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PROJECT SYNOPSIS

1. Name of college : SBGI College of Engineering ,Miraj.

2. Name of course : B.E. Mechanical

3. Name of students: 1.Saheblal M. Mulla 2. Vinayak T. Lamdade 3. Rohan S. Patil 4. Sunil N. Koli 5. Umesh D. Vhaval

4. Year of Project: 2012-2013

5. Name of Project Guide: Prof. A.S. Bhandare

6. Proposed title: Design and Development of Rotary Table Fixture for Drilling Machine

7. Sponsorship: Ashok Engineering Works Kupwad MIDC.

Aim: Design and Development of Rotary Table Fixture for Drilling


Machine

Introduction To subject :
In this project we design & manufacture the Rotory Table for the company named Ashok Engineering Works situated at Kupwad MIDC, Kupwad. A rotary table is a precision work positioning device used in metalworking. It enables the operator to drill or cut work at exact intervals around a fixed (usually horizontal or vertical) axis. Some rotary tables allow the use of index plates for indexing operations, and some can also be fitted with dividing plates that enable regular work positioning at divisions for which indexing plates are not available. A rotary fixture used in this fashion is more appropriately called a dividing head (indexing head). This project aim to minimize the lead time, minimize the worker fatigue & increase the production rate & Accuracy. Rotary tables are most commonly mounted "flat", with the table rotating around a vertical axis, in the same plane as the cutter of a vertical Drilling Machine. An alternate setup is to mount the rotary table on its end (or mount it "flat" on a 90 angle plate), so that it rotates about a horizontal axis. In this configuration a tailstock can also be used, thus holding the work piece "between centers." Powered tables under the control of CNC machines are now available, and provide a fourth axis to CNC drilling machines. Rotary tables are made with a solid base, which has provision for clamping onto another table or fixture. The actual table is a precision-machined disc to which the work piece is clamped (T slots are generally provided for this purpose). This disc can rotate freely, for indexing, or under the control of a worm (hand wheel), with the worm wheel portion being made part of the actual table. High precision tables are driven by backlash compensating duplex worms. The ratio between worm and table is generally 40:1, 72:1 or 90:1 but may be any ratio that can be easily divided exactly into 360. This is for ease of use when indexing plates are available. A graduated dial and, often, a vernier scale enable the operator to position the table, and thus the work affixed to it with great accuracy.

Relevance:In manufacturing industries time plays a key role in production of extent component. In this competitive era of time every companies aim is to achieve maximum production in less time to meet requirement of vendor or customer. This can be achieved by making a machine using appropriate mechanism to

achieve particular goal like accuracy and minimization of lead time. The mechanism is used to reduce lead time in operations. There are various problems on assembly line regarding the fitment of component. These problems can be solved by using special designed operated machines.

This yields an appropriate output with the following advantages they are follows. Increase production Rate. Reduce Lead time. Reduce the worker fatigue. This mechanism used for Drilling as well as Milling machine. Simple working. Unskilled worker also operate.

Present Theory and Practices:In present days the manufacturing of component is done by manually operated machines, which are time consuming and causes fatigue to operator. These works are drilling holes on circular components and milling the jobs etc. The present working on drilling machine is carried out manually means on circular job like coupling flange, pump casing, bearing cap etc if one drill is drilled then for drilling another hole the job is removed and placed in proper place where drill is drilled. It causes to change the setting of component which is placed on the drilling machine table it also increases the lead time of work piece and causes the fatigue to operator and reduces production of assembly

Proposed Project work :Mechanism Used:A worm drive is a gear arrangement in which a worm (which is a gear in the form of a screw) meshes with a worm gear (which is similar in appearance to a spur gear, and is also called a worm wheel). The terminology is often confused by imprecise use of the term worm gear to refer to the worm, the worm gear, or the worm drive as a unit. A gearbox designed using a worm and worm-wheel will be considerably smaller than one made from plain spur gears and has its drive axes at 90 to each other. With a single start worm, for each 360 turn of the worm, the worm-gear advances only one tooth of the gear. Therefore, regardless

of the worms size (sensible engineering limits notwithstanding), the gear ratio is the "size of the worm gear - to - 1". Worm drives have been used in a few automotive rear-axle final drives (although not the differential itself at this time). They took advantage of the location of the gear being at either the very top or very bottom of the differential crown wheel. In the 1910s they were common on trucks; to gain the most clearance on muddy roads the worm gear was placed on top. In the 1920s the Stutz firm used them on its cars; to have a lower floor than its competitors, the gear was located on the bottom. The worm gear carries the differential gearing, which protects the vehicle against rollback.

