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A) Introduction
E) Manufacturing of Machine
H) References
INTRODUCTION
PROCESS OF ROLLING
Rolling is a metal forming process in which metal strip is passed through
one or more pairs of rolls to reduce the thickness and to make the
thickness uniform. The concept is similar to the rolling of dough. Rolling
is classified according to the temperature of the metal rolled. If the
temperature of the metal is above its recrystallization temperature
(0.4-0.5 times of melting point of the metal strip), then the process is
known as hot rolling. If the temperature of the metal is below its
recrystallization temperature, the process is known as cold rolling. The
invention of the rolling mill in Europe 600 BC may be attributed
to Leonardo da Vinci in his drawings.
Flat rolling is the most basic form of rolling with the starting and ending
material having a rectangular cross-section. The material is fed in
between two rollers, called working rolls that rotate in opposite
directions. The gap between the two rolls is less than the thickness of
the starting material, which causes it to deform. The decrease in
material thickness causes the material to elongate. The friction at the
interface between the material and the rolls causes the material to be
pulled through as it is along the same direction of the metal strip feed
direction thus favorable in the leading side but on the lagging side
friction hinders this forward motion hence unfavorable.
Here, in the first stage the plate is kept between top roller and bottom
rollers and the top roller is given vertical displacement by adjusting the
lead screw and within controlled gap by using Dial Gauge to get the
required thickness. In next stage the bottom roller is driven manually in
forward direction to get the roll bending of the strip.
Reinforcing Elements:
Fibrous elements
a) Glass Fiber
b) Carbon Fiber
c) Natural Fiber
Particulate elements
a) Silicon Carbide particle (SiC)
b) Boron Carbide particle (B4C)
c) Natural particles
Matrix Elements:
Polymers
a) Linear
b) Branched
c) Cross-linked
Metals
Types of Composites
Composite materials are usually classified by the type of reinforcement they use.
This reinforcement is embedded into a matrix that holds it together. The
reinforcement is used to strengthen the composite. For example, in a mud brick,
the matrix is the mud and the reinforcement is the straw. Common composite types
include random-fiber or short-fiber reinforcement, continuous-fiber or long-fiber
reinforcement, particulate reinforcement, flake reinforcement, and filler
reinforcement.
LAMINAR COMPOSITES:
PARTICULATE COMPOSITES:
Composites refer to a material consisting of two or more individual constituents.
The reinforcing constituent is embedded in a matrix to form the composite. One
form of composites is particulate reinforced composites with concrete being a good
example. The aggregate of coarse rock or gravel is embedded in a matrix of
cement. The aggregate provides stiffness and strength while the cement acts as the
binder to hold the structure together.
USES IN INDUSTRY:
The most common particulate composite materials are reinforced plastics which
are used in a variety of industries.
Automotive
Glass reinforced plastics are used in many automotive applications including body
panels, bumpers, dashboards, and intake manifolds. Brakes are made of
particulate composite composed of carbon or ceramics particulates.
Consumer Products
Many of the plastic components we use in daily life are reinforced in some way.
Appliances, toys, electrical products, computer housings, cell phone casings,
office furniture, helmets, etc. are made from particulate reinforced plastics.
BENEFITS:
Selection of machine
Electromagnetic stir-casting machine
Accumulative Roll Bonding machine
Now,
Torque required to drive the roller, τ = 0.5 * F * L = (0.5*9752*6.71)/1000
= 32.716 N-m
Force applied = (τ/0.2) = (32.716/0.2) = 163.6 N (possible)
Human body can apply a maximal push force of 778 N with both hands.
As our calculated force is 360 N which lies within (40-50)% of maximum i.e
778 N. hence we can
do the rolling operation manually.
Power (in kW) = (2*π*F*L*N)/60000 = (2*3.14*9752*6.71*(10-3)*6)/60000
= 0.0411 kW = 41.1 Watt
Power (in hp) = (41.1)/(745.7)= 0.055 hp (Where 1 hp=745.7 W)
From the above two steps we get different value of force ,torque ,power and for
calculation purposes we consider the maximum of the two. i.e.
Maximum power required = 0.055 hp.
Maximum torque required = 32.716 N-m.
Maximum force required = 9752 N.
Roller shaft
A shaft is a rotating machine element, usually circular in cross section, which is
used to transmit power from one part to another, or from a machine which
produces power to a machine which absorbs power.
Shaft is a common and important machine element. It is a rotating member, in
general, has a circular cross-section and is used to transmit power. The shaft may
be hollow or solid. The shaft is supported on bearings and it rotates a set of gears
or pulleys for the purpose of power transmission. The shaft is generally acted
upon by bending moment, torsion and axial force. Design of shaft primarily
involves in determining stresses at critical point in the shaft that is arising due to
aforementioned loading. Other two similar forms of a shaft are axle and spindle.
