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INTRODUCTION

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Introduction Manufacturing industries are basically meant for production of useful goods and services at low

cost. All the tasks in everyday lives have been made quicker due to technological advancements.

However, this advancement also demands huge investments and expenditure. In view of this, every

industry desires to achieve a high productivity rate while maintaining the quality and standard of

the product at a low cost. The idea behind this project is to develop a conceptual machine tool

which would be capable of performing different operations simultaneously while also being

economically efficient. Machining is one of the processes of manufacturing in which the specified shape to any work piece

is imparted by removing the surplus material. Conventionally, this surplus material from the

workpiece is removed in the form of chips by interfacing the workpiece with an appropriate tool.

The process of chip formation during metal cutting is affected by relative rotatory or translator

motion between a tool and the workpiece achieved with the aid of a device called machine tool. A machine tool is a machine for shaping or machining metal or other materials, usually by cutting,

boring, grinding, shearing, or other forms of deformation. Machine tools usually employ some

types of tools that do the cutting or shaping. All machine tools have a means of constraining the

workpiece and as well as providing a guided movement of the different parts of the machine. Thus,

the relative movement between the workpiece and the cutting tool which is called the tool-path is

controlled or constrained by the machine to at least some extent, rather than being entirely offhand

or freehand. The proposed synchronous machine tool will have different work-stations which will be capable of

carrying out a series of machining operations on the same machine which would otherwise require

several machines in order to perform the same machining operations the purpose of this paper is to

design and construct a low capital synchronous operation machine tool for the machine shop of the

college of engineering at Jazan University, Kingdom of Saudi Arabia. The idea behind this project

is to teach designing and other analytical skills in order to train individuals or students to find

solutions to difficulties they may encounter during real engineering problems. This project also

offers the future scope to make more complex variations of the machine tool for different

engineering requirements.

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LITERATURE

REVIEW

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Literature Review

Before starting our work, we have undergone through many research papers which indicates that for a production based industries machine installation is a tricky task as many factor

being associated with it such as power consumption (electricity bill per machine), maintenance cost, no of units produced per machine i.e. capacity of machine, time consumption and many

more…. Some research papers which have led us to approach to the idea of a machine which may

give solution to all these factors are as follows: Heinrich Arnold1 November 2001[1]: Rather long re-investment cycles of about 15 years have

created the notion that innovation in the machine tool industry happens incrementally. But looking

at its recent history, the integration of digital controls technology and computers into machine tools

have hit the industry in three waves of technology shocks. Most companies underestimated the

impact of this new technology. This article gives an overview of the history of the machine tool

industry since numerical controls were invented and introduced and analyzes the disruptive

character of this new technology on the market. About 100 interviews were conducted with

decision-makers and industry experts who witnessed the development of the industry over the last

forty years. The study establishes a connection between radical technological change, industry

structure, and competitive environment. It reveals a number of important occurrences and

interrelations that have so far gone unnoticed.

Dr. Toshimichi Moriwaki (2006) [2] Ref.: Recent trends in the machine tool technologies are surveyed from the viewpoints of high speed and high performance machine tools, combined

multifunctional machine tools, ultra-precision machine tools and advanced and intelligent control technologies. Frankfurt-am Main, 10 January 2011: The crisis is over, but selling machinery remains a tough

business. Machine tools nowadays have to be veritable “jack of all trades”, able to handle all kinds of materials, to manage without any process materials as far as possible, and be capable of adapting to new job profiles with maximized flexibility. Two highly respected experts on machining and forming from Dortmund and Chemnitz report on what‟s in store for machine tool manufacturers and users.

