REPLACEMENT OF ADVANCED DEBURRUNG MACHINE IN THE MANUFACTURING YOKE LINE

A PROJECT REPORT

Submitted By

V. Vijay Mahesh Reg.No 10807114041

V. Subha Lakshmi Reg.No 10807114318

In partial fulfillment for the award of the degree

Of

BACHELOR OF ENGINEERING

IN

MECHANICAL ENGINEERING

DEPARTMENT OF MECHANICAL ENGINEERING

MAGNA COLLEGE OF ENGINEERING

MAGARAL, CHENNAI

(Affilated to Anna University, Chennai-600 025)

MAGNA COLLEGE OF ENGINEERING MAGARAL, CHENNAI

DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE

This is to certify that this report is the bonafide work of

V. Vijay Mahesh Reg.No 10807114041

V. Subha Lakshmi Reg.No 10807114318

Who carried out the project entitled “REPLACEMENT OF ADVANCED

DEBURRUNG MACHINE IN THE MANUFACTURING YOKE LINE”

Under our supervision from 14.12.2010-12.01.2011

External Guide

(Mr.Duraivenkatraman.V)

Training Manager

(Mr.Prabhakaran.R)

DECLARATION

We V. Vijay Mahesh and V. Subha lakshmi here by

declare that the project report entitled “ REPLACEMENT OF

ADVANCED DEBURRING MACHINE IN THE

MANUFACTURING YOKE LINE” is done by under the

guidance of Mr.Mohan.V and the head of

Mr.Duraivenkatraman.V at LUCAS TVS LTD, CHENNAI is

submitted in the partial fulfillment of the requirements for the

award of the degree on BACHELOR OF ENGINEERING.

DATE: Vijay Mahesh. V

PLACE: CHENNAI Subha Lakshmi. V

ACKNOWLEDGEMENT

A few words of gratitude written on single sheet of

paper can never completely describe our feeling of indeptedness

to the people involved in the successful completion of project

First and foremost we would like to thank the

almighty for his blessing to complete our project successfully in

time.

Our deepest thanks to Mr. Duraivenkatraman. V our

head and also our guide Mr. Mohan. V for guiding and

correcting us whenever we wrong with attention and care. He

has taken great pains in going through the project and guiding us

the entire time meticulously.

My deep sense of gratitude to Mr. Prabhakaran. R

(Assistant Manager, Training Center), TVS LUCAS for giving a

chance to do a project in his prestigious company and for his

support and guidance. Thanks and appreciation to all the people

at LUCAS TVS for their help and support.

Contents Introduction

About TVS TVS groups About the TVS group TVS awards TVS group of companies

Introduction of LUCAS-TVS Mission Vision About LUCAS-TVS Awards getting Milestones of LUCAS-TVS Products manufacturing Major customers Various departments

Commercial starter business unit Starter Main components ofstarter Starter motors and its application

Yoke Magnetic poles Field coils Bipolar and multipolar field Armature Commutator

Brushes Types of carbon brushes Starter solenoid

Yoke assembly REPLACEMENT OF ADVANCED DE-BURRING

MACHINE Burr Types of burrs De-burring Manual deburring Electrochemical deburring Thermal energy method Cryogenic deburring

Introduction Main objectives Need for the project Works to be done Construction of existing deburring machine

Working Construction of advanced deburring machine

Comparison with earlier machine Working Specifications Automatic deburring machine Part names

conclusion

INTRODUCTION :

ABOUT TVS

The TVS group was established in 1911 by Shri. T V

Sundaram Iyengar. As one of india’s largest industrial entities it

epitomizes

T-Trust

V-Value

S-Service

Today, there are over thirty companies in the TVS group,

employing more than 40,000 people worldwide and with a

turnover in excess of USD 4 billion.

With steady growth, expansion and diversification, TVS

commands a strong presence in manufacturing of two-wheelers,

auto components and computer peripherals.

We also have vibrant business in the distribution of heavy

commercial vehicles passenger cars, finance and insurance.

