improvement in design of the manual small ... in design of the manual small press machine vivek...

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Int. J. Mech. Eng. & Rob. Res. 2014 Vivek Sharma et al., 2014

ISSN 2278 – 0149 www.ijmerr.com

Vol. 3, No. 3, July, 2014

© 2014 IJMERR. All Rights Reserved

Research Paper

IMPROVEMENT IN DESIGN OF THE MANUAL

SMALL PRESS MACHINE

Vivek Sharma1*, Suman Rani2 and Parvesh1

*Corresponding Author: Vivek Sharma � [email protected]

In an attempt to improve the accuracy and efficiency according to the requirement. No work isdone in proper designing of special manual machine press machine, these days, rather rule ofthumb prevails. To keep pace with company demands improvement in the design of the manualpress is needed. So I worked to improve the designing of the machine for getting the bestresults by designing the balls of cast iron that provides appropriate pressure to stop fluctuationin size of components. The specific dimensions of the press machine is as Improvement indesign of the manual small press machine for sheet metal job under 900mm2 area X 1mmthickness in stainless steel grade 304. Though in extreme case it can work even on 2.0 mmthick stainless steel of specified area, without any problem.

Keywords: Press machine, Balls, Cast iron, Manual

INTRODUCTION

There is an increase in technological methodsin all daily activities in the industries. This isdone to improve the quality, efficiency andcost deduction of a particular product. Manymanufacturer companies try to be up-to-datein their products’ improvement with thinkingthe effects on their customers. Although it isgood for customers side to have the latestversion of particular products but if theinterest of their valued current customers isto be put into consideration there should bea stand-by solution to their existing productsimprovement to suit the latest version to some

1 Ganga Institute of Technology & Management, Kablana Jhajjar.2 PDM College of Technology & Management, Bahadurgarh.

extent if not one hundred percent. This hasbeen one of the major problems of companiesnowadays because their equipment andcustomers to buy the new products anytimethey are released. This was the reason toexamine equipment modification machinesare very expensive and high maintenanceand the manufacturers should not expect the.

Fly Press

Fly press is a press machine which is usedto make some press and punch operationsin the industries. The main function of pressmachine is to punch or press the metal sheet

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or the specific portion of the assembly/workpiece which we are going to make with thehelp of that press machine. The basic pictureof the fly press machine used till now isshown. This type of fly press machine is usedfor the different purposes in the industries likejoint of the door. This press machine is widelyused in the small scale industries where thedemand of special item for the product ischanged time to time with the main product.If the new machine is purchased for each odditem than the regular demand, the cost of thatodd item is so high that the profit level ofindustry is down. So, after study the wholeworking of the industries I suggest an idea tosolve the problem up to some extend byimprove the design of that fly press machine.

Problems Facing the Company in

Using Existing Press Machine

Due to technological and industrial advan-cement, some of the old manual andhydraulic press attachments (e.g. made forodd design product) are not suitable for thenew big machines this causes a big problemfor the company because it means that theyhave to buy new attachments again for thenewly bought machine.

Another problem that the worker has toface while using the hydraulic press machineis that he must needed to trained with thathydraulic machine and also know the wholeworking process with the all workingconditions of electricity fluctuation,temperature etc. all this make the worker somuch costlier that the rate of that specificproduct is also so much high that the workingwith that is not suitable for the owner.

A common problem that we are going toface with the working with fly press is thatthe weight of the flywheel is fixed no changecan be done with that weight. Because thewhole fly press is made up of by casting .Sothe rigidity of the machine is comes in a formof a big problem regular product by thecustomer.

Suggested Solutions

1. Buying a new attachment for thedifferent product to be assembled. (Highcost)

2. Managing the old one with help of somesupports (Low efficiency and cost)

3. Redesigning of the coupling area/partsfor easy fittings (High efficiency, low costand less Time)

4. Redesigning of the coupling area/partsfor easy fittings with use of different typeof press machines of lower working withlower cost and power (high efficiency,low cost, less power and less time).

By carefully checking the all above, it willbe seen that the target area can be found inthe fourth point which makes it the mostsuitable option to choose.

LITERATURE REVIEW

The press machine Gutenberg (JohanGensfleisch) a German invented in 1400was modified one from a wooden screw typepress machine for squeezing olive oil andgrapes. This was exactly the root of the screwpresses and all press (punching, stamping)machines, stamping inked print boards ontosheet with the screw. This is the type ofmachine to apply static pressure.

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Until 1700 AD fly press were not inengineering application. Earlier open Die orHammer were used to produce smallcomponents .Then gradually by 1767 AD;small fly presses particularly for Gold smithwork in ornamental work were evolved andused effectively.