Multi-purpose machines are the declarations of independence. The trend towards the kind

of multi-purpose machining centers that are able to cost efficiently handle a broad portfolio of products with small batch sizes accelerated significantly during the crisis. “With a multi-purpose machine, you‟re less dependent on particular products and sectors”, explains Biermann

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I. Proposed Methodology In this project, we will generally give the power supply to the shaft on which a bevel gear is

mounted on it, and a second bevel gear at a right angle to it has been mounted on a drill shaft to

which a drill bit is being attached. At one end of the shaft is connected to power supply, other end

is being joined to a circular disc, through this circular disc scotch yoke mechanism is being

performed (rotator y motion is converted to reciprocating motion). Also in between these two, a

helical gear is mounted which transfer its motion to other helical gear which is mounted on a shaft

consist of grinding wheel

Fig. 1. Flow chart

Experimental Set-Up

In this conceptual model we have involved the gear arrangement for power transmission at

different working centers , basically gear or cogwheel is a rotating machine part having cut teeth,

or cogs, which mesh with another toothed part in order to transmit torque, in most cases with teeth

on the one gear being of identical shape, and often also with that shape on the other gear. Two or

more gears working in tandem are called a transmission and can produce a mechanical advantage

through a gear ratio and thus may be considered a simple machine. Geared devices can change the

speed, torque, and direction of a power source. The most common situation is for a gear to mesh

with another gear; however, a gear can also mesh with a non-rotating toothed part, called a rack,

thereby producing translation instead of rotation.

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II. Functional Descriptions

The functional description of the project work is explained in brief here. For better understanding,

the total project work is divided into various blocks and each block explanation is provided here.

The following is the description of overall function of the module.

In this project, generally the power is applied to the shaft on which a bevel gear is mounted on it

and a second bevel gear at a right angle to it has been mounted on a drill shaft to which a drill bit

is being attached. At one end of the shaft, power is applied by a motor and other end is being

joined to a circular disc, through this circular disc scotch yoke mechanism is being performed

(rotator y motion is converted to reciprocating motion). Also in between these two, a helical gear

is mounted which transfer its motion to other helical gear which is mounted on a shaft consist of

shaper.

III. Working Principal There are only two major principles on which this proposed model generally works. They are: 1) Scotch-Yoke mechanism and 2) Power transmission through gears.

Bevel gears

Scotch Yoke Mechanism: The Scotch yoke is a mechanism for converting the linear motion of a slider into rotational motion

or vice-versa. The piston or other reciprocating part is directly coupled to a sliding yoke with a

slot that engages a pin on the rotating part. The shape of the motion of the piston is a pure sine

wave over time given a constant rotational speed.

Fig.2 Front view of Scotch Yoke Fig.3 Line diagram of Scotch Yoke Mechanism. Mechanism.

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The scotch yoke mechanism is constructed with iron bars. Here the crank is made of wood in some

length and the yoke is made of iron. It is noted that the minimum length of the yoke should be

double the length of the crank. The crank and yoke is connected with a pin. Iron bars are welded to

both sides of the yoke to get the reciprocating motion. The yoke with the iron bars is fixed on the

display board with the help of square pipe that is a bit bigger than that of the iron bars. Now the

crank is connected through a screw mechanism to the end of the shaft of the bevel gear mechanism.

Now the pin on the crank is connected to the yoke. The pin used to connect yoke and crank is a

bolt.

Bevel gears are gears where the axes of the two shafts intersect and the tooth-bearing faces of the

gears themselves are conically shaped. Bevel gears are most often mounted on shafts that are 90

degrees apart, but can be designed to work at other angles as well. The pitch surface of a gear is the

imaginary toothless surface that you would have by averaging out the peaks and valleys of the

individual teeth. The pitch surface of an ordinary gear is the shape of a cylinder. The pitch angle of

a gear is the angle between the face of the pitch surface and the axis. More description about gears

and their drive mechanisms is provided in the further chapters.

The working medium adopted is Mechanical power.

The machine work without the help of electricity.

The Rotary motion of drilling operation performed is also used for performing other tasks

like cutting and grinding simultaneously.

The work pieces are to be clamped on the work table using suitable clamping device like

vice for the three operations.

After machining the work pieces are to be removed and cleaned.

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IV. Components of The Machine 1) Frame 2) Scotch Yoke mechanism 3) Bevel gear 4) Bearing (Ball)

5) Motor 6) Rocker arm 7) Hacksaw blade 8) Tool post 9) Drilling chuck 10) Drill tool 11) Single cutting tool 12) Nut and Bolt 13) Other components

Frame The frame will support the whole assembly of the multi-operational machine. The frame structure

is hard enough to withstand the machine structure. The pedal powered hacksaw set up, has a simple

mechanism operate with chain and sprocket arrangement. The chain is placed on the teeth of the

wheel and pinion. Pedal and connecting rod are interconnected to each other with the help of bolts.

