Paper cutting & rewinding machine project report sreesangh p ghosh

PAPER CUTTING & REWINDING MACHINE Project Report

2012-13

ACKNOWLEDGEMENT

I am very glad to represent project report on "PAPER CUTTING AND REWINDING MACHINE" fully designed, fabricated and tested in our polytechnic as part of our curriculum is awarding the Diploma in Engineering. I have tried my level best to focus upon each and every parameter. In concern with this topic the detail, necessary figure, definition, tabular analysis has been enumerated in very easy, simple, compact and lucid manner.

I have been able to achieve this task by the dynamic guidance of honorable SIVARAMAN sir; I have no wards to express my gratitude towards his kind, persistent inspiration, parent advice and outstanding treatment while clarifying my confusion.

I also extend my sincere thanks to our esteemed Head of Mechanical

Engineering Department Mr. M.R JAYACHANDRAN, whose guidance and constant inspiration where a great use in working of this project. We are also grateful to our tutor MR. P.P. DEVADAS.

I am also grateful to our honorable work shop superintendent

Mr.N.M.SATHEESAN and members of staff of our workshop for providing numerous facilities and guidance due to which this difficult task turned in a convenient task.

The permission granted to us by the honorable principal

Mr.V.V.SADASIVAN, to do the project work in greatly acknowledged. Last but not least, I am very thankful to my project partners without whose

kind cooperation it was difficult and impossible to go through the leaps and bounds while preparing this project. Also thanks to them who directly or indirectly co-operated and contributed during work.

Triprayar SEVENTH BATCH 03/13/2013 Mechanical Engineering

Department of Mechanical Engg. S.R.G.P.T.C Triprayar Page 1


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ABSTRACT

Paper Cutting & Rewinding Machine is one of the simplest machine which cuts

rolled paper in needed amount and re-winded form. The conventional paper rewinding

machine has complex mechanism and bulk size. We made some modification to the

conventional machine and eliminating its defects. The main peculiarity of machine is its

simplicity, reduced size, weight. And also reduces floor space. This project can be

directly implemented to paper cutting and rewinding machines in Paper mills. This

machine can also use in textile mills, plastic and rubber sheets cutting and rewinding

process in various industries by changing its cutting components.

By applying these modifications to the conventional machine reduce

maintenance and servicing cost, floor area and overhead expenditures. It is well suited

for small scale industries.



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CONTENTS TOPIC NO. TOPIC NAME PAGE-NO.

1. INTRODUCTION 4

2. ORGANISATION FOR FINANCIAL ASSISTANCE 6

3. FINANCIAL MANAGEMENT 12

4. MARKET SURVEY 13

5. SMALL SCALE INDUSTRIES 17

6. SITE SELECTION 20

7. CHARACTERISTICS OF MATERIAL & WELDING 28

8. COMPONENTS OF MACHINE 30

9. MANUFACTURING PROCESS 35

10. WORKING OF MACHINE 42

11. PROCESS OF MANUFACTURING 43

12. ADVANTAGES & DISADVANTAGES 46

13. SPECIFICATIONS OF MACHINE 46

14. DRAWINGS 47

15. MATERIAL REQUIREMENT & COST 49

16. BIBLIOGRAPHY 51



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INTRODUCTION

Definition Of Project :- A project is a group of unique, inter-related activities that are planned

and executed in a certain sequence to create a unique product or service, within a

specific time frame, budget and the client’s specifications. Some of the

characteristics of the task that qualify to be projects are:

1) Unique Activities

2) Attainment of a specific goal

3) Sequence of activities

4) Specified time

5) Interrelated activities

The success of the project is depending on the ability to strike a balance

between the following interrelated variables or constraints that are:

1) Scope of product

2) Quality of product

3) Cost (design cost, material cost, Service & Transportation charges)

4) Time (lead time, manufacturing time)

5) Resources



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AWARENESS FOR PREPARING A PROJECT REPORT

A project is investment activities where resources are create some capital assets

that will produce some benefits over a spread of time. Every project will definitely have

the following characteristics.

1) It will be specific in its activity, good and planning and performance.

2) A project will be continues process.

3) There will be an effort to identify and quantify in monitory terms for cost

benefits analysis.

The whole cycle of a project has to come through seven different stages

1) Containing of idea (identification of an activity)

2) Formulation of a scheme (here we prepare the project report)

3) Project reports Appraisal

4) Project monitoring

5) Implementation

6) Evaluation of the project implementation

7) Taking corrective measures for improvement

A Project Report needs to cover from very general information up to detailed

examination of specific issues relating to entrepreneurs profile with special reference to

these academic qualifications past experience and competence, comprehension and

confidence, market demand and existing sources of supply of the products proposed,

technological requirement, plant and machinery, cost of production profitability and

financing pattern etc.



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The important uses of project reports are:

1) It helps in obtaining provisional /registration.

2) It helps com procuring developed land or shed forgot.

3) It helps in securing supply of scarce raw materials.

4) It helps in approaching tank for getting loan (term/working capital)

5) It helps the entrepreneur is establishing techno-economic liability of the project.

6) It helps the entrepreneur to plan the sequence of operation you’re the

implementation of the project.

