased from outside.4. Determine the most economical process or material to manufacture a product.5. Initiate means of cost reduction in existing production facilities by using new materials which result in savings due to lower scrap loss and revised methods of tooling and processing.6. To determine standards of production performance that may be used to control costs.

ELEMENTS OF COST ENCOUNTERED IN THE PROJECT:-The cost encountered in this project is material cost, labour cost, cost of standard parts, designing cost and cost of indirect expenses.

1) DESIGN COST:-The designing cost is calculated by considering the amount taken by the designer (if so) and the cost of designing material.

2) MATERIAL COST:-The material cost can be calculated by finding the total volume of the material used and the weight of the material. For calculation the value and the weight, the following procedure is adopted: In actual procedure, there are some holes and shapes cut. But they are considered to be solid while calculation the total volume of material used. While calculation the volume the triangle shaped parts and the T shaped parts are considering as rectangular or square plates. The weight of the parts is calculation by multiplying the total volume and the density of the material (M.S.) which is equal to 7.76665x10 3 Kg/Cc. The total cost can be obtained by multiplying the total weight by the rate of material.

COST OF RAW AND FINISH MATERIALSR NOPART NAMERATEQTYTOTAL

1FRAME 50/ kg40kg2000

2FLYWHEEL50/ kg15kg750

3SHAFT1502300

4BIG SPROKET 20/teeth24teeth480

5FREE WHEEL 1001100

6DYNAMO6001600

7BELT1251125

8CHAIN 3501350

9BIKE SUSPENSION 150011500

10RACK8001800

11HANDEL45/kg2 KG90

12NUT BOLT WASHER---------------200

13SUPPORT----------1450

14WELDING ROD10 /pcs25250

15COLOUR300/lit1 lit300

TOTAL

B) DIRECT LABOUR COST:-

SR. NO.OPERATIONHOURSRATE / LABOURAMOUNT

1.

Turning101501500

2.

Milling2150300

3.

Drilling7100700

4.

Welding161752800

5.

Grinding360180

6.

Tapping340120

7.

Cutting840320

8.

Gas cutting850400

9.

Assembly2100200

10.

Painting2100200

TOTAL6720/-

INDIRECT COSTTransportation cost = 500/-Coolent & lubricant = 100/-Drawing cost = 500/-Project report cost = 2000/-TOTAL INDIRECT COST = 2100/-

TOTAL COST Raw Material Cost + STD Parts Cost + Direct Labor Cost +Indirect CostTotal cost of project = A + B +CTotal cost of project = --------- /-

CHAPTER NO 10MACHINE DESIGN

STRUCTURAL DESIGN METHODS

Introduction : This chapter describes some of the mathematical technique used by designers of complex structures. Mathematical models and analysis are briefly describe and detail description is given of the finite element method of structural analysis. Solution techniques are presented for static, dynamic & model analysis problems. As part of the design procedure the designer must be analyses the entire structure and some of its components. To perform this analysis the designer will develop mathematical models of structure that are approximation of the real structure, these models are used to determine the important parameters in the design.The type of structural model the designer uses depends on the information that is needed and the type of analysis the designer can perform.Three types of structural models are

1. Rigid Members: The entire structure or parts of the structure are considered to be rigid, hence no deformation can occur in these members.1. Flexible members : The entire structure or parts of the structure are modeled by members that can deform, but in limited ways. Examples of this members trusses, beams and plates.1. Continuum : A continuum model of structure is the most general, since few if any mathematical assumptions about the behavior of the structure need to be made prior to making a continuum model. A continuum member is based on the full three dimensional equations of continuum models.