WORM AND WORM WHEEL MECHANISM Material used for Worm wheel:-

Material Acetal /Nylon Phos Bronze Cast Iron

Properties Low Cost, low duty Reasonable strength, low friction and good compatibility with steel Excellent machinability, medium friction.

Application Toys, domestic appliances, instruments Normal material for worm gears with reasonable efficiency Used infrequently in modern machinery

Image of Project:-

S.V. Principle of Operation

T.V.

Each complete rotation of the crank moves the table 1/72 of a full rotation (5 degrees). For smaller increments there are two rings of holes on the dividing plate. The outer ring has 28 equally spaced holes and the inner ring has 15 equally spaced holes. Advancing the crank using the outer ring rotates the table 1/28 of 1/72 of a rotation (0.1786 degrees). Advancing the crank using the inner ring rotates the table 1/15 of 1/72 of a rotation (0.3333 degrees). By selecting the appropriate ring of holes and by counting turns and hole advancement, a large number of equal circle divisions may be obtained. The various combinations have been tabulated in the chart below for quick reference. The sector plates help you count holes. Set them so that they include the starting and ending holes for each increment of crank advancement. Then, lock the setscrew to maintain the setting. Between table advancements, rotate the secrors to the next position. Make sure the indexing pin does not strike the sectors during rotation of the crank.

Methodology adopted for completion of task:


Sr. No. Task Target tentative Months require to complete August2012 September2012

1 2

Literature and Market Survey Methodology

Selection of parameters

October2012

Experimentation

November2012

Analysis by using analysis techniques

December2012

Result and Discussion

January2013

Conclusions and Recommendations

February2013

Report writing

March2013

BILL OF MATERIAL Sr. No. Component (All dimensions in mm ) 1 Base plate: Area-2702705 2 Vertical shaft Lenth-220, Dia.- 30 3 Bearing holder OD-100, ID-55, Thickness-10 4 Ball Bearing holding rectangular plate Area-1671675 5 Working Table OD-275,ID25,Thickness-15 6 Disc plate for demonstration OD-248,ID-28, Thickness-3.5 7 Worm and worm wheel 1/36/11/4 Mild Steel, 1 2500 Mild Steel 40C8 1 800 Mild Steel 40C8 1 1000 Cast Iron FG 200 1 800 Cast Iron FG 200 2 2000 EN8 1 900 M.S. 1 1500 Material Quantity Cost

8 9

Square plate M16 Hexagonal Nuts and bolt Diameter- 16mm, e30mm

EN8 M.S.

1 4

700 100

10

M10 Hexagonal Bolts and nut Diameter10mm.length-140mm

M.S.

100

11

Machining cost

3000

12

Other expenses

3000

Total project approximate cost

16400/-

This project is sponsered by ASHOK ENGG. WORK PVT. LTD., MIDC SANGLI.

References:
1. Rattan S.S. Theory of machines,3rd Edition, Tata McGraw Hill Education India Pvt. Ltd.,2000 2. R.S. Khurmi, P.S. Gupta, Theory of machines, 14th Edition, S Chand Publication Delhi. 3. V.B.Bhandari, Design of machine element, 3rd Edition, Tata McGraw Hill Education India Pvt. Ltd.,1994 4. R.k.Jain , Machine design by, Khanna Publication. 5. Hajara Choudhari,Workshop Technology, 8th Asia Publication house, Bombay,1986. 6. Kemster, An introduction to jig and fixtures, 3rd viva books Pvt. Ltd 1998

7. Visits: a. ASHOK ENGINEERING WORKS KUPWAD MIDC, SANGLI. b. MAHABAL METALS PVT. LTD. MIRAJ

SR. NO. 1 2 3 4 5

NAME Mr. Saheblal Mahiboob Mulla. Mr. Vinayak Tanaji Lamdade. Mr. Sunil Nandkumar Koli. Mr. Rohan Suresh Patil. Mr. Umesh Dnyandev Vhaval.

SIGN.

Guide:

Mr. A.S.Bhandare. (Assistant professor of Mechanical department)

Mr. S.M. Ranade. (Head Of Department of Mechanical engineering)

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