Bearing is provided between the centre of the wheel or pedal and to delivers a smooth running of

the hacksaw in to and fro motion during pedaling. The hacksaw is connected to the end of a rod.

We use 3mm thickness cast iron. Frame of the model: length=112cm, width=75cm, height=75cm.

Fig.4 Frame

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Scotch Yoke mechanism The Scotch yoke (also known as slotted link mechanism) is a reciprocating motion mechanism,

converting the linear motion of a slider into rotational motion, or vice versa. The piston or other

reciprocating part is directly coupled to a sliding yoke with a slot that engages a pin on the rotating

part. The location of the piston versus time is a sine wave of constant amplitude, and constant

frequency given a constant rotational speed.

Fig.5 Scotch Yoke

Bevel Gears: General: Bevel gears are primarily used to transfer power between intersecting shafts. The teeth

of these gears are formed on a conical surface. Standard bevel gears have teeth which are cut

straight and are all parallel to the line pointing the apex of the cone on which the teeth are based.

Spiral bevel gears are also available which have teeth that form arcs. Hypocycloid bevel gears are

a special type of spiral gear that will allow nonintersecting, non-parallel shafts to mesh. Straight

tool bevel gears are generally considered the best choice for systems with speeds lower than 1000

feet per minute: they commonly become noisy above this point. One of the most common

applications of bevel gears is the bevel gear differential.

Fig.6 Bevel gears

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Limitations:

Limited availability cannot be used for parallel shafts, can become noisy at high speeds.

Advantages:

Excellent choice for intersecting shaft systems.

Fig 7: Bevel Gears & it‟s line diagram

Bearing

A bearing is a machine element that constrains relative motion to only the desired motion, and

reduces friction between moving parts. The design of the bearing may, for example, provide for

free linear movement of the moving part or for free rotation around a fixed axis; or, it

may prevent a motion by controlling the vectors of normal forces that bear on the moving parts.

Most bearings facilitate the desired motion by minimizing friction. Bearings are classified broadly

according to the type of operation, the motions allowed, or to the directions of the loads (forces)

applied to the parts.

A pillow block, also known as a plummer block or housedbearing unit, is a pedestal used to

provide support for a rotating shaft with the help of compatible bearings & various accessories.

Housing material for a pillow block is typically made of cast iron or cast steel. [6]

Fig.8 Bearing Fig.9 Pedestrial Bearing

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Motor

A pump is a device that moves fluids (liquids or gases), or sometimes slurries, by mechanical

action. Pumps can be classified into three major groups according to the method they use to move

the fluid: direct lift, displacement, and gravity pumps.

Mechanical pumps serve in a wide range of applications such as pumping water from

wells, aquarium filtering, pond filtering and aeration, in the car industry for water-cooling and fuel

injection, in the energy industry for pumping oil and natural gas or for operating cooling towers. In

the medical industry, pumps are used for biochemical processes in developing and manufacturing

medicine, and as artificial replacements for body parts, in particular the artificial heart and penile

prosthesis.[6]

Fig. 10: 1/5HP Motor (2800RPM)

Drilling chuck

A chuck is a specialized type of clamp. It is used to hold an object with radial symmetry, especially

a cylinder. In drills and mills it holds the rotating tool whereas in lathes it holds the rotating

workpiece. On a lathe the chuck is mounted on the spindle which rotates within the headstock. For

some purposes (such as drilling) an additional chuck may be mounted on the non-rotating tailstock.

We use 0.5mm diameter drill chuck. [6]

Fig.11: Drill chuck

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Single Point Cutting Tool

In the context of machining, a cutting tool or cutter is any tool that is used to remove material from

the workpiece by means of shear deformation. Cutting may be accomplished by single-point or

multipoint tools. Single-point tools are used in turning, shaping, planing and similar operations, and

remove material by means of one cutting edge. Milling and drilling tools are often multipoint tools.