In selecting a model of the structure, the designer also must consider type of analysis to be performed. Four typical analysis that designers perform are :

1. Static equilibrium : In this analysis the designer is trying to the determine the overall forces and moments that the design will undergo. The analysis is usually done with a rigid members of model of structure and is the simplest analysis to perform.1. Deformation : This analysis is concerned with how much the structure will move when operating under the design loads. This analysis is usually done with flexible members.1. Stress : In this analysis the designers wants a very detailed picture of where and at what level the stresses are in the design. This analysis usually done with continuum members.1. Frequency : This analysis is concerned with determining the natural frequencies and made shape of a structure. This analysis can be done with either flexible members of a structure. This analysis can be done with either flexible members or continuum members but now the mass of the members is included in the analysis.

The subject of MACHINE DESIGN deals with the art of designing machine of structure. A machine is a combination of resistance bodies with successfully constrained relative motions which is used for transforming other forms of energy into mechanical energy or transmitting and modifying available design is to create new and better machines or structures and improving the existing ones such that it will convert and control motions either with or without transmitting power. It is the practical application of machinery to the design and construction of machine and structure. In order to design simple component satisfactorily, a sound knowledge of applied science is essential. In addition, strength and properties of materials including some metrological are of prime importance. Knowledge of theory of machine and other branch of applied mechanics is also required in order to know the velocity. Acceleration and inertia force of the various links in motion, mechanics of machinery involve the design.

CONCEPT IN M.D.P.

Consideration in Machine DesignWhen a machine is to be designed the following points to be considered: -i) Types of load and stresses caused by the load.ii) Motion of the parts and kinematics of machine. This deals with the type of motion i.e. reciprocating . Rotary and oscillatory.iii) Selection of material & factors like strength, durability, weight, corrosion resistant, weld ability, machine ability are considered.iv) Form and size of the components.v) Frictional resistances and ease of lubrication.vi) Convince and economical in operation.vii) Use of standard parts.viii) Facilities available for manufacturing.ix) Cost of making the machine.x) Number of machine or product are manufactured.

GENERAL PROCEDURE IN MACHINE DESIGNThe general steps to be followed in designing the machine are as followed.i) Preparation of a statement of the problem indicating the purpose of the machine.ii) Selection of groups of mechanism for the desire motion.iii) Calculation of the force and energy on each machine member.iv) Selection of material.v) Determining the size of component drawing and sending for Manufacture.vi) Preparation of component drawing and sending for manufacture.vii) Manufacturing and assembling the machine.viii) Testing of the machine and for functioning.

Design of Rack

Design load = 500kg = 500 x 9.81 = 4905 N

Selecting Material as C 45y = 360 N / mm F.O.S. = 2c = 360 / 2 c = 180 N / mm

5 x c = 0.5 x 180 N / mm = 90 N / mm

To find Shear Stress induced = F / A = 4905 / (20 x 5) N / mm = 49.05 N / mm

F (induced) = 49.05 < 90 N / mm (induced) < permissibleDesign of RACK is SAFE

Since, the standard RACK available in market is of 10 DP corresponding standard pinion available is of 10 DP.Design of Transmission System

1) Speed of Pinion = 34 RPM (MEASURED)2) Transmission Ratio of chain drive = 2.43) Number Of Teeth On Small Sprocket = T1 = 18

To find number of teeth on big sprocket = T1 x T.R = 18 x 2.4 = 43.2 = 44 TEETH

As big sprocket & Pinion on same shaft,Speed of Pinion = Speed of Big sprocket = 34 RPM

To Calculate the RPM obtained at Small sprocket = 34 x 2.4 RPM = 81.6 RPM

Torque induced on Pinion Shaft, T1 = F x R where, R = Radius of Pinion = 4905 x 25 T1 = 122.63 x 10 N-mm

Selecting Material for Shaft as C 45, y = 360 N / mm F.O.S. = 2 c = 360 / 2 c = 180 N / mm

5 x c = 0.5 x 180 N / mm = 90 N / mm

Applying Max. Shear Stress Theory we get, T1 = ( / 16) x d x 122.63 x 10 = ( / 16) x d x 90 d = 19.07 mm so we select dia of shaft =20 mm