Once a project has been identified the first step is to find out the price of

machinery and raw materials. Get the latest quotations for the machineries.

After ascertain the price of plant, machinery and raw materials. Find out the mages of

employees prevalent in the area. Now calculation regarding the profit return and break-

even point etc. has to be done.

A detailed market study had to be conducted and the same should be

incorporated into the project report (it is a must when the project cost is over 20 lakhs).

The market study should certain in the total demand for the product and present

manufacturers of the product, their installed capacities. Marketing arrangement

including channels of distribution, logistics, etc.

The financial institutions on the receipt of project report are interest in

appraising the project from the following angles.

I. Technical area

II. Economic area

III. Commercial area

IV. Financial area

V. Managerial area and

VI. Social area



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GENERAL ASPECTS OF A PROJECT

Up on the completion of the project the students will be able to:

1) Practice in machine drawing

2) Practice in selecting the right materials

3) Practice in are welding

4) Practice in painting

5) Practice in turning operation

6) Practice in thread cutting

I. Topic covered:

1) Selection of the materials

2) Arc welding

3) Types of fits

4) Types of threading

5) Estimating and costing

6) Quality control

7) Production drawing

II. Equipment and tools:

1) Machine shop tools

2) Fitting shop tools

3) Arc welding equipment

4) Painting equipment

5) Gas cutting equipments



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Procedure for Design of Machine Elements :-

The design of machine element is the most important step in the complete procedure of machine design. In order to ensure the basic requirement of machine elements, calculations are carried out to find out the dimensions of the machine element. These calculations form an integral part of the designing of machine elements. The basic procedure of the design of element is as follows:

1) Determine Forces Actin on Element.

2) Select Suitable Material for Element.

3) Determine Failure Mode Of Element.

4) Determine Geometric Dimensions of Element.

5) Modify Dimensions for Assembly and Manufacturing. 6) Prepare Working Drawing of Element.



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ORGANISATION

FOR FINANCIAL

ASSISTANCE



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FINANCIAL ASSISTANCE AVAILABLE TO SMALL SCALE INDUSTRIES IN KERALA

For healthy growth of small scale industries it is necessary that they adequate financial assistance may be made available to them at appropriate time. They are number of agencies at centered and state level providing financial assistance to small scale industries in Kerala- some of them are,

1) KERALA FINANCIAL CORPORATION LIMITED

They provide financial assistance for setting up new industry or for expansion, diversification, modernization or renovation of existing ones assistance from the corporation’s available for the following activities.

1. They require testing or servicing of machinery of any description vehicles vessels, motor boats and trailers tractors.

2. Mining, hotel industry etc.

2) TECHNOCRAFT ASSISTANCE SCHEME Under the scheme financial assistance to the extent of 90% of the fixed

cost of this. Project subjected to a maximum of Rs.20 lakhs one in the case of techno craft is available to technically qualified entrepreneurs who set their units. 3. KERALA STATE DEVELOPMENT CORPORATION FOR SCHEDULED CASTE AND SCHEDULED TRIBES LTD. 1. Loan for small business trade or industry 2. Margin money loan for starting industries 3. Supply of machineries for productive purpose 4. Loan to encourage traditional industries



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BANK

State bank of India operates a scheme of coordinate credit assistance to small scale industries. The financial assistance is provided to craftsman and technical qualified entrepreneurs who have sound project and are not able to provide what is called ‘owner equity ’ of minimum capital usually required to secure loan.

Other facilities available to the small scale industries in Kerala facilities for incentives available from the state governments are :- 1. Subsidiary to meet the cost of project reports 2. Subsidiary to meet the cost of technical knows how 3. Modernization subsidy 4. Assistance of development of prototypes 5. Electricity duty concession FACILITIES AVAILABLE FROM CENTRAL GOVERNMENT

The small scale industries assistance mainly from the following financial bodies, 1. Kerala financial corporation (KFC) 2. District industrial Centre (DIC) 3. National small scale industries corporation (NIC) 4. Industrial cooperative bank



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FINANCIAL MANAGEMENT



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INTRODUCTION

Every business enterprise erective of its nature and scale of business needs finance to carry out its activities and accomplish certain business objectives. No business venture can assure can succeed unless it has enough money to take advantage of any opportunities that may arise. Finance is the life blood of any business.

The management of finance therefor plays a key role in the anticipation of financial needs, acquiring financial resources and allocating funds in the business. In fact it determines the success or failures of any business activity. The economic objectives of a business organization are profitable, growth and survival. The attainment of these objectives largely depends up on the efficient management of finance.

Financial management basically deals with procurement of funds needed by the enterprises on the most favorable terms in the light of their objectives. It is only concerned with effective procurement of funds but also on the efficient utilization of funds.

DEFINITION

The finance function is concerned with the process of acquiring and efficiently utilizing the funds of a business system, with the objective of maximizing the value of firm. Financial management involves the application of general management principles to the financial function.

According to hog land, ’’financial management deals with how the corporation obtains the funds and how it uses them’’.

Financial management may also be defined as that part of management, which is concerned mainly with raising the funds for the enterprises in the most economical manner, utilizing those funds are profitably as possible for a given risk level, planning future investments and controlling current performance and the future development through financial statistics and other means.