Grinding tools are also multipoint tools. Each grain of abrasive functions as a microscopic single-

point cutting edge (although of high negative rake angle), and shears a tiny chip. [6]

Fig.12: HSS Single Point Cutting Tool

Lock Nut A locknut, also known as a lock nut, locking nut, prevailing torque nut, stiff nut

[1] or elastic stop

nut, is a nut that resists loosening under vibrations and torque. Elastic stop nuts and prevailing

torque nuts are of the particular type where some portion of the nut deforms elastically to provide a

locking action. The first type used fiber instead of nylon and was invented in 1931.[6]

Fig.13 Lock Nut

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V. Operation Performed by The Machine 1) Drilling 2) Cutting 3) Shaping

Drilling: Drilling machine can be defined as an instrument which is used to drill holes. Drilling machine

plays an important role in mechanical workshops. The purpose of this project work is to get hold of

complete information pertaining to drilling machines. A drilling machine comes in many shapes

and sizes, from small hand-held power drills to bench mounted and finally floor-mounted models.

Today the Industrial growth is purely depending up on latest machines; therefore, the subject of

drilling machines is extended too widely, because today wide varieties of drilling machines are

designed for various applications. The most advanced version-drilling machine is CNC (Computer

Numeric Control); it is used for drilling the PCB‟s (Printed).[6]

Cutting: A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame, used for cutting

materials such as metal or plastics. Hand-held hacksaws consist of a metal arch with a handle,

usually a pistol grip, with pins for attaching a narrow disposable blade. A screw or other mechanism is used to put the thin blade under tension. The blade can be mounted

with the teeth facing toward or away from the handle, resulting in cutting action on either the push

or pull stroke. On the push stroke, the arch will flex slightly, decreasing the tension on the blade,

often resulting in an increased tendency of the blade to buckle and crack. Cutting on the pull stroke

increases the blade tension and will result in greater control of the cut and longer blade life.[6]

Shaping: The shaping machine is used to grind flat metal surfaces especially where a large amount of metal

has to be removed. Other machines such as milling machines are much more expensive and are

more suited to removing smaller amounts of metal, very accurately. A shaper is a type of machine

tool that uses linear relative motion between the work piece and a single-point cutting tool to

machine a linear tool path. Its cut is analogous to that of a lathe, except that it is (archetypal) linear

instead of helical. (Adding axes of motion can yield helical tool paths, as also done in helical

planning.) A shaper is analogous to a plane, but smaller, and with the cutter riding a ram that

moves above a stationary work piece, rather than the entire work piece moving beneath the cutter.

The ram is moved back and forth typically by a crank inside the column; hydraulically actuated

shapers also exist. [6]

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VI. Brief Description About Bevel Gear and Drive

Mechanisms.

Gear:

A gear or cogwheel is a rotating machine part having cut teeth, or cogs, which mesh with another

toothed part in order to transmit torque, in most cases with teeth on the one gear being of identical

shape, and often also with that shape on the other gear. Two or more gears working in tandem are

called a transmission and can produce a mechanical advantage through a gear ratio and thus may

be considered a simple machine. Geared devices can change the speed, torque, and direction of a

power source. The most common situation is for a gear to mesh with another gear; however, a gear

can also mesh with a non-rotating toothed part, called a rack, thereby producing translation instead

of rotation.

Comparison with Drive Mechanisms: The definite velocity ratio which results from having teeth gives gears an advantage over other

drives (such as traction drives and V-belts) in precision machines such as watches that depend

upon an exact velocity ratio. In cases where driver and follower are proximal,

gears also have an advantage over other drives in the reduced number of parts required; the

downside is that gears are more expensive to manufacture and their lubrication requirements may

impose a higher operating cost. [6]

Spur Gears General: Spur gears are the most commonly used gear type. They are characterized by teeth

which are perpendicular to the face of the gear. Spur gears are by far the most commonly available,

and are generally the least expensive. [8]

Limitations:

Spur gears generally cannot be used when a direction change between the two shafts is required.

Advantages:

Spur gears are easy to find, inexpensive, and efficient.

Fig. 14: Spur Gear (front and isometric view)

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Helical Gears: General: Helical gears are similar to the spur gear except that the teeth are at an angle to the

shaft, rather than parallel to it as in a spur gear. The resulting teeth are longer than the teeth on a

spur gear of equivalent pitch diameter. The longer teeth cause helical gears to have the following

differences from spur gears of the same size. [9]

Limitations:

Helical gears have the major disadvantage that they are expensive and much more difficult to find.

