vertical milling attachment

7/29/2019 vertical milling attachment

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ABSTRACT

The Project is based on attaching an additional VERTICAL MILLING ATTACHMENT to

the HORIZONTAL BORING MACHINE. The objective of project is to reduce the time required to

setting of the job this type of work is fatigue to the operator. Another objective is to produce jobs

having more accuracy.

All these results are accompanied by accurate design and


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COMPANY PROFILE


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COMPANY INFORMATION


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CHAPTER 1

COMPANY INFORMATION

NAME: GEAR TORQUE TRANSMISSIONS

ADDRESS: PLOT NO.W-48, Additional M.I.D.C., Satara, Maharashtra, (INDIA)

PRESENT PRACTICES & PROBLEMS

1. For machining the two mutually perpendicular face they machine 1st face & after that

they rotate the job & machine 2nd face

2. For heavy jobs it becomes fatigue to rotate the job

3. It is also time consuming for setting & clamping the job

SUGGESTIONS ON PROBLEM

1. Vertical Milling Attachment driven by same drive

2. Vertical Milling Attachment driven by same drive with gearing attachment

3. Vertical Milling Attachment driven by same drive with clutch system

4. Vertical Milling Attachment with independent driven drive

CHAPTER 2

LITERATURE REVIEW


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To complete our project design we refer following Design Data Books &

Reference Books.

1. PSG design data book:We use PSG design data book for the design of gear. We refer chapter bevel gear &

according to the formulae we complete our design.

2. CMTI design data hand book:

We refer material specification of gear & shaft, various stresses of material & also

design of gear from the CMTI hand book.

3. MACHINE DESIGN by V.B. BHANDARI:

For the calculation of forces acting on the gear & shaft we refer reference book of

machine design. We refer chapter bevel gear for gear design & force calculations.

4. MACHINE DESIGN by R.S. KHURMI:

For the calculations of the shafts, keys & also for the design of gear we use this book.

We refer chapter design of shaft for shaft & key design.

5.IS STANDARD FOR SELECTION OF BEARING


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CHAPTER 3.

DESIGN

SELECTION OF MOTOR

Required RPM: 500

Motor Specification: 3Phase Induction Motor

RPM: 1440

Torque:

We selected the available motor from company.

DESIGN OF BEVEL GEAR

Abbreviations:

m= Module

= Pitch Angle

i= Gear Ratio

b= Face Width

mt =Transverse Module

mn = Normal Module

Zp=No. of Teeth on Pinion

Zg=No of Teeth on Gear

R1= Cone Distance

dp= Reference Diameter For Pinion

dg= Reference Diameter For Gear

dpt= Tip Diameter Of Pinion

dpg= Tip Diameter Of Gear

Zcw= No of Teeth Crown Wheel

Zu = Minimum No of Teeth on Pinion to Avoid the Undercutting

m= Helix Angle

= Pressure Angle

ap= Addendum Angle For Pinion

ag = Addendum Angle For Gear


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c = Clearance

ap= Tip Angle For Pinion

ag= Tip Angle For Gear

rp= Root Angle For Pinionrg= Root Angle For Gear

ha= Tooth Height

hd= Tooth Height

DESIGN:

By considering required speed

We assume,

m=3, Zp=24, Zg=72

i=Zp/Zg

=20/60

=1/3

i =1:3

1. for ,Tan =i

Therefore, =tan-1 (i)

=tan-1(1/3)

=18.430

2. for mt,

mt=mm+

=3+

mt =3.1mm

3. for mm

mm= mtX cosm

=3.12Xcos0 .......... (since, m=0)


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=3.1mm

4. For cone distance R

R=0.5Xmt Zp2+Zg2)

=0.5X3.12X 242 +722)

=117.636mm

5. Reference diameter,

dp=mt X Zp

=3.12X 24

=74.4mm

dg=mt X Zg

=3.12 X 72

=223.2mm

6. Tip diameter

dpt= mt X (Zp+ 2cosp)

= 3.12 X (24+2cos18.43)

= 80.28mm

dgt= mt X (Zg+ 2cosg)

= 3.1 X (72+2cos71.57)