FUNCTIONS OF FINANCIAL MANAGEMENT

The financial management begins a strategic and key area of

management involves variety of functions form the view point of effective management of finance, the finance function can be categorized as 1. Executive finance functions. 2. Routine finance functions.



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EXCECUTIVE FINANCE FUNCTIONS

1) DETERMINING FINANCIAL NEEDS

The anticipation of the total finance need of the organization is also

known as the ‘capitalization division’. It means determining total financial requirements of an organization in terms of long – term requirements. This key is a division, which decides the size of the organization and the scale of an operation. Sometimes the top management prescribes the maximum limit on the total financial requirement should be very carefully anticipated, otherwise it is likely that the organization may face a situation of over capitalization (i.e.; available of more funds with little chance of their profitable investment) or under capitalization (i.e.; sacrifice of profitable channels of investment due to in adequate funds)

2) DETERMINING CAPITAL STRUCTURE AND SOURCE OF FUNDS

The capital structure and source decides the blending owned and

borrowed funds in the total financial requirements. It also implies determination of the sources, timing and procedure to obtain funds, which an enterprise needs for its long terms and conditions of different financial resources very significantly depending up on the financial image of the enterprise. The financial management should have full knowledge of the different sources of funds along with their advantages and limitations to make use of them in the best interest of the enterprise. Different types of securities and debentures may raise the funds or they could be borrowed from financial institution or banks.

3) INVESTMENT DECISION (ALLOCATION FUNDS) Allocation of funds in business means investing them between the

different components of fixed and current assets. The investment in fixed and current assets must yield reasonable returns. The returns from the business operations using fixed and current assets must be sufficiently high to meet the case of raising funds. Assets are balanced by weighting their profitability against the liquidity; profitability depends up on the factors such as cost, control, pricing, forecasting, future profits and measuring the cost of the capital, liquidity cash.



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4) MANAGAMENT OF FIXED ASSETS

The investment in fixed asset as like land, building, machinery,

equipment, furniture, fixture etc. 60% to 80% of total investments. It involves long term commitment of funds for their purchase or replacement. This needs careful decisions after evaluating their utility and productive capacity. The investment in fixed asset is governed by the top level policies like owning the asset, to hire or to get it on lease, to make or buy the components etc. it also formulate the appropriate depreciation policies for the replacement of fixed assets.

5) ROUTING FINANCE FUNCTIONS

These are certain routine functions, which are falling within the

jurisdiction of the financial management. Generally, these functions are delegated to the subordinate staff in the finance department some of the important routine functions are,

Control on cash Custody and safe guard of the document Record keeping Management reporting

OBJECTIVES OF FINANCIAL MANAGEMENT

The objective of financial management may be such that they should be beneficial to the owners, management, employees and the customers. These objectives can be achieved by maximizing the value of the firm. Some of the important objectives of the dynamic management are: INCREASE IN PROFILES

A firm should increase its revenues in order to maximize its value. The

profits of the firm are maximized, when the firm is in the equilibrium. At stage in the average cost and the revenues are equal. REDUCTION INCOST

A firm should make efforts to reduce the cost of the capital and to launch

its economy in its operation.



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SOURCES OF THE FUNDS

A firm should make a judicious choice of funds so that they maximize its

value. The financial should carefully evaluate the financial risk involved before making an investment decision when achieving the goal of maximization of project or value of the firm. LONG RUN VALUE

The financial management should not only maintain the business in

sound financial health but also strive to produce a rate of earning which will reared the owners adequately for their investment and keep the business in sufficient liquidly for the confidence of its creditor and investors.

CAPITAL

In order to start to run a business i.e.; to produce and to sell goods or

services, money has to be invested the money invested in the business in order to yield an income is known as capital.

Capital is needed for the following purposes;

o Purchasing fixed assets (building, equipment, machinery, tools, furniture etc.)

o Purchase raw materials and other supplies o To meet the day expenditure such as wages of workers, selling

and distribution expenses, equipment and plant maintenance cost etc.

IMPORTANCE AND SCOPE OF CAPITAL

Capital plays a vital role in the life of modern productive system. Capital

is the life blood of any business production without capital is not possible. Nature cannot furnish goods and materials to man unless he has the tools and machinery, for mining, farming, forecasting, finishing etc. with the growth of technology and specialization, the capital has to play a vital role. Productivity of the modern economy is mainly due to the extensive use of the capital, i.e.; machinery tools or equipment’s in the productive system.

Capital is one of the important factors of production. It plays a strategic role in raising productivity. Economic development is not possible without making and using machinery, construction of irrigation work, the production of agricultural tools and implements, building dams, bridges and factories, railway, airports ships, harbors, etc. which are all capital.



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SMALL SCALE INDUSTRIES



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SMALL SCALE INDUSTRIES

Everybody knows that the major problem in our country is to give employment

for the unemployment youth. In order to create substantial employment opportunities, the new industrial policy lays stress on executive promotion and development of college and small-scale industry in the college and small-scale industry in the country. This will not only solve the unemployment problem. It also help to utilize the local resources where ever available. But unfortunately due to lack of proper knowledge among the entrepreneurs, the small scale industries get up by them may not be working economically due to various reasons.

