Ijraset Journal For Research in Applied Science and Engineering Technology

Abstract

The paper presents the development of a automatic operated compress which encompasses the design, fabrication and performance evaluation of the press. The components parts of the machine were designed using various design equations. The design results were used to select materials for various components. The detailed drawing of the developed machine was done using solid works software. In fabricating the machine, mild steel was used as the locally sourced material. The use of mild steel is due to the fact that its strength, rigidity and machinability falls within the design specifications. Some components of the machine developed include; the frame, working bed, and buttons (on / off ). Some of the bought out parts include: ram assembly, rotaey motor, pressure indicator. Here the automation of a pressing machine using electric rotary motor. Generally, the manual operation of the pressing machine is automated. The main objective is to reduce man power, cost, production time and to increase the quantity and quality of production. The existing system of pressing process are manual controlling of pressing and unloading and the chance of human errors and production time are more. In order to overcome these errors, we have designed this electric rotary machine pressing . The automatic press machines that are incorporated with a electric rotary motor are made for heavy-duty pressing operations. In a heavy-duty pressing operation, the production is bulky and precision is required.

Introduction

I. INTRODUCTION

Automation plays a major role in all fields, especially in the production field. In earlier days more number of persons was involved in production field. To reduce the time consumption and men power, the automation came into play.

In general industrial manufacturing, a press machine is used to exert high pressure onto or against the workpieces or the manufactured parts to change the materials into a desired shape or form. The pressing process is mostly done for nonmetal and metal also materials since the malleability of metal allows the materials to withstand the pressure without breaking apart.

In engineering, the pressing operations are conducted with automatic press machines which are usually hydraulically powered or mechanically powered. The automatic press machines that are incorporated with electric rotary motor are made for heavy-duty pressing operations. In a heavy-duty pressing operation, the production is bulky and precision is required.

A press machine, either the automatic press machine or the manual press machine, is also known as a forming press that is used in the modern manufacturing industry to deform a workpiece. This type of machine comes in with numerous styles and configurations, yet the anatomy of the press machines is similar.

II. LITERATURE REVIEW

This section highlights on reviews related to study and research such as journals, case studies, books, technical documents, and internet sources, that has been selected relavent to this project . firstly, an overview of design and development of new product which is, includes the product specification and requirement, concept selection, and various types of prototypes. Then, material used in press machine show the variety of materials often used.

Using the optimum resources possible in designing the Automated press components can effect reduction in the cost by optimizing the weight of material utilized for building the structure. An attempt has been made in this direction to reduce the volume of material, cost of the press and to make is portable.

Today I’d like to discuss Automated presses. Yes I know a broad subject so we are going to take it down to the basics give you a layman’s description and give you a little history. After searching the web and showing my findings to my techs the most basic description of a Automated press which is a machine tool and used in the manufacturing industry was found on wiseGeek.com here it.

“A automated press is a mechanical machine used for compressing non-metallic items. The force is generated through the use of motor to increase the power of a standard mechanical level. This type of machine is typically found in a manufacturing environment”

III. METHODOLOGY

In achieving the aim of his work, component parts of the machine were de-signed using various design equations. The design results were used to select materials for various components The  detailed  drawing  of  the  developed Automated press machine  was  done  using SOLIDWORKS software. In fabricating the machine, mild steel was used as the locally sourced material. The use of mild steel is due to the fact that its strength, rigidity and machinability falls within the design specifications. It is also available and cost effective.

IV. DESIGN AND ANALYSIS OF SOME COMPONENTS

Some components  parts  of  the  machine  developed  include;  the  frame  (stand,  base  support,  column,  top  plate), mounting  table,  working bed, ram  assembly, hand  lever,   pressure indicator.

A. Machine Frame

A frame is a structure on which main units of a machine tool are assembled. For this work, the frame was  designed  to  accommodate  ram  assembly,  hydraulic  pump,  oil  thank,  and  work  ing  table  (bed).  The design consideration is that of direct tension imposed on the pillars. Other frame  members  are  subjected  to  simple bending stresses.

Dimension of the frame,

Length: 750

Width: 750

Height: 650                                      

1. Material : Mild steel

Mild Steel: It contains 0.05 to 0.3 percent carbons it has for almost all purpose replaced wrought iron, its greater strength giving it under viable advantages. Mild steel can be rolled, wielded and down. It can even be cast, though not very successfully. Among its application are plates for ship building, bicycle frame tubes, mesh work, bolts, nuts, studs etc. solid and hollow constructional sections, sheet metal parts and steel castings such as flywheels and locomotive wheel centers.