Helical gears are also slightly less efficient than a spur gear of the same size

Advantages:

Helical gears can be used on non-parallel and even perpendicular shafts, and can carry higher loads

than can spur gears.

Fig 15: Helical Gear (top view, side view & isometric view)

Bevel Gears: General: Bevel gears are primarily used to transfer power between intersecting shafts. The teeth

of these gears are formed on a conical surface. Standard bevel gears have teeth which are cut

straight and are all parallel to the line pointing the apex of the cone on which the teeth are based.

Spiral bevel gears are also available which have teeth that form arcs. Hypocycloid bevel gears are

a special type of spiral gear that will allow nonintersecting, non-parallel shafts to mesh. Straight

tool bevel gears are generally considered the best choice for systems with speeds lower than 1000

feet per minute: they commonly become noisy above this point. One of the most common

applications of bevel gears is the bevel gear differential. [10]

Limitations:

Limited availability cannot be used for parallel shafts, can become noisy at high speeds.

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Advantages:

Excellent choice for intersecting shaft systems.

Fig 16: Bevel Gears & it‟s line diagram

Worm Gears General: Worm gears are special gears that resemble screws, and can be used to drive spur gears

or helical gears. Worm gears, like helical gears, allow two non-intersecting 'skew' shafts to mesh.

Normally, the two shafts are at right angles to each other.

A worm gear is equivalent to a V-type screw thread. Another way of looking at a worm gear is that

it is a helical gear with a very high helix angle. Worm gears are normally used when a high gear

ratio is desired, or again when the shafts are perpendicular to each other. One very important

feature of worm gear meshes that is often of use is their irreversibility: when a worm gear is turned,

the meshing spur gear will turn, but turning the spur gear will not turn the worm gear. The resulting

mesh is 'self-locking', and is useful in ratcheting mechanisms. [11]

Fig 17: Worm Gear

Limitations:

Low efficiency. The worm drives the drive gear primarily with slipping motion, thus there are high

friction losses.

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Advantages:

Will tolerate large loads and high speed ratios. Meshes are self-locking

(which can be either an advantage or a disadvantage).

Racks (straight gears) General: Racks are straight gears that are used to convert rotational motion to translational

motion by means of a gear mesh. (They are in theory a gear with an infinite pitch diameter). In

theory, the torque and angular velocity of the pinion gear are related to the Force and the velocity

of the rack by the radius of the pinion gear, as is shown below: Perhaps the most well-known

application of a rack is the rack and pinion steering system used on many cars in the past. [12]

Limitations:

Limited usefulness, difficult to find.

Advantages:

The only gearing component that converts rotational motion to translational motion. Efficiently

transmits power. Generally, offers better precision than other conversion method.

VII. Maintenance and Lubrication. Many bearings require periodic maintenance to prevent premature failure, although some such as

fluid or magnetic bearings may require little maintenance. Most bearings in high cycle operations

need periodic lubrication and cleaning, and may require adjustment to minimize the effects of

wear. Bearing life is often much better when the bearing is kept clean and well-lubricated.

However, many applications make good maintenance difficult. For example, bearings in the

conveyor of a rock crusher are exposed continually to hard abrasive particles. Cleaning is of little

use because cleaning is expensive, yet the bearing is contaminated again as soon as the conveyor

resumes operation. Thus, a good maintenance program might lubricate the bearings frequently but

never clean them.

Packing: Some bearings use thick grease for lubrication, which is pushed into the gaps between the bearing

surfaces, also known as packing. The grease is held in place by a plastic, leather, or rubber gasket

(also called a gland) that covers the inside and outside edges of the bearing race to keep the grease

from escaping. Bearings may also be packed with other materials. Historically, the wheels on

railroad cars used sleeve bearings packed with waste or loose scraps cotton or wool fiber soaked in

oil, then later used solid pads of cotton.

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VIII. Brief Description About Bevel Gears.