One of the identification and selection suitable entrepreneurs are according to our opinion, the entrepreneurs starting small scale industries should be selected only by a component agency and proper project should be identified to him rather than going it for this opinion. ROLE AND SCOPE OF SMALL SCALE INDUSTRIES

The role of small scale industries in the national economy has been greatly appreciated and it has in to distinct entity of its own. The small scale industries provided rest scope of increasing employment. They are labor intensive and comparatively little capital to start with. They help production on prices, and they accelerate the rate of industrial growth. This help in equitable distribution of national wealth. PROCEDURAL STEPS TO SET AND MANAGE A SMALL SCALE

INDUSTRY

The steps involved to start small scale industry are conduct market survey and study the products as regard their demands in the market and select one of them. The selection of production is guided by,

MARKET ABILITY

It is very essential to know Present users and prospective users of the proposed products. Demand for the product in the state and side the state. Study the similar products available in the market that can be competitors.

analyses them as regards their utility, quality and cost. Check whether it is seasonal product or it has throughout the year. Find whether the product can be exported.



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PROFITABITITY

Any product proposed to be manufactured should ensure reasonable return on investment the manufacture of the product should be economical viable. The proposed product should have come out from the laboratory levels to exploitation. TECHNICAL FEASIBILITY

The proposed product should be technically feasible. It should be within the technological competency of the entrepreneur. STABILITY

The proposed product should have stable sails all the year round otherwise the cost of production may go up and make product unstable. This may cause difficult to plan May production and procurement program. In such cases it necessary to find out alternatives uses for man machinery and equipment’s during the slack season. REASONABLE GROWTH OVER TIME

The proposed product should give reasonable growth over a period of time in order to ensure a progressive return to the entrepreneurs. PROJECT CAPACITY

After conducting market survey the capacity of the project must be decided considering the amount of money can be arranged i.e.; by partnership, through banks, financial corporation or shares. While deciding the capacity of the project following are the factors which should also be considered.

1) Demand product 2) Whether the demand is regular or fluctuating 3) Quality of powder, water, land, material available 4) Nature of product



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SITE SELECTION



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SITE SELECTION

Having taken a decision to start a factory it is important to select a suitable site

or location. The site has great effect on the success or failure of the operation of the factory, so maximum importance should be given to the site selection. Therefore while selecting a site the owner or management must consider technical, commercial and financial aspects and then to select a site the owner or management must consider technical. Sometimes it is not an easy affair to find a place where possess all requirements. In such cases we have to analyses the merits and demerits of the place to be selected and taken a favorable decision.

The problem of site selection of factory can be solved in the following two

stages

A. The selection of actual site B. General location of factory

A. GENERAL LOCATION OF FACTORY

The following factors must be considered this regard. They are

1. NEARER TO THE RAW MATERIAL

As far as possible, the site selected should be nearer the source of raw materials. This will reduce the cost of transportation of raw materials from the place to the plant. Further if the raw materials are bulky and heavy it becomes very essential to select the site near it. This why the most of the iron and steel located in Orissa and Bihar due to proximity of the raw material such as coal and iron ore.

2. NEARER TO THE MARKET

The cost transportation of the finished goods and distribution cost etc. will be reduced if the factory is situated near the market. The goods can be sold at cheaper rate and moreover it will be help in quick service to customer. Their requirements also studied.

3. TRANSPORTATION FECILITIES

Transportation costs play a very important role then we have to see that the cost of transportation should remain fairly small in production to the total cost depending upon the order of raw materials and finished goods. A suitable method of transportation like road, rail, air and water is selected and accordingly the plant location is decided.



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4. AVAILABILITY OF CHEAP AND EFFICIENT LABOUR

It is necessary to consider that whether right kind of labor cost is an important

item of the total production cost in manufacturing a product.

5. AVAILABILITY OF PURE WATER All factories need soft and pure water for various uses as chemical industry

require a large quantity of water for processing, so should not be set up at a location which is famous for storage, if pure water is not available in one location of water to the location.

6. AVAILABILITY OF POWER AND FUEL

Due to development of electricity this factor has not much effect. Even then we

have to see that where the electricity is cheaper but most of the steel industries are located near the source of fuel.

7. CLIMATIC CONDITIONS

It is governing factor for fuel several industries, textile factories require moist

climate that is why most of the textile mills have been located at Bombay and Ahmadabad but now a days with the use of air conditioning facilities it has been possible to control the atmospheric moisture content in the factory according to the requirements.

8. LAND

Topology, area and shape of the site, cost drainage and other facilities are also to

be considered at the time of the site selection.

9. COMMERCIAL FACILITIES

Availability of the financial and banking facilities is an important factor, since the factories require a constant feeding of working capital this is considered to the most.

10. EXISTANCE OF RELATED INDUSTRIES

Specially, increase of small scale industries, repairing is a problem if such

facilities are in the existing area repairs are carried out immediately without affecting production target. The factors like local bylaws, fire production, hospital, school and security etc should be considered.