B. Design for Bolts

The  diameter  of  bolt  was  determined  from  Equation (2)  according  to Khurmi  and Gupta, 2005:

V. DETAILED DRAWINGS OF THE MACHINE

The detailed Isometric view and Orthographic view of the machine are shown in Figure 2 respectively.

VI. MACHINE FABRICATION PROCESSES

The various processes used in the fabrication of this hydraulic press machine in-clude:   Measurement,   Marking   out,   Cutting,   Drilling,   Welding,   Fastening,   Grinding and Painting.

A. Technical Specification

1. Electric Motor, 2 HP
2.  With provide Plywood Board
3.  Forwarding and Reversing Switch
4. Make of Gears NTN / SKF / NBC
5.  With all Standard Accessories Complete

B. Assembly and Welding of Machine Components

In welding various components of this machine together, MIG Welding technique  was  used  because  of  the  ease  of  concentration  of  heat. Heat spread  reduces  buckling  and  warping.  The  heat  concentration  also  increases  the  depth  of penetration and speeds up the welding operation. The base which is made of  mild steel pipes was first set up. The base has a length of 750 mm, breadth of 25 mm and thickness of 04 mm. The column which is made of four pieces of vertical mild steel pipes was welded to the base that has been set up. Each of the pipe has length of 650 mm (vertical height), breadth of  25 mm and thick-ness of 04 mm. They were all welded to the base to form the column of the ma-chine.  Having  done  this, four pieces mild  steel angles  (length  of  750mm, breadth of 25 mm and thickness of 04mm) were welded to the top part of the frame.  With  all  the  major  frame  parts  in  firm  position,  the  frame  stand  was  welded  to  the  base  of  the  frame  to  provide  for  stability  of  the  machine  during  operations.

Two holes each of 06 mm in diameter was made on each of the column. This is to give room for adjustment of the bed (table).

VII. RESULTS AND DISCUSSION

The developed manually operated hydraulic press was achieved by following the stated objectives  of  this  work. The  machine  developed  was  made  from  locally  sourced materials. Mild steel was used in fabricating majority of the components of the machine. One important feature of this press machine is interchange ability of mould and die without dismantling the ram assembly.

Prior  to  machine  performance  evaluation,  machine  frame,  structural  members, weld, rotary motor, rod and gears mechanism were inspected in order to check for any  fault  or  leakages. Tests were carried out on the multipurpose press  machine  by  using  it  to  press  different  non-metals (materials)  at  maxi-mum  pressure.  The motorized press  machine  developed  was  used  to  perform  various  press  works.  The  machine  worked  without  any  challenge  as  there  was  no  distortion,  deformation,  no  weld  failure,  no  leakages  and  the  operation  of  rotary  motor,  ram  and gears  mechanism  was  quite  satisfactory  under  the  varying loads.

A. Advantages

1. Power accuracy, efficiency and easy maintenance.
2. With the introduction of automation systems, the pressing operation has becomes automated and the efficiency of production is highly improved.
3. Reduced maintenance
4. Easier feeding
5. Fewer errors
6. Wider variety

B. Future

1. Automated pressing machine used for shaped refractory. E.g. Replace friction presses, Solve law, Efficiency, High scrap rate and difficult employment.
2. Also known as a forming press, a is a tool used in the manufacturing industry to deform a non metallic material  under high pressure.

VIII. ACKNOWLEDGEMENTS

The  Guide  would  like  to  acknowledge  who  contributed  immensely to the success of this work.

We declare that no funding was received from any source as financial support for this research.

Conclusion

A automatic press machine has been developed. The machine was fabricated using locally made materials. The machine is capable of performing various press works. Various machine parts such as motor, hand buttons, ram assembly worked effectively and efficiently. Some of press work operations performed on the machine include: bending, drawing and stamping. Performance evaluation of the machine shows that it can compete favourably with imported press machines of the same designed capacity. The cost of developing the machine locally as at the time of fabrication was Rs. 13000 compared to the cost of purchasing the imported ones of same capacity which ranges from 80,000 to 1,00,000 excluding cost of importation. The development of more of this important workshop machine is expected to boost our local manufacturing industries.

References

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Copyright

Copyright © 2022 Ajinkya M. Rote, Aishwarya S. Harode, Diksha B. Chaware, Shivani P. Chavhan, Mohit K. Katole, Roshan R. More. This is an open access article distributed under the Creative Commons Attribution License, which permits unrestricted use, distribution, and reproduction in any medium, provided the original work is properly cited.