Bevel gears are used to transmit power between two non-parallel shafts. The shafts may be

intersecting or non-intersecting. Bevel gears can be described as conical gears as they are cut on

conical blanks (tapered). They are not interchangeable and always designed in pairs. The

commonly used bevel gears are: straight, spiral and hypoid based on the geometry as given below:

Straight Bevel Gears: The straight bevel gears are the simplest types of bevel gears. They are the important gears to

transmit power between intersecting shafts. Straight bevel gears are shown in Figure below. The

teeth are cut straight, have a taper, and if extended inward, would intersect each other on the axis of

shaft. The meshing gears have line contact. Hence, they are not smooth in operation; generate more

vibrations and noise at high-speed. They produce thrust load on shaft bearings. Straight bevel gears

are used for speed ratio 1:1. Their precision is as good as parallel helical gears, but higher than

crossed helical gears, spiral bevel gears, hypoid bevel gears and worm gears. [13]

Fig 18: Straight level Gears Mounted on shafts Fig 19: Left-on loom; Right-on Carding Machine.

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Fig 20: Thrust load on Bevel gears

Fig.21: Gear Terminology

Spiral Bevel Gears: These gears are mounted on shaft whose axes are intersecting. The pitch surface is conical as

shown in Figure below. Spiral bevel gears have curved oblique teeth (spiral), which allow contact

to develop gradually and smoothly. They have more contact length and area and less power

transmission efficiency compared to straight bevel gears. They are useful for high-speed

applications and others requiring less noise and vibration. They are difficult to design and costly to

manufacture, as they require specialized and sophisticated machinery for their manufacture. They

produce more thrust load on shaft bearings than straight bevel gears. [13]

Fig 22: Spiral bevel gears

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Their advantages compared with straight bevel gears at high speeds are: (a) smoothness and

quietness of operation; (b) strength; and (c) durability due to the followings:

Longer contact length and larger contact ratio compared to straight bevel gears of same

size.

Teeth engage gradually, the contact beginning at one end and gradually working over other

end; whereas in the straight bevel gear the contact takes place along the entire face of the

tooth at the same instant.

Hypoid Bevel Gears: Hypoid bevel gears are used to connect shafts whose axes do not intersect. They are very similar

to spiral gears. However, their pitch surfaces are hyperboloids rather than cones. As a result, their

pitch axes do not intersect. They permit certain amount of sliding action along the direction of

tooth element, which requires good lubrication. Their power transmission efficiency is poor

compared to other straight and spiral bevel gears. In general, hypoid gears are most desirable for

those applications requiring large speed reduction ratios, nonintersecting shafts, and also great

smoothness and quietness of operation. [14]

Fig 23: Hypoid bevel gears

Miter and Angular Bevel Gears: In majority of bevel gear drives, the shafts of the meshing gears are 90º to each other. If the angles

between the shafts are 90°, and the two gears of a pair are having the same number of teeth, then it

is called as “Miter Gear”. A pair of spiral miter gears is shown in Figure. In some bevel-gear

drives, the angles between the shafts may not be 90°, but either more or less than 90°. These gears

are called „Angular bevel gears‟. A pair of angular bevel gears is shown in Figure below.[6]

Fig 24: Spiral miter gears Fig 25: Angular bevel gears

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Applications of Bevel Gears: Straight bevel gears are used primarily for low speed application with pitch line velocities up to

300 m/min. They are widely used in textile machines. Few of applications are listed below:

drive to bobbin rail on roving machine

drive between the doffer and feed roller on low speed carding machines

drive from calendar roller to coiler rollers, top coiler to bottom coiler plates in card, comber

and drawing machine

drive between calendar roll and lap stop mechanism-lever in lap former of conventional

blow room. [6]

IX. Fabrication of The Machine.

There are few types of fabrication methods that are done on the machine. They are: Arc cutting.

Drilling.

Grinding.

Turning.

Further Operation: Cleaning. Assembling.

Further Operations: Cleaning: It is the operation to clean the all machined parts without burrs, dust and chip formals. By

meaning the parts they are brightened and good looking.

Machining Operations: In this paper, it is used to cut the raw material such as plates, rod. This is done by arc cutting

machine.

Drilling: Drilling is used to produce holes in objects. In this project, the square type pipe required the holes

for making rake assembly. These holes are done by vertical type drilling machine.