For 20 mm dia shaft we select pedestal bearing from design data book = P204

Design of Flywheel

As we know 500 ROM is required. To generate electricity by dynamo so we design diameter of FLYWHEEL

Dia of FLYWHEEL N (dynamo) _________________________ = __________________

Dia of Dynamometer Pulley N (Flywheel)

D (flywheel) 500___________ = _____________ 50 85

D (flywheel) = 294 mm

Hence, we have selected diameter of Flywheel as 300mm available in market

FREEWHEEL 100 mmDIA=300mmSHAFTFLYWHEEL

CALCULATION OF EXCESS ENERGY IN FLYWHEEL

We know

E = I Kw 2

E = EXCEES ENERGY IN FLY WHEEL

Kw = COIEFFICIENT OF FLUCTION OF SPEED = MEAN ANGULAR VELOCITY

I = MASS MOMENT OF INERTIA

I = m X k2

m = X V ( = density of concrete = 0.00078 )

V = (3.14 x d2 x t ) / 4

V = (3.14 x 302 x 10 ) / 4

V = 7065 cm3

m = 0.00078 X 7065

m = 5.5 kg

k2 = D2/8 (for disc type flywheel from PSG DESIGN DATA BOOK )

k2 = 3002/8

k = 106mm

Kw = (1 - 2) /

= 2 x 3.14 x N / 60

= 2 x 3.14 x 85 / 60

= 8.90 rad/sec

1 = 9.9 rad/sec ( By trial & error method )

2 = 7.9 rad/sec ( By trial & error method )

Kw = (9.9- 7.9) / 8.9

Kw = 0.224

E = I Kw 2

E = 684.36 x 103 x 0.224 x 8.92

E = 12.2 x 106 / 106

E = 12.2 watt

DESIGN OF CHAIN & SPROCKETWe know, TRANSMISSION RATIO = Z2 / Z1 = 44/18 = 2.44For this transmission ratio number of teeth on pinion sprocket is in the range of 21 to 17 , so we select number of teeth on pinion sprocket as 18 teeth.So , Z1 = 18 teethSELECTION OF PITCH OF SPROCKETThe pitch is decided on the basis of RPM of sprocket.RPM of big sprocket is variable in normal condition it is = 34 rpmFor this rpm value we select pitch of sprocket as 12.7mm from table.P = 12.7mm

CALCULATION OF MINIMUM CENTER DISTANCE BETWEEN SPROCKETSTHE TRANSMISSION RATIO = Z2 / Z1 = 44/18 = 2.44 which is less than 3.So from table,MINIMUM CENTER DISTANCE = C + (30 to 50 mm )Where C = Dc1 + Dc2 2 C = 60 + 200 2 C = 130 mm MINIMUM CENTER DISTANCE = 130 + (30 to 50 mm )MINIMUM CENTER DISTANCE = 180 mmDue to size of system restriction we select center distance = 400 mmCALCULATION OF MODULE

We know module m = ( ( Z1-Z2 ) / 2 * 3.14 )2We know module m = ( ( 44-18) / 2 * 3.14 )2 m = 17.14 mmCALCULATION OF VALUES OF CONSTANTS K1 K2 K3 K4 K5 K6Load factor K1 = 1.25 ( Load with mild shock )Factor for distance regulation K2 = 1.25 (Fixed center distance)Factor for center distance of sprocket K3 =0.8Factor for position of sprocket K4 = 1Lubrication factor K5 = 1.5 (periodic)Rating factor K6 = 1.0 (single shift)CALCULATION OF VALUE OF FACTOR OF SAFETY

For pitch = 12.7 & speed of rotation of big sprocket = 34 rpm FACTOR OF SAFETY = 8.55CALCULATION OF VALUE OF ALLOWABLE BEARING STRESSFor pitch = 12.7 & speed of rotation of big sprocket = 34 rpmALLOWABLE BEARING STRESS = 2.87 kg / cm2= 2.87 * 981 / 100 =28 N /mm2CALCULATION OF COEFFICENT OF SAG K