=225.160mm

7. No of teeth on crown wheel

Zcw=2R/mt

=

=75.89mm

8. Minimum no of teeth on pinion to avoid undercutting


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Zu=

= .................... (=200)

=16.22

9. Addendum angle

tan ap= tan ag =

ap = ag = tan-1

ap = ag =1.50

10. dedendum angle

tan dp= tan dg =

dp = dg = tan-1

dp = dg =1.810

11. tip angle

ap = + ap

=18.43 + 1.5

=19.930

ag = + ap

= 71.57 + 1.5

= 73.070

12. Root angle

rp = dp

= 18.43 1.81

= 16.620

rg = dg

= 71.57 1.81


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= 69.760

13. Tooth height, h

h= ha + hd

ha = mt

=3.1mm

hd = 1.1236 mt ................. (Reinecker)

=3.50mm

GEAR TOOTH PROFILE


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FORCES ACTING ON GEAR TOOTH

Abbreviations:

b = Ultimate tensile stress

P = Power in kW

Np = Speed of pinion in rpm

Ng = Speed of gear in rpm

rm = Radius of pinion at midpoint of face-width

Ps = separating force between two meshing teeth

Pt = tangential or useful component

Mt = torque transmitted by gear

Pa = axial component on pinion

Pr = radial component on pinion

1. ultimate tensile stress

b =63kgf/mm2

= 63 X 9.81

= 618.03 N/mm2

= 620 N/mm2

2. power to be transmitted by the motor

1.5kW @ 1440 rpm

3. for radius of the pinion at midpoint of face width

rm =

=

=32.45mm


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4. Tangential or useful component

Pt=

But, mt= Pt X rm

Therefore

mt=

= 9947.18 N-mm

Pt=

=

= 306.53N

5. separating force between two meshing teeth

Ps=Pt tan

=306.53 tan20

=111.57 N

6. axial component on pinion

Pa=Pssin

=111.57 X sin18.43

=35.27 N

7. radial component on pinion

Pr=Ps cos

= 111.57 cos18.43= 105.84 N


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8. axial component on gear

Pa= Pttan tan

=376 X tan20 Xsin18.43=43.26 N

9. radial component on gear

Pr=Pt tan sin

= 306.63Xtan20Xsin18.43

=35.27N


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Strength of Bevel Gear:

Abbreviations:

Wt=strength of wear gear

o=shear start

yp= form factor for pinion

yg=form factor for gear

Zep=equivalent teeth of pinion

Zeg=equivalent teeth of gear

Cv=velocity factor

1. Wt=( o*Cv)*b**n*y*

o= 620/1.5

=413.34 N/mm2

`Form factor for pinion

Yp=0.154-

Zep=Zpsec

=20*sec18.43

=21.08

Therefore,

Yp=0.154-

=0.1107


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Vm=

=

=4.70 m/s

Therefore,

Cv=

=

=1.78

Wt=413.34 X 1.78 X 30 X X 3 X 0.1107 X

=17155.75117 N

2. form factor for gear

yg=0.154-( )

Zeg=Zg sec

=60sec18.43

=63.24

yg=0.154-

=0.139

Wt=413.34 X 1.78 X 30 X X 3 X 0.139 X

=21539.35 N


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WEAR STRENGTH:

Sw=wear strength

Q=

=

=1.80

k=0.16( )2

=0.0484 N/mm2

Wear strength

Sw=

=

=123.97 N

Effective loadPeffbetween two meshing teeth is given by


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Peff=

=

=264 N


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DESIGN OF SHAFT

d= 0.5R

= 0.5 X 117.63= 58.82mm

d1= 1.6 X d

= 1.6 X 58.82

= 94.1088mm

a= 0.2 X R

= 0.2 X 117.63

= 23.53mm

c= 0.3 X d= 0.3 X 58.82

= 17.64mm

l= 1.1 X d

= 1.1 X 58.812

= 64.70mm

TAPER BERINGS SELECTION

SELECTION OF BEARINGS


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STANDARD TABLE FOR BEARING

Selected bearings- SKF DESIGNATION 32208 & 32210

CHAPTER 4

ASSEMBLY AND PART DRAWINGS

1) PART DRAWINGS


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GEAR DESIGN:

PINION DESIGN:

BASE PLATE:


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INPUT SHAFT:


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OUTPUT SHAFT:

VERTICAL BEARING FLANGE:


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HORIZONTAL CASING:

45O ATTACHMENT


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VERTICAL CASING:

HORIZONTAL BEARING FLANGE:


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ASSEMBLY DRAFTING


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CHAPTER 5

CRITICAL PATH METHOD DIAGRAM

Activity Name of Activity Immediate

Predecessor

Duration(in

days)A Project search - 20

B Project finalization A 5

C Documentation B 30

D Design C 30

E Analysis and force calculation D 15

F Manufacturing of pinion E 1H Manufacturing of gear F 2

G Manufacturing of input shaft H 2

I Manufacturing of output shaft G 3

J Manufacturing of bearings H,I 1

K Manufacturing of flanges J 3

L Manufacturing of horizontal casing K 2

M Manufacturing of vertical casing K 3

N Manufacturing of 450attachment L,M 4

O Nut and bolts L 0

P Manufacturing of support O 4Q Motor selection P 1

R Assembly Q 15

S Testing R 10

T Painting S 5

U Attachment T 5

TOTOL DAYS= 161

days


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Critical path-

1-2-3-4-5-6-8-9-10-11-13-14-15-16-17-18-19-20

Total duration= 133 Days.

Activity Duration Earliest time Latest time Total floatStart Finish Start Finish

1-2 20 0 20 0 20 0

2-3 05 20 25 20 25 0

3-4 7 25 32 20 32 0

4-5 30 32 62 32 62 05-6 15 62 77 62 77 0

6-7 1 77 78 79 80 2

6-8 2 77 79 77 79 0

7-9 2 78 80 80 82 2

8-9 3 79 81 79 82 0

9-10 1 82 83 82 83 0

10-11 3 83 86 83 86 0

11-12 2 86 88 90 92 4

11-13 3 86 89 86 89 012-14 1 88 89 92 93 4

13-14 4 89 93 89 93 0

14-15 4 93 97 93 97 0

15-16 1 97 98 97 98 0

16-17 15 98 113 98 113 0

17-18 10 113 123 113 123 0

18-19 5 123 128 123 128 0

19-20 5 128 133 128 133 0


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CHAPTER 6

BILL OF MATERIAL

Sr. No. Part name Material No off Make/buy1 SUPPORT MS 1 Make

2 BEVEL GEAR

a) PINION

b) GEAR

EN 353

EN353

1

1

Make

Make

2 HORIZONTAL CASING MS 1 Make

3 INPUT SHAFT EN 36 1 Make

4 OUTPUT SHAFT EN 36 1 Make

5 BEARING SUPPORT FLANGE

a) INPUT SHAFT

b) OUTPUT SHAFT

MS

MS

1

1

Make

Make

6 TAPER BEARING

a) INPUT SHAFT

b) OUTPUT SHAFT

B.S.

B.S.

1

1

Buy

Buy

7 45 ROTATION

ATTACHMENT

MS

(HARDENED)

1 Make

8 BOLT

a) M 12

b) M 16

EN 8

EN 8

28

06

Buy

Buy

9 NUT

a) M 16 EN 8 06 Buy

EN 353 Case Hardened Steel - 251570

MATERIAL COMPOSITION - 15Ni 2Cr 1Mo 15


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CHAPTER 7

CONCLUSION

After completion of design of VERTICAL MILLING ATTACHMENT for

horizontal boring machine, a final design is submitted to the company. The company is

satisfied with our work and also we had a great experience working with the company.

The cost of purchasing of new machine for milling is very high. By using our

attachment the cost is reduces. Also at one time we not only bore but also mill the same job

as per requirement.


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CHAPTER 8

REFERANCES

1. DESIGN DATA BOOK (PSG)

2. MACHINE DESIGH BY V.B. BHANDARI

3. CMTI

4. MACHINE DESIGN BY KHURMI GUPTA

5. ISO STANDARD

6. MACHINE TOOL DESIGN BY N.K. MEHTA

vertical milling attachment

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