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B. THE SELECTION OF ACTUAL SITE

The most important factors in this aspect are as follows

1) The availability of cheap land to build and expand the plant in future. 2) The cost of leveling the land and providing foundation subsoil and drainage. 3) Cost of building materials like granite, bricks, literate sand and cement, lime. 4) Facilities for transport in getting and sending materials. 5) Facilities for housing the workers and if necessary, 6) Cost of installation of electricity, gas and other facilities. 7) Cost laying the water supply and providing the sewage. 8) Cheap possibilities of disposing of trade waste efficient treatment. REGISTRATION OF PLANT

The next step is to ensure the implementation of the project. If in case, the

entrepreneur is interested in getting financial assistance from institutional agencies, it is necessary for him to prepare and submit a feasible project report for their acceptance.

To apply and avail of the various facilities, incentives and assistance available from various instructions like district industrial Centre, national small scale Industries Corporation and various financial institutions. It is necessary for the unit to itself registered with director of industries and commerce. The registration of the unit is done in two stages via 1) Provisional registration 2) Regular registration PROVISIONAL REGISTRATION

Provisional registration is meant to enable party to make necessary steps during the unit into existences. A provisional registration is valid up to six months and it can convert to regular registration later on. The provisional registration entities the part to i. Apply for a shed in an industrial state, developed site in an industrial area/ material for the construction of the shed, as the case may be. ii. Apply to corporation, municipal/ panchayath other local authorities for construct the establish a unit. iii. Apply for power connection iv. Apply for the financially institution on the basis of a project may require by them v. Apply to the N.S.L.C/S.S.L.C/ other institution for procuring machinery in hire purchase basis. vi. Obtain sales tax, exercise, and duties etc. registration whenever required.



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REGULAR REGISTRATION

When the party has taken all steps for establishing the unit, i.e.; when the factory

building is ready, power connection is given the machinery has been installed etc. and he can apply for the machinery has been installed etc. and he can apply for the regular registration of the unit. Within the seven days on the receipt of application, the district industries officer or other designed officer will inform the party to the date and time for inspection of the unit. On being satisfied that the unit is capable of production activity, a registration certificate is issued by the directorate of industries and commerce. MANAGEMENT

It is easier to a new unit, than to manage it successfully managing a unit is a

continuous process; the entrepreneur should have initiative, drive clarity of ideas and should be in a position to enlist the cooperation of the workers to achieve the common goals in order to achieve this goal, the entrepreneur must be in a position to manage all this firm i.e. manage all the things come in action successfully. His success depends upon the attention that the entrepreneur pays to the various things, problem like arrangement of raw materials, scheduled production, proper management of labor, timely arrangement of finance, to the scheduled and asserting to cost of production.



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MARKET SURVEY



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INTRODUCTION

Market survey is a scientific study of all problems relate to the transfer

and sale of goods produced from producers to consumers. Market survey provides necessary statistics helpful for forecasting and planning a project before starting a business, market survey is very essential to know about what must be produced, how much be produced, who are the purchasers, and where they are located, margins of profit etc.

Thus the main object of market survey is find out the future of the proposed products in the initial stage preliminary survey is done by some experienced analyst and if this preliminary survey supplies sufficient information that there is no profitable market for the product to be manufactured then further detailed survey is not required. If preliminary survey provides some hope then only detailed survey is done.

The following points area of the most importance while making market

survey.

1) Demand for product in the market. 2) Selling method to be adopted. 3) Possible new market for the products. 4) Comments of customers for the product. 5) To see that existing size, quantity and design suit the consumers or not.

USEFULNESS OF MARKET SURVEY

Helps the entrepreneur to know the market potential for his products(s). To know other competitions producing the same product(s). Fix the production rate proportional to consumers demand. Helps in fixation of price in accordance with demand. Accelerate sales. Helps to discover new market opportunities Induces confidence in entrepreneur to make investments in production. Helps in predicting changes in market. I.e. Sales position or

expansion/shrinkage for a particular product. Reveals customers’ requirements, tastes, purchasing capacity,

preferences for a particular brand, buying motives and habits etc.



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STEPS IN MARKET SURVEY

Typically a market survey consist of the following steps

1. Define the target group or population. 2. Selection of sampling scheme and sample size. 3. Preparation of questionnaire. 4. Recruiting and training field investigators. 5. Obtaining information from responses by target group in the questionnaire. 6. Security of information gathered in the survey.

MARKET RESEARCH All industries enterprises it develops product for direct market applications without having any idea in advance of consumer acceptance of the product takes quicker risk. On the country another concern lends to learn consumer action to product prior to manufacturing the same.it does not involve any risk associating high expenditures. Market research may be defined as organized approach which includes all our research activities involved in the market. 1) Gathering recounting and analyzing the activity and marketability of the Product. 2) The nature of the demand 3) The nature of completion 4) The method of marketing 5) Other aspects of movements of problems from the stage of production to the point where they consumed. Market research provides an effective sales forecast. It also promotes soundness of marketing decisions.



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CHARACTERISTICS OF MATERIALS AND WELDING

PROCESS Plain Carbon Steels :-

Depending upon the percentage of carbon, plain carbon steels are classified into following three groups:

a) Low carbon steel b) Medium carbon steel c) High carbon steel

Low carbon steel: -

They contain less than 0.3% carbon. It is popular as 'mild steels'. Low carbon steels are soft and very ductile. They can be machined and welded easily. However, due to low carbon content, they are unresponsive to heat treatment. So M.S is used for project.