For horizontal position coefficient of sag K = 6CALCULATION OF MAXIMUM TENSION ON CHAINAs we know maximum torque on shaft = Tmax = 98 x 103 N-mmWhere , T1 = Tension in tight sideT2 = Tension in slack sideO1,O2 = center distance between two shaftFrom fig.Sin = R1 - R2 O1O2Sin = 100 - 30 660Sin = 0.1 = 6TO FIND = (180 2 ) X 3.14/180 = (180 2*6 ) X 3.14/180 = 2.9 radwe know that,T1/T2 = eT1/T2 = e0.35 x 2.9T1 = 1.1 T2We have,T = ( T1 T2 ) X R98000= ( 1.1 T2 T2 ) X 100T2 = 9800 NT1 = 1.1 X 9800T1 = 10780 NSo tension in tight side = 10780 NCALULATION OF MINIMUM BREAKING LOAD OF CHAINLENGTH OF CHAIN

L = 2C/P + ( Z1 +Z2 ) / 2 + ( ( Z2 Z1 ) /3.14 * 2) 2 * C/ PL = 2*660/12.7+(18 +44) / 2 + ( ( 44 18 ) /3.14 * 2) 2 * 660/12.7L = 1026mmCalculation of chain velocity = (3.14*Np) / (60000Sin (180 / Z1) ) v = (3.14*350) / (60000Sin (180 / 18)v = 0.1m / secWe know, Q = N*75*n* Ks / vWhere ,N = rpm of small sprocketQ = minimum breaking load of chainV = chain velocity.n = allowable factor of safetyKs = K1*K2*K3*K4*K5*K6Q = 350*75*8.55*1.875 / 0.1Q = 4208203.125 kgf Q = 41.28 * 106 NAs minimum load bearing capacity is much more than applied load so design of chain is safe.Design of bolt:- Bolt is to be fastened tightly also it will take load due to rotation. Stress for C-25 steel ft =420 kg/cm2 . Std nominal diameter of bolt is 10mm. From table in design data book, diameter corresponding to M12 bolt is 8.160mmLet us check the strength :-Also initial tension in the bolt when belt is fully tightened.P = 2.5 kg is the value of force for belt P = 2.5 kg Being the four bolts the load is shared asP= p/4 =6.25 N.Also, P = /4 dc2x ft 6.25 x 4 ft = ------------------------------ = 0.078 N / mm2 3.14 x ( 12 x 0.84)2 the calculated ft is less than the maximum ft hence our design is safe.

CHAPTER- 11MANUFACTURING

The process of conversion of raw material in to finished products using the three resources as Man, machine and finished sub-components. Manufacturing is the term by which we transform resource inputs to create Useful goods and services as outputs. Manufacturing can also be said as an intentional act of producing something useful. The transformation process is shown below-

Conventional processOUTPUTINPUT

ElementMaterialDataEnergyVariable costUseful productProductsKnowledgeServicesRevenueTransformationMachinesInterpretationSkillFixed cost

FIG 7:- Transformation ProcessIt is the phase after the design. Hence referring to the those values we will plan The various processes using the following machines:-1. Universal lathe2. Milling machine3. Grinding machine 4. Power saw5. Drill machine6. Electric arc welding machineFABRICATION AND OPERATION SHEET:NAME OF THE PART SHAFTMATERIAL BRIGHT STEELQUANTITY 2SR.NO.DETAIL OPER.M/C. USEDTOOL USEDACCESMEA.INST.

1.Marking on shaft - - -Scale

2.Cutting as per dwgPower hack saw Hock saw bladeJig & fixturesScale

3.

Facing both side of shaftLathe machineSingle point cutting toolChuck Vernier caliper

4.Turning as per dwg size - - - -

5.Filling on both endFlat fileVice -

COMPONENT: FRAME MATERIAL: - M.S. ANGLEQUANTITY: -1 SR. NO DESCRIPTION OF OPERATIONMACHINE USEDCUTTINGMEASUREMENTTIME

1Cutting the angle in to length as per dwgGas cutting machineGas cutterSteel rule15min.