Doc Smith & Mates in 1999 work onhydraulic press machine & give conclusionthat the press work on the Hydraulic versionof the press machine

Oseni K Owolarafe, Michael OFaborode 25 May 2000 work on pressmachine & give conclusion that Thecomparative evaluation of the DSP systemwhich is being developed and theconventional hydraulic press systemundertaken in this study revealed that theDSP system has many comparativelyfavorable attributes and is to be preferred tothe hydraulic system. Isaac Bamgboye andMorakinyo T.A An improved oil screw presshas been designed and constructed having98. 6 % efficiency and a capacity of 0.86 tons/day. Abrasion rate of screw-shafts has beenreduced from 63.3% to 12.6% by using highcarbon steel material instead of low-carbonsteel. Peter Beerens in 2007 gives an ideaabout press machine and the result isextended due to improvement in the plateform in the design of the machine.

METHADOLOGY

The steps in the design process proposedas follows:

1. Problem identification

2. Preliminary ideas

3. Problem refinement

4. Analysis

5. Decision, and

6. Implementation

Problem Identification

It need to gather data of several types : fixeddata, opinion surveys, experimentaldata,personal observations

Preliminary Ideas

It is the generation of as many ideas aspossible . these ideas should be sufficientlybroad to evolutionize existing methods. Allthoughts should be recorded in written formwith diagrams. A technical approach shouldbe used to gather preliminary ideas for thedesign problem. The following sequence ofthe step is suggested:

i. Hold brainstorming session

ii. Prepare sketches and notes,

iii. Researches existing designs, and

iv. Conduct surveys.

Deign Refinement

Several of the preliminary ideas are selectedfor further refinement to determine their truemerits. Consideration is given to spatialrelationships, angles between planes lengthsof structural members, intersections of thesurfaces and planes.

Analysis

In involves the evolution of the best designto determine the required merits of each partof the machine with respect to price, cost,strength function and market appeal. Theanalysis is done in all respect, that is,Functional analysis, human engineering,market and product and model analysis.

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Decision

Decision of any design is taken after thedifferent type of the analysis done with thedesign and its matching with the requirementin the industries. It is the final stage of theadministration group before implementationof any design in the factory. So, it is the crucialstage of the administration how and up towhich extant the design is to be implementingfor the improvement.

Implementation

It is the presentation of the final designconcept in a workable form, primaryly asworking drawings and specifications that areused as the actual for fabrication of a product.Implomentation phase of the design processis shown in figure below.

DESIGN CALCULATION FOR

MANUAL PRESS MACHINE

Rankine - Gorden Formula

Crippling load:

Wcr= Ac σσσσσy[1-(σσσσσy/ (4cπππππ2E) (L/k)]

(all dimensions are in mm & N)

= (1662 x 200)[1-(200/ (4(0.25 2E)(l/k)]

= (1662 x 200) [1-(200/(4 (0.25 π2

200000)(750/(46/4))]

= 332400(1-0.430852)

=189184.61 Newton

Or =189.18 kN

Here,

Wcr = Crippling load

Ac= Cross Sectional Area Of the screw

σσσσσy = Yield Stress C = End-Fixity Co-efficientE = Modulus of Elasticity l =Length of Screwk = Least Radius of Gyration.

Since, 189.18kN is greater than our maxi-mum required of load 140 KN (includingfactor of safety as 2)

Hence, the Design is very safe.

Design of the Ball Attached

Mass of ball

Radius of ball (r) =68 mm

4/3πr2ρ = mass of a ball

4/3π (0.068)3 7300 = 10kg

Here ρ = mass density of the material of theball i.e., cast iron

RESULTS AND DISCUSSION

Designed machine is capable to do work withsome shear force so we can made somemodification to improve the shear force of thepress machine for that some of the load inaccordance with the design of the existingpress machine is attached. This improvementis helpful for the working of the machine withthe odd products too without any difficultiesand solve all objectives mention in this paper.The press machine is helpful in many ways,i.e. accuracy, lower cost of machining andimprove the efficiency of the machine.

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CONCLUSION

By putting (diametrically opposite) variableadditional weights on the flywheel we canobtained that desired energy levels to suitthe maximum load required for manufacturingdifferent types of engineering parts. Of courseit is understood that only limited variation incapacity is possible. If at all some bigger orodd components to be manufactured one canchoose the next higher range of the flypress.Itis very clear that for given press reasonableflexibility is possible as far as energy is totalload is concerned.

REFERENCES

1. Automatic punching Machine in Buschplant products manual.

2. Design and construction of Briquettingmachine with slicer By Ganiyu Tajudeen.

3. Details on the metal manufacturingprocesses and their uses by DR.SOTIRISL. OMIROU.

4. Hydraulic Presses Smith& Associates,530 Hollywood Drive, Monroe, Michigan.

5. Idealized Compression Ratio for A ScrewBriquetting Press By Peter Biath, JurajOndru ska.

6. Manually operated punch press Designreport draft 3 by Wilson Burton, JonCarlson andTeam.

7. Metallurgical Properties of Cast Irons.ppt

8. Punching & press processes M45.docSachsen& Associates.

9. Screw-pressing of Jatropha seeds forfuelling purposes in less developedcountries by PeterBeerens.

10. Screw-pressing of Jatropha seeds forfuelling purposes in less developedcountries by Prof Dr. Ir. A.B. de Haan,Peter Beerens.

improvement in design of the manual small ... in design of the manual small press machine vivek...

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