Strength of Welded Joints:-

Welded joints are classified into following two categories:- a) Where strength of weld is more than the strength of parts joined together. b) Where strength of weld is less than strength of parts joined together. In first category the failure occur in the parts joined together by weld while

in second one it will occur in the weld deposit. Strength of weld deposit is more than the strength of connected parts under the following conditions:

a) The components are mead up of mild steel with less than 0.3% of carbon. b) The welding electrode contains 0.15% carbon. c) Electrode is coated resulting in shielded wilding. During the welding process coating on the electrode gives off an inert gas

which acts as a shield, protecting the arc from the surrounding atmosphere. Coating also forms the slag on the molten metal and protects it during cooling process. When components are mead up of material such as high carbon steel or alloy steel the weld deposits is weaken than the strength of connected components.



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WELDED JOINTS OFFER FOLLOWING ADYANTAGES

COMPARED WITH OTHER JOINTS:

a) Riveted joints required additional cover plates, gusset plates, straps, clip angles and a large number of rivets that increase weight.

b) Due to elimination of these components cost of welded assembly is lower than that of riveted assembly.

c) Welded structures are lighter than corresponding iron casting by 50% and

steel casting by 30%.

d) Welded structure has smooth and pleasant appearance; the projection of rivet head adversely affects the appearance of riveted structure.

e) Strength of welded joint is high, very often the strength of weld is more than

the strength of the plates that are joined together.

f) Machine components of certain shape such as circular steel pipe find difficult in riveting, however they can be easily welded.

Stress Reliving Of Welded Joints:-

Welded joints are subjected to residual stresses due to non-uniform

heating of parts being joined. There is always possibility that localized thermal stresses may result from uneven heating and cooling during fusion and subsequent cooling. This is also results in distortion. The magnitude of residual stresses cannot be predicted with any degree of certainty. This is the major disadvantage of welded joints. Following two methods can reduces the residual stresses. a) Preheating of the weld area to retarded cooling of the metal in the

vicinity of the joint. b) Stress reliving of weld area by using proper heat treatment such as

normalizing and annealing in temperature range of 550 C to 675° C.

One of the methods of stress reliving is 'hand peening'. It consists of hammering the weld along the length with peen of hammer while joint is hot. It reduces residual stress and induced residual compressive stress on surface. This improves fatigue strength of joint.



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COMPONENTS OF PAPER CUTTING &

REWINDING MACHINE



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COMPONENTS OF PAPER CUTTING & REWINDING

MACHINE

The main components of Paper Cutting & Rewinding Machine are listed below. 1) BASIC FRAME

The entire unit is mounted on a rigid frame. The frame is made of

mild steel C- Channels (75X40 mm) connected in rectangular form and weld at their joints.

2) ROLLERS

The paper rotating element in this device is the ϕ 89 mm outer

diameter rollers with ϕ 40 mm outer diameter journals, which made up of three components.

1) G. I Hollow Pipe of ϕ 89 mm outer Diameter. 2) M.S Rod of ϕ 40 mm Diameter. 3) M.S Circular Plate of ϕ 81 mm Diameter.

The rotation of motor is transferred to the one of the four rollers on which cut paper is mounting in operation. The rotating roll makes all other three rollers to rotate. The roller is supported at its two ends by Plummer block with ball bearing blocks. The main functions of roller are to favor the cutting operation by moving paper and rewind it to rolls.



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4) PLUMMER BLOCK

The roller is supported at the two

ends with the help of Plummer block fitted with ϕ 40 mm diameter Ball bearings. The bearings are cleaned and greased for easy rotation of roller.

5) BEARINGS

Ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.

The purpose of a ball bearing is to reduce rotational friction and

support radial and axial loads. It achieves this by using at least two races to contain the balls and transmit the loads through the balls.

In most applications, one race is

stationary in Plummer block and the other is attached to rollers journal. As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other

kinds of rolling-element bearings due to the smaller contact area between the balls and races. However, they can tolerate some misalignment of the inner and outer races.



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6) INDUCTION MOTOR

An induction or asynchronous motor is an AC motor in which all electromagnetic energy is transferred by inductive coupling from a primary winding to a secondary winding, the two windings being separated by an air gap.

The machine is powered by 1 Hp motor with 1440 rpm. This makes

one roll rotates and rotating roll makes other rollers to rotate and not only wound the paper but also pull the paper to make the operation going. 7) SINGLE V-BELT AND PULLEY SYSTEM

Vee belts (also known as V-belt or wedge rope) solved the slippage and alignment problem. It is now the basic belt for power transmission. They provide the best combination of traction, speed of movement, load of the bearings, and long service life. They are generally endless, and their general cross-section shape is trapezoidal (hence the name "V").

The "V" shape of the belt tracks in a mating groove in the pulley (or

sheave), with the result that the belt cannot slip off. The belt also tends to wedge into the groove as the load increases-the greater the load, the greater the wedging action, V-belts may be homogeneously rubber or polymer.