Fine Grinding: It is nothing but a grinding process, which is done as smooth with fine grains. It is done by

convention grinding machine.

Turning: It is used in this project to make the groove on the both sides of top cover plate. This is done by

conventional lathe.

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X. Working of The Model. In the conceptual model of “Multi-Functional operating machine” we are giving supply to

the main shaft (refer fig.13), as we move along the axis of shaft we have mounted a pair of bevel

gears, through the pinion shaft we are giving drive to drill shaft through belt-pulley arrangement, we have installed the stepped pulley in the arrangement therefore we can have made the speed

variation. Now again as we move along the axis of main-shaft further we have again used the bevel

gear arrangement to give the drive to grinding center. As we can see that the scotch yoke mechanism is directly fabricated to the main shaft and

have same angular velocity as that of main-shaft. It is the operation, its deals with the assembling of various parts produced by above operations.

Fig.26: Over view

Fig.27: Turning process Fig.28: Group work

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Fig.29: Welding process

Fig.30: Group work

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XI. Specification of the Components used in the

Conceptual model.

i. Frame of the model: length=112cm, width=75cm, height=75cm ii. Bevel gears: no. of teeth T1=16, T2=10.

iii. For Pinion Face width = 1.5cm

Circular pitch = 1cm Tooth thickness = 0.5cm

Clearance = 0.1cm

Teeth = 10 Flank =1.7cm

iv. For Gear

Face width = 1.7cm Circular pitch = 1cm

Tooth thickness = 0.4cm Clearance = 0.1cm

Teeth = 16 Flank =2.2cm

v. Shaft

Diameter =2cm (approx.), length=46cm

Diameter =2.5cm (approx.), length=50cm vi. Material of bevel gears is mild steel

vii. Shaft is also of mild steel. viii. Frame is made of metal.

ix. Operation can be performed are: sawing/cutting, drilling, grinding & shaping.

Fig. 21: - Design of mode

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XII. RESULT

The scotch yoke mechanism is made and its advantage and disadvantage are discussed. Its

motion characteristics are studies. It is concluded that this mechanism is a good choice to convert rotating motion into reciprocating motion because of fewer moving parts and smoother operation.

The Scotch yoke is a mechanism for converting the linear motion of a slider into rotational motion

or vice-versa. The piston or other reciprocating part is directly coupled to a sliding yoke with a slot that engages a pin on the rotating part. The shape of the motion of the piston is a pure sine wave

over time given a constant rotational speed. The presented result can help to help the machining of work piece with expected tolerance.

The following major conclusion may be drawn from the study.

Multipurpose machine is derived from turning lathe which has been a well-established industrial process offering attractive capabilities for handling work piece of various length

to be use at micro level.

We have presented the development of multipurpose machine in various mode by which it can be actively adopted.

We have explained the various part and component of multipurpose machine using scotch yoke mechanism.

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XIII. COSTING OF PROJECT

S.NO. PARTICULANS TOTAL

QUANTITY

COST

Rs/unit

TOTAL

COST

1. Motor 2800RPM 1 800 800

2 Bearing(Ball) 8 150 1200

3 Bearing (Roller) 4 120 480

4 Gear and Pinion 5 200 1000

5 Circular Disk 2 80 160

6 Shaft (M.S.) 4 90 360

7 Iron Angle(thickness-3mm) 10Kg 45 450

8 Drill Chuck 1 110 110

9 Drill Tool 1 40 40

10 Hacksaw Tool 2 60 120

11 Shaping Tool 2 250 500

12 Scotch and Yoke 2 250 500

13 Nut and Bolt 18 10 180

14 Holder (shaping) 2 90 180

15 Cable and Regulator 2 30 60

16 Transportation and other Expensive - 200 200

Rs6490

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XIV. Conclusion The scotch yoke mechanism is made and its advantages and disadvantages are discussed. Its

motion characteristics are studied. It is concluded that this mechanism is a good choice to convert

rotating motion into reciprocating motion because of fewer moving parts and smoother operation.