2Cutting the angle in to number of piece as per dwgGas cutting machineGas cutterSteel rule15min.

3Filing operation can be performed on cutting side and bring it in perpendicular C.S. Bench viceFileTry square15 min.

4Weld the angles to the required size as per the drawingElectric arc welding machine-------Try square20 min

5Drilling the frame at required points as per the drawing.Radial drill machineTwist drillVernier calliper10 min.

COMPONENT: GEARMATERIAL: - M.S QUANTITY: -1 SR. NO DESCRIPTION OF OPERATIONMACHINE USEDCUTTINGMEASUREMENTTIME

1Take standard gear as per design--------------------------------------

2Face both side of hub portionLathe machineSingle point cutting toolVernier caliper15 min.

3Hold it in three jaw chuck & bore inner dia as per shaft size Lathe machineSingle point cutting toolVernier caliper20 min.

4Cut key way as per dwgSlotting machineSingle point cutting toolVernier calliper10 min.

5Filling burrsFlat fill-------------------------5 min.

COMPONENT: PULLEYMATERIAL: - pvcQUANTITY: -1SR. NO DESCRIPTION OF OPERATIONMACHINE USEDCUTTINGMEASUREMENTTIME

1Take standard pulley as per design--------------------------------------

2Face both side of hub portionLathe machineSingle point cutting toolVernier caliper15 min.

3Hold it in three jaw chuck & bore inner dia as per shaft size Lathe machineSingle point cutting toolVernier caliper20 min.

4Drilling the hub at required points as per the drawingRadial drill machineTwist drillVernier calliper10 min.

5Tap the hub at drill area.Hand tap setTapVernier calliper10 min.

COMPONENT: RACKMATERIAL: - M.SQUANTITY: -1SR.NO.OPERATIONMACHINETOOL / GAUGETIME

1.Cut the rectangular rod for required lengthPower saw machineH.S. blade15 min

2.Straighten it and grind it on surface grinderSurface grinderTry square20 min

3.Set it on milling machine and set the indexing for the same pitch as the pinion gearMilling machineIndexing head, gear tooth Vernier60 min

4.Keep both the rack and pinion in oil bath and heat it.

FurnaceTongue25 min

5.Suddenly quench it in oil bathOil bath Tongue10 min

COMPONENT: HINGE PLATEMATERIAL: - M.SQUANTITY: -1SR.NO.OPERATIONMACHINETOOL/GAUGETIME

1.Cut M.S. Sheet of 3mm thickness of required dimensions.Hand lever cutting machineSteel rule15 min.

2.It is bent at its edges Hand pressBending dies20 min.

3.Weld hinge at one edgeWelding machineWelding rod10 min.

4.Corners are rounded off -----------Hand grinder 10 min.

5.

It is coated with red oxide and then after paintedAir compressorRed oxide and green paint20 min

CHAPTER 15PREACUTIONS & SAFETY MEASURES

Following precautions and safety measures are taken to make our creation a grand success.

PRECAUTION:-

1. The suspension plate should be adjusted uniformly2. The alignment of rack and pinion arrangement should be properly done.3. Lubricate moving component4. The system should be robustly designed.

SAFETY MEASURES:-

1. Do not touch the top plate when the system is in operating condition2. Do not touch the transmission system.

CHAPTER 13MAINTENANCE

Maintenance:- No machine in the universe is 100% maintenance free machine. Due to its continuous use it is undergoing wear and tear of the mating and sliding components. Also due to the chemical reaction takes place when the material comes in the contact with water, makes its corrosion. Hence it is required to replaced or repaired. This process of repairing and replacing is called as maintenance work.

AUTONOMOUS MAINTAINENCE ACTIVITY:-1. Conducting initial cleaning & inspection.2. Eliminate sources of dirt, debris, excess lubricants etc.3. Improve cleaning maintainability.4. Understand equipment functioning.5. Develop inspection skills.6. Develop standard checklists.7. Institute autonomous inspection.8. Organize and manage the work environment.9. Manage equipment reliability.