TVS GROUP

ABOUT THE TVS GROUP

In 1911 Mr.TV Sundaram Iyengar inaugurated a bus

seervice between Madurai to devakoottai.

In 1911, he commenced business in Madurai as a dealer in

automobile spars, by 1929 the business developed into a

limited company as direct dealership for general motors

india limited and was named T.V Sundaram Iyengar and

sons private limited

Since the time, the company has expanded into versatile

group(knoun as TVS group) to offer comprehensive service

to the automobile and transport industry.

Today the TVS group operates a road transport fleet for

goods in the southern markets.

Automobile vehicles and parts with the service and

reconditioning facility, manufacturers auto auxiliaries like

wheels, electrical equipments, foundation brakes and

related components.

Air assisted equipments for vehicle brakes, road springs,

high tensile fasteners, brake linings, and rubber

components, body building on chasis and finances, hire

purchase of vehicles and rethreading of fires.

TVS AWARDS

GROUP AWARDS AND RECOGNITIONS

There are various awards and credits given to the

company for the service made to the customer and for the

quality of the product. The various awards and recognitions

are as follows.

One of the top 10 business group in india

Sundaram Clayton

Brakes India

TVS Motor company

Sundaram Brake lining

Deming Quality Awards

Sundaram clayton

Brakes India

TVS Motor company

Sundaram Brake Lining

LUCAS-TVS

Japan Quality Metal

Sundaram Clayton

TPM Excellence awards

Sundaram fasteners

Brakes India

TVS Motor company

TVS Rubber

TVS Tyres

GM North America, Best Supplier Awards

Sundaram Fasteners(1998-2002)

JIT Grand Prix awards

Lucas-TVS:Only company outside Japan

and South Korea to win

ACMA Productivity and Technology awards

(Automotive Components Manufacturer’s Associations)

TVS GROUP OF COMPANIES

Lucas TVS Limited

Delphi TVS

Axles India Limited

Brakes India Limited

Harita Finance Limited

India Japan Lighting Limited

India Motor Parts and accessories Limited

India Nippon Electricals Limited

Lakshmi Auto Components Limited

Lucas Indian Service

Southern Railways Limited

Sundaram Brake lining Limited

Sundaram- Clayton Limited

Sundaram Dynacast Limited

Sundaram Fasteners Limited

Sundaram Industries Limited

Sundaram Textiles Limited

Transenergy Limited

Turbo Energy Limited

TVS Cherry Limited

TVS Electronics Limited

TVS Interconnect system Limited

TVS Lanka Pvt Limited

TVS-Motor Company Limited

TVS Sewing Needles Limited

TV Sundaram Iyengar & sons Limited

TVS Automotive Europe Limited

Wheels India Limited

Wabco-TVS India Limited

INTRODUCTION OF LUCAS-TVS

MISSION

To be a respected supplier in the global auto industry, by

customers through creative skills and involvement of employees,

suppliers and dealers and use of contemporary technology.

VISION

To be the supplier of choice of all leading vehicle

manufacturers in india.

To be recognized OE supplier in Asia Pacific and

Middle East Market

To achieve global recognition for innovative

approach to products and solutions

By 2010, sell INR 2000 crores USD 450 million of

products and solutions with a third to customers

outside India

ABOUT LUCAS-TVS

Lucas-TVS was set up in 1961 as a joint venture of Lucas

industries plc, UK and T V Sundaram Iyengar & sons

(TVS0, India, to manufacture Automotive Electrical

Systems.

Its manufacturing and sales activities span five continents

One of the top ten automotive suppliers in the world,

Lucas varity was formed by the merger of the Lucas

industries of the UK and the varity corporation of the US in

September 1996

The company designs, manufacturers and supplies advance

technology systems, products and services to the worlds

automotive, after market, diesel engine and aerospace

industries

The combination of these two well-known group has

resulted in the establishment of a vibrant company, which

has a successful track record of sustained growth over the

last three decades

TVS is the one of the india’s twenty large industrial houses

with twenty-five manufacturing companies and a turnover

in excess of US$ 233 billion

The turnover of Lucas –TVS and its divisions is US$ 233

million during 2003-2004

Incorporating the strengths of Lucas TVS Group, Lucas

Tvs has emerged as one of the foremost leaders in the

automotive industry today

The group has a product range that includes auto electrical,

diesel fuel injection system, breaking system, automotive

wheels and axles, fasteners, power metal components,

radiator caps, two wheels and computer peripherals to

mentions the significant ones.