It can be used in direct injection engines like diesel engines, hot air engines. In this project report

we provide an overview of the issues concerning different aspects of multipurpose machine using

scotch yoke mechanism. The paper focused on the principle of scotch yoke mechanism, type of

tooling and machining parameters and process performance measure, which include cutting speed,

depth of cut, material removal rate with different type of equipment which can be run

simultaneously and fabricate the work piece in multipurpose machine has been presented. The

presented results can help to plan the machining of work piece with expected tolerance. The

following major conclusions may be drawn from the study.

Multipurpose machine is derived from turning lathe which has been a well-established

industrial process offering attractive capabilities for handling work piece of various length

to be used at micro level.

We have presented the development of multipurpose machine in various modes by which it

can be actively adopted.

We have explained the various parts and components of multipurpose machine using scotch

yoke mechanism.

Different types of attachments and tools which can be implemented on multi-purpose

machine have been discussed.

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XIV. Scope for Further Work

In this research, an integrated manufacturing application framework to link design stage to the

other stages in the manufacturing systems has been developed. An IPPPIS (Integrated Payroll and

Personnel Information System) has been developed to have a computer-based method for the

concurrent design of the part design, the tool design and the process design. Some directions for

further work are given below. Only the limited aspects of fixture issues were considered here.

However, fixture planning and fixture design is indispensable in setup planning which requires

more attention. Multi-spindle machine tools are widely used in mass production. They can execute

multiple processes at the same time, which can greatly increase productivity and reduce cycle time.

The machine tool capability model can be extended to multiple spindle machine tools in future

studies. In the part coding area, coding was restricted to 19-digit code in the design and process area. This

is to reduce the time for coding and overall prototype model development. This can be further

extended to more number of digits to enhance the accuracy of the retrieval. Some of the attributes

such as tolerance, tools, fixtures, etc., can be elaborated further in this context, according to the

requirement of the industry on which it is to apply.

In this research domain, knowledge in the setup planning and fixture design area is restricted with

more focus being given on process and design. This can be further elaborated with details of

fixtures design and setup planning depending upon the type of machine tools that are being used,

which can be linked with the framework.

Future research work can be planned for the improvement of the proposed framework, for creation

of a model for evaluation of productivity improvements, in order to quantify time and cost

reduction. Enhancement of the model through a workflow perspective, using the object-oriented

approach used here, will help extending the use of the model for the entire production system.

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References

[1]. Heinrich Arnold the recent history of the machine tool industry and the effects of

technological change “University of Munich,

Institute for Innovation Research and Technology Management, November 2001. [2]. Dr. Toshimichi Moriwaki “Trends in Recent Machine Tool Technologies”

Professor Department of Mechanical Engineering Kobe University, NTN Technical Review

No.74(2006). [3]. T. Moriwaki “Multi-functional machine tool”, Department of Industrial and Systems

Engineering, Setsunan University, Neyagawa, Japan CIRP Annals - Manufacturing Technology DOI: 10.1016/j.cirp.2008.09.004 .

[4]. Frankfurt am Main “Multi-purpose machines ensure enhanced “, 1 January 11.

[5]. “Selecting and Planning the Process of Manufacture: Dr.Pulak M.Pandey. http://paniit.iitd.ac.in/~pmpandey

[6]. “Scotch Yoke Mechanisam ” from Wikipedia by google

“https://en.wikipedia.org/wiki/scotchyokemechanisam”

[7]. “Drilling” from Wikipedia by google “https://en.wikipedia.org/wiki/Drilling(engineering)”

[8]. “Spur Gear” from S.S.RATAN book, chapter 10 & page no.372

[9]. “Helical Gear” from S.S.RATAN book, chapter 10 & page no.372

[10]. “Bevel Gear” from S.S.RATAN book, chapter 10 & page no.373

[11]. “Worm Gear” from S.S.RATAN book, chapter 10 & page no.412

[12]. “Racks” from S.S.RATAN book, chapter 10 & page no. 420

[13]. “Straight Bevel Gear” from Wikipedia by google

“https://en.wikipedia.org/wiki/straightbevelgear”

[14]. “Hypoid Bevel Gear” from Wikipedia by google

“https://en.wikipedia.org/wiki/hypoidbevelgear”

[15]. Fadooengineers.com.

[16]. www.Scribd.com.