Belts are looped over pulleys. The belt drives the pulleys in the same

direction. As a source of motion, the belt is one application where the belt is adapted to continuously carry a load between the motor and pulley fitted on the roller.



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8) CUTTER CLAMP (C-CLAMP) WITH BOLTS C-clamp with the two bolts are used to clamp the cutter to the frame and one extended piece of flat for mounting of cutter.

9) NUT AND BOLTS Bolt, is a type of fastener characterized by a helical ridge,

known as an external thread or just thread, wrapped around a cylinder.

A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a mating bolt to fasten a stack of parts together. They are made up of Mild Steel. Nuts and Bolts of different size is used for fixing the Plummer block to the main frame and to install the cutter clamp.



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MANUFACTURING PROCESS



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MANUFACTURING PROCESS

I. STRUCTURE FABRICATING PROCESS :-

For structure fabrication, the c-channel of size 75 X 40 mm is used. The approximate wt. of it per meter is 6.8 kg. Steps in fabrication of structure are given below.

Step One:

First cut the c-channel in pieces of length 71" (i.e. 6 feet [180 mm]- two pieces)

and in 36" (i.e. 3 feet[91.5 mm] - three pieces). Then Put the two lengths of 6 feet parallel to each other at a distance of 3 feet from each other. Then put the lengths of 3 feet on either end of two parallel lengths and weld them as shown below. The two diagonals must be same.

Step Two:

Then cut four pieces of c-channel of length 24" (i.e. 2 feet[61 mm]) and weld

two of them on one end of rectangular structure vertically using engineers block. Then weld remaining two pieces vertically at a distance of 30" from previous pieces. Step Three:

Then brought the two pieces of flat of size 75 X 12 X 760 mm and weld them on

the top of four columns as shown.



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Step Four:

Then cut another two pieces of

length 48" (i.e. 4 feet[122 mm]) and weld them vertically at a distance of 16" from previously welded columns. Afterwards weld the previously cut piece of 36"[41 mm] on top and in between the upper ends of these columns.

Step Five: Then cut two pieces of C-channel of

length 15". And four pieces of 4" length. Then at a distance of 4.5" from nearest end weld them to form a frame as shown below.



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II. ROLLER MACHINING PROCESS

Roll is mead up of hollow pipe, solid circular plates & solid shaft journal. So we have to manufacture each part as per required size and then assemble it as a roll. Steps in this task are:-

Step one:

First, brought the hollow pipe of required dimensions. I.e. of required outer, inner and length. If it not available, then cut it on hacksaw machine.

Step two:

Then brought two circular plates of 10 mm thickness, face them from both

sides by holding them on lathe machine. And turn out to the diameter as equal to inner diameter of hollow pipe so they can fit into pipe for welding purpose.

Step three:

Take solid bar of M.S. of 50 mm diameter cut it to length 110 mm. Hold this bar on lathe chuck and turn it out up to the diameter 38 mm so that it can be fit in pedestal self-aligning bearing block.

Step four:

Now, weld the turned solid bar to each of two s o l id circular plates axially.



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Step five:

Now, weld these plates in the bore of hollow pipe.

Step six:

The roll is completed, but because of welding different parts it

need to be turned again using lathe machine. Hold the journal on one side in chuck and turn the other journal as well as hollow pipe part of roll. Do the same operation by holding other journal in chuck so the roll will rotate along its axis accurately.

GROOVE FOR WELDING THE M.S ROD AT CENTRE-



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III. CUTTER CLAMP MAKING PROCESS

The c-clamp with the two bolts to clamp and one extended piece of flat for mounting of cutter is welded. It is used to hold the cutter. Step One:

First take the flat of 25 X 10 and cut it by bend saw in size of 90 mm,

65mm, 60 mm and 40 mm. Step Two:

Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of 40 mm

in length and weld it on the 65 mm side of clamp. Step Three:

By using drilling machine, make three holes of 10 mm at the points shown below in the complete assembly of cutter. Afterwards perform the tapping operations using tap of ½ inch.



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IV. DRIVING MECHANISM

As our project as a demo and also designed for small weight

we use the 1 Hp A.C. motor. It is having the 1440 rpm speed. We use two pulleys of three [7.62 mm] & eight [20.32] inch diameter respectively on motor and roller. One on the motor shaft and another is on the shaft of roll. The numbers of belts required for given application is one. V-belt is used for this purpose.



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V. WORKING OF MACHINE

As we give number of modifications it is necessary to briefly

explain working procedure of machine. When the paper being manufactured in paper mill it is not of standard size an also get torn out at the edges. And here is the need of re-winding machine. The roll of paper manufactured is mounted on the roll (A). In our machine we have given the self-aligning bearing with inner extended ring for ease in mounting and urn-mounting.

Then paper is passed around roll (B) to ensure that paper remain

straight and tight. Then it passed through the cutter and grooved roll on top of machine, where it is cut. Because of our modification to this cutter roll the wt. of machine is decreased.

Then the paper which is cut is come to the roll at bottom, The roll is

powered by 1 Hp motor with 1440 rpm. This rotating roll makes other roll (C) to rotate and not only wound the paper but also pull the paper to make the operation going.