Lucas TVS reaches out of all segments of the automotive

industry such as passenger cars, commercial vehicles,

tractors jeeps, two-wheelers and off- highway vehicles as

well as for stationary and marine applications

Currently the components producer over a half million

starters and alternators per annum, and has plan to double

the quality-the fuel injection equipment division makes the

state of the act rotary pumps, the providing a welcome

supply option for this vital component

With the automobile industry in india currently undergoing

phenomental changes, Lucas-TVS, With its excellent

facilities, is fully equipped to meet the challenge of

tomorrow

Lucas-TVS is the leader in autoelectrical in India today

with 40 years of experience in design and manufacturing

Today Lucas-TVS operate from three plants located at

padi, Pondicherry and Rewari

AWARDS GETTING

1981 Dr.C.K.Ramachandran Award-Best environment in

industry

1982/88 National competition for young managers

1985/99 ACMA Awards for best technology

1986 Good industrial relations award

1987/92 National competition for supervisors- IIT

1990 State level award qc competition

1993 Quality circle forum of india awards

1995 ICQC award, Yokohama quality circle, japan

1997 CII-9th national first QC competition

2001/07 ACMA awards for best technology

2003 Best performer award

2004 Gold Trophy for manufacturing excellence

2005 Frost and Sullivan award

2006 Best vendor award

2007 Best quality award

MILESTONES OF LUCAS- TVS

1962 Incorporated as public limited

1963 First starter supply to Telco

1966 Commencement of export to Egypt

1968 Lucas Indian service Ltd becomes wholly owned

subsidiary of Lucas-TVS

1973 Recognition of R&D by the department of science &

technology Government of India

1975 Introduction of alternator on commercial vehicles

1976 Millionth starter /Generator produced

1979 Permanent magnet wipers introduced

1984 Millionth distributor produced

1985 Introduction of cellular system of manufacture

Alternator/Starter supply to Maruti Udyog

1986 Introduction of vaccum pump alternator Automatic

planting plant commissioned

1987 Expansion of Training facilities

1991 Rawari plant commences production Introduction of

Nagare cells in manufacturing

1994 Turnover crosses Rs.200 crore

PRODUCTS MANUFACTURING

Starter motor

Alternator

Wiper motor

Distributors

Fan motor

Head lamp

Ignition coil

Regulatory/Dynamo

Compressor motor

MAJOR CUSTOMERS

Hyundai Motor India

Ford Motor Ltd

Tata Motor

General Motor

Bajaj Auto Limited

Bajaj Tempo Limited

Marati Udyog Limited

VARIOUS DEPARTMENTS CMSBU [Commercial Starter Business Unit]

CSBU [Car Starter Business Unit]

ABU [Alternator Business Unit]

PMTC [Plant Manufacturing Technology Center]

EPU [Export Product Unit]

WBU [Wiper Business Unit]

EC [Engineering Center]

MTC [Machine Tool Center]

TC [Training Center]

Reliability and proving lab

Auto plating

Heat Treatment

Phosphating

COMMERCIAL STARTER BUSINESS UNIT [CMSBU]

PRODUCTION IN MY DEPARTMENT

STARTER :

A starter motor (also starting motor, or starter) is an

electric motor for rotating an internal-combustion engine so as

to initiate the engine's operation under its own power.

The modern starter motor is either a permanent-magnet

or a series-parallel wound direct current electric motor with a

starter solenoid (similar to a relay) mounted on it.

When current from the starting battery is applied to the

solenoid, usually through a key-operated switch, the solenoid

engages a lever that pushes out the drive pinion on the starter

driveshaft and meshes the pinion with the starter ring gear on the

flywheel of the engine.