CLAIR CLEANING, LUBRICATING, ADJUSTMENT, INSPECTION

CLEANINGWhy cleaning?Prevent or eliminate contamination.Find ways to simplify the cleaning process.Facilitates through inspection when done by knowledgeable operators and \ or maintainers.CLEANING IS INSPECTION

Clean equipment ThoroughlyIdentify difficulties to clean areasDetect deterioration and defective parts in EquipmentLook at and touch every area on the equipmentFree equipment from Contamination Expose hidden DefectsRemarkable sources of contamination Normal Or Abnormal

CLEANING PROCESS

What to look for when cleaning.1. Missing part2. Wear3. Rust and corrosion4. Noise5. Cracks6. Proper alignment7. Leaks8. Play or sloppiness

VISUAL AIDS TO MAINTAIN CORRECT EQUIPMENT CONDITION:- Match marks on nut and bolts Color marking of permissible operating ranges on dials and gauges Marking of fluid type and flow direction of pipes Marking at open / closed position on valves Labeling at lubrication inlets and tube type Marking minimum / maximum fluid levels Label inspection sequences

ADJUST & MINOR REPAIR:- Minor repairs if Trained Experienced Performs safety Simple tool required Not longer than 20/30 minutes

CRONIC DEFECTSCHRONIC LOSSESRemedial action Unsuccessful LOSS ISRECOGNISED LOSS ISUNRECOGNISED Remedial action Can not be takenRemedial action is not taken

EQUIPMENT IMPROVEMENT:-1. Restore obvious deterioration throughout.2. Establish plan select pilot area, determine bottleneck.3. Study and understand the production process.4. Establish goals for improvement.5. Clarify the problem, collect the reference manuals contact resources.6. Conduct evaluation through such techniques as RCM analysis, FMECA, FTA (Root cause failure analysis).7. Determine improvement priorities, costs and benefits.8. Execute improvement in pilot area standardize technique and document what you have done.9. Monitor results and optimize based on those results.10. Implement plant wide

EQUIPMENT RESPONSIBILITIES OF OPERATOR:-

Operation with the proper standard procedure. Failure prevention. Failure resolution. Inspection. Equipment up keep. Cleaning. Lubricating. Lightning fasteners. Minor repairs. Trouble shooting.

CHAPTER-16BIBLIOGRAPHY

Following different references are taken while collection and manufacturing Literature and project: -

1. WORKSHOP TECHNOLOGY HAZARA CHOUDHARY2. ELECTRICAL MACHINE DESIGN A.K.SAWHNEY3. MACHINE DESIGN R.S. KHURMI4. PRODUCTION TECHNOLOGY BANGA AND SHARMA5. PRODUCTION PLANNING AND CONTROL BANGA AND SHARMA6. METROLOGY & QUALITY CONTROL R.K.JAIN7. www.google.com8. www.altavista.com

LIST OF SUPPLIERS

ADDRESSES OF SUPPLIER

ESBEE ENGINEERING.Authorized Dealer & Distributor; pumps & accessories2, Amrapli, 90 Feet Road, Mulund (E) Mumbai 400081.

VENUS NUT BOLT MFG . COManufacturer of All Types of Nut & Bolts30, Trimbak Parshuram Street, Kasam Building, 6th KumbharwadaMumbai 400004.

PRABATH METAL CORPORATION.Suppliers Of: - S.S.Steel Rod, Aluminum, Brass, Copper, M.S Angle, M.SChannels, Ms SheetPatrawalla Chawl, 169, Trimbak Parshuram Street, Kasam Building, 6thKumbharwada Mumbai 400004.

RELIANCE TOOLS & BEARING.Dealers in All Kind Of: - Ball Roller & Tapered Bearing163 Mutton Street, Mumbai 400003.