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PROCESS OF MANUFACTURING



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Various manufacturing process combines together in the production

of this machine. Each product however, has its own place and can particularly be adopted to get a certain specifications. The following operations are adopted for the manufacturing of Paper Cutting & Rewinding Machine. Marking :-

This is the process of dimensioning the raw material to the required

size. This is usually done by scriber and steel rule. After marking, the lines are punched by using a dot punch. Cutting :-

Cutting is used for the separation of parts. This operation has been adopted on the following items:

C-Channel, M.S Flat, M.S Rod, G.I Pipe, M.S Circular Plate, Cast Iron Block. Grinding :-

Grinding operation are used for finishing the surfaces which are previously file or cut by a hack saw. Grinding is also for removing excess material and foe smoothing the sharp curves of the welded portion. A grinding machine which is either fixed or flexible is used for the above operations. Welding :-

Welding is the process of making a permanent joint by establishing inters atomic bonds between two or more pieces of metal by using heat and pressure, with or without using filler metal. It is the essential part of our project.

Welding is used to make the frames, clamps, rollers and installing blocks etc. Drilling :-

It is the process of making holes in the desired position. For

fixing clamp to the frame by bolts has been done.



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Lathe operations :-

The most essential part of the manufacturing of Paper Cutting & Rewinding machine is the lathe work. The roller making and boring pulleys are done by lathe work. The main operations included in the lathe work are turning, drilling, chamfering etc. Cleaning :-

Cleaning consist of removing the chips, Fluxes, Scraps and many other waste particles from the production area. Inspection :-

After the manufacturing of various parts it requires inspection on whether it is within the limit or not. For this gauges and other precision instruments are used. Assembling :-

This is the process of joining all the components together to get the complete product. That includes fixing bearing to the roller, installing Plummer block & clamp etc. Painting :-

This is the process of polishing and finishing work of the product. It prevents the corrosion of the parts of a machine. This forms the final phase of production.



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Advantages

1) It is more compact as compared with conventional one. 2) Operation is simple Because of eliminating complex mechanisms. 3) Saving of floor space as motor is adjusted inside the structure. 4) New cutter clamping assembly given will eliminate the biggest disadvantage of machine i.e. high weight.

Disadvantages

6) When the winding and cutting operation is going on there is no way to find that how much paper had been wound and how much is remained.

SPECIFICATIONS OF MACHINE

Length 6 feet ( 152.4") = 387.096 mm

Width 0.914 feet ( 36") = 91.44 mm

Height 4 feet ( 48" ) = 121.92 mm

Components 4 Hollow rolls, 8 Plummer blocks,8 bearings

Motor 1 Hp, 3 phase, induction motor



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DRAWINGS



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MATERIAL REQUIREMENTS & COST

SL No. DESCRIPTION QTY. RATE AMOUNT

1 760 X ϕ 89 mm G.I Pipe(4 No’s ) 25 Kg. Rs. 81 per Kg. Rs. 2025.00

2 M.S. Rod

135 mm X ϕ 50 mm

24 Kg.

Rs. 58 per Kg. Rs. 1392.00

3 M.S Circular Plate 12mm X ϕ 90 mm

(8 No.) 7 Kg. Rs.58 per Kg. Rs. 406.00

4 M. S. Flat 12 X 75 X

760 (2 No

11 Kg.

Rs. 58per kg.

Rs. 638.00

5 C-channel 75 X 40 ( 12.2 meter )

76 Kg.

Rs. 58 per kg.

Rs.4400.00

6 Plummer Blocks

No 208 i.e. ϕ 40 mm

8 No. Rs.200 per block

Rs.1600.00

7 Bearings ϕ 40 mm

Inner 8 No. Rs.30 per Bearing Rs. 240.00

8 Pulleys 3"

Pulley 8"

1 No.

1 No.

Rs. 240 per Pulley

Rs. 540 per Pulley

Rs. 150.00

Rs. 540.00

9 V- Belt of B-type 1 No. Rs.180 per Belt Rs.180.00

10 Paper 4.1 kg Rs. 35 per kg. Rs.131.00

11 Motor 1 Hp Induction Motor (2nd Hand) 1 No. Rs. 2500 Rs. 2500

12 Travelling Charge --- ------ Rs.1,160.00 Total Rs.14,962.00



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CONCLUSION

The matters discussed in the earlier pages just have a broad outline for starting

and managing an industry in small scale sector. We have tried our level best to give a

clear picture about the needs, and requirement of industries which produces. We have

been made an attempt to reduce handling cost and material movement. The main

consideration in the layout and planning is practical rather than the accuracy of facts and

figures. It is hoped that the report will be an immersed us to all investigator Interested in

preparing the project. However it shall be always born business and practical standpoint

We hope that we can be proud of the efforts. We employing in getting this

project work completed. It helped us to study a lot of things and practice in various

techniques. We hope that this project will helpful to the students in polytechnic to

understand the working of “Paper Cutting & Rewinding Machine”. We will be grateful

those who have co-operated with us once again thanking them.



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BIBLIOGRAPHY

Forbes Marshall- Engineering Data Book Workshop Technology- B.S. Raghuwanshi (Vol. I & II)

Production Management- ICFAI University

Elements of machine design- V. B. Bhandari

Strength of materials- R. K. Bansal