Axle is a non-rotating member used for supporting rotating wheels etc. and do
not transmit any torque. Spindle is simply defined as a short shaft. However,
design method remains the same for axle and spindle as that for a shaft.
Typical sizes of solid shaft that are available in the market are,
Up to 25 mm 0.5 mm increments
25 to 50 mm 1.0 mm increments
50 to 100 mm 2.0 mm increments
100 to 200 mm 5.0 mm increments
Design based on Strength In this method, design is carried out so that stress at
any location of the shaft should not exceed the material yield stress. However, no
consideration for shaft deflection and shaft twist is included.
Material used:- high carbon steel
Tolerance provided:-
Fit:- Interference fit between shaft and bearing.
Bearing
Thrust bearing:- A thrust bearing is a particular type of rotary bearing. Like other
bearings they permit rotation between parts, but they are designed to support a
predominantly axial load.
Bearing selection:
The net radial load acting on each bearing:
fo = ( )N = 4974 N
Lth=350 * 8 * 10 =28000 hrs
L10 = = 10.08 million rev.
P = fo = 4974 N
C = p * (L10)1/3 = 4974 * (10.08)1/3
C = 10744.66
Let, load factor = 1.5
Then, C = 1.5 * 10744.66
C = 16117
Depending on the value of C we refer to the chart given in machine design by
(bhandari) to obtain the bearing dimension and designation .
Hence , we use bearing of dimension ,
Internal diameter-30mm and outer diameter-55mm
Thus for bearing selection, series will be: 6006
Angle bar
An angle bar, also known as an "L-bracket" or an "angle iron," is a metal bracket in
the form of a right angle. It is made of galvanized steel and often used in masonry
or applied to different surfaces through welding or drilling. Angle bars are often
utilized to support beams and other platforms, but their usefulness goes beyond
their usual role. Angle bars can provide additional strength, protect structures
from corrosion and even provide additional stability.
Size used:-2”*2”*3/16”
Steel Plates:- Mild Steel Plates can come in various sizes and grades. Thicknesses
available range from 3mm up to as thick as150mm. Stock sizes range from 2000 x
1000mm up to 4000 x 2000mm.
Sizes used for the roll bonding cage and support plate are;
½” mild steel plate
Dial guage: dial gauge. : a gauge consisting of a circular graduated dial and a
pointer actuated by a member that contacts with the part being calibrated.
possible range 0.25 mm to 300 mm.
Used here:- spherical tip type dial gauge having range 1 mm to 10 mm and least
count of 0.01mm.
Making Of Machine
From design it is clear which type of material will be used, what will be
its dimension, what type of load will be there, how much machine can
carry etc. but still it is theoretical calculation, but main fundamental is
hiding behind practical. Practical way only can tell you original.
During making of Accumulated Roll Bonding Machine not only we used
machine parts with which it can be made but also we had to use machine
tools.
List of materials, which are used, listed below:
1. Angle [M.S.]
2. Plate [M.S.]
3. Roller [C.S.]
4. Solid Rod [H.C.S. with High Chromium]
5. Shaft [C.S.]
6. Channel Section [M.S.]
7. Nut [H.C.S]
8. Adapter [H.C.S]
9. Bearing [Deep Groove Ball and Thrust]
10. Square Block [M.S.]
11. Rod [M.S.]
12. Nut, Bold and Washer [C.S]
13. Pipe [M.S.]
14. Rectangle rod [M.S.]
15. Dial Gauge [KANN]
List of Machine tools are used:
1. Hand Cutter [Bosch]
2. Hand Grinder [Bosch]
3. Stand Grinder
4. Range [Fixed and Adjustable]
5. Hammer [ Different size]
6. Vise
7. Hand Drilling
8. Welding Machine [Arc Welding]
9. Chipping Hammer
10. Ellen key
11. File
12. Sieve Cutter
13. Punching
14. C Attachés
2. Suprim Sardar, Atanu Mandal, Surjya Kanta Pal, Shiv Brat Singh.
“Accumulative Roll Bonding of AA6005 and AA1060 Metal Strip: Study
on Microstructure, Mechanical Properties and Evaluation of Minimum
Bonding Criteria”. 5th International & 26th All India Manufacturing
Technology, Design and Research Conference (AIMTDR 2014) December
12th–14th, 2014, IIT Guwahati, Assam, India.
3. Saeed Tamimi, Mostafa Ketabchi, Nader Parvin, Mehdi Sanjari and Augusto
Lopes. “Accumulative Roll Bonding of Pure Copper and IF Steel”.
Hindawi Publishing Corporation International Journal of Metals Volume 2014,
Article ID 179723, 9 pages.
4. Frank Kümmel, Tina Hausol, Heinz Werner Hoppel and Mathias Goken,
“Enhanced fatigue lives in AA1050A/AA5005 laminated metalcomposites
produced by accumulative roll bonding”. 2016 Acta Materialia Inc.
Published by Elsevier Ltd. All rights reserved.