The solenoid also closes high-current contacts for the

starter motor, which begins to turn. Once the engine starts, the

key-operated switch is opened, a spring in the solenoid assembly

pulls the pinion gear away from the ring gear, and the starter

motor stops. The starter's pinion is clutched to its driveshaft

through an overrunning sprag clutch which permits the pinion to

transmit drive in only one direction.

In this manner, drive is transmitted through the pinion

to the flywheel ring gear, but if the pinion remains engaged (as

for example because the operator fails to release the key as soon

as the engine starts, or if there is a short and the solenoid

remains engaged), the pinion will spin independently of its

driveshaft.

This prevents the engine driving the starter, for such

backdrive would cause the starter to spin so fast as to fly apart.

However, this sprag clutch arrangement would preclude the use

of the starter as a generator if employed in hybrid scheme

mentioned above, unless modifications are made.

Also, a standard starter motor is only designed for

intermittent use which would preclude its use as a generator.

This overrunning-clutch pinion arrangement was phased

into use beginning in the early 1960s; before that time, a Bendix

drive was used. The Bendix system places the starter drive

pinion on a helically-cut driveshaft. When the starter motor

begins turning, the inertia of the drive pinion assembly causes it

to ride forward on the helix and thus engage with the ring gear.

When the engine starts, backdrive from the ring gear causes the

drive pinion to exceed the rotative speed of the starter, at which

point the drive pinion is forced back down the helical shaft and

thus out of mesh with the ring gear.

In any course, we always begin at the starting point One cannot reach the top with full knowledge and

experience without stepping on the first level

In the complicated engineering of vehicles, the machine shall not run unless the starter is activated

It is the part of the car’s electronic system bound to initiate the very first process of its operation, acting like switch that makes the other performance system to follow

Starter is the electronic motor powered by the battery that turns the crankshaft before the pistons operate

Basically starter is crafted to convert electrically into mechanical energy, which happens in two stages

Let’s take a look at its technical process In turning the ignition switch on, a small amount of

power from the battery is released, which goes to the solenoid above the starter

In such ways , the magnetic field that causes pulling force that brings the solenoid plunger forward is produced

This makes the attached shift yoke move the starter drive, accordingly the piston gear meshes with the engine’s crankshaft flywheel

After the plunger completes its travels, it will strike a contact, permitting greater amount of current to flow from battery to starter

Then the motor will spin the drive and turn the meshed gears so as to provide power to the

crankshaft thus every cylinder is being prepared for ignition

Right after the engine starts, the ignition is then released to break the starting circuit

The solenoid’s magnetic field disintegrates and the return spring pulls plunger back, marking the starter to motor to automatically shut off and disengage the starter drive

As soon as the starter is activated, the forward movement of the solenoid plunger makes the shift yoke to move the drive which is situated in its opposite direction and engage the pinion and flywheel

The pinion is then locked to its shaft by a clutch that unlocks if the engine starts up and the flywheel begins turning faster than its normal speed

For a moment, the pinion is allowed to spin freely so to let the clutch protect the motor from damage until the drive is retracted

This very important auto part is provided by the industry for the customers needs in different vehicle brands, for cars, trucks, vans, and SUVs you can find the starter for a specific model, trim and year in the traditional way or through advance use of internals

MAIN COMPONENTS OF STARTER:

1. Main Housing (yoke)2. Overrunning clutch3. Armature4. Field coils5. Brushes6. Solenoid

YOKE

Yoke provided mechanical support for the machine and acts as a cover for the machine

It forms the portions of magnetic circuits. The yoke is made of cast iron for smaller machine

For larger machine it is made up of fabricated steel

MAGNETIC POLESThe field magnets consist of pole cores and pole shoes

They spread out the flux in the air gap

They support the field coils

The pole shoes are built with thin laminations of steel. The

laminations are held together using rivets. The cores are

laminated to reduce eddy current loss.

FIELD COILS A field coil is the magnetic field component of an

alternator, generator, dynamo, motor or rotary converter.

The phrase is also often used in the plural form, as field

coils.

1. The field coils can be mounted on either the rotor or

the stator, depending on whichever method is the

most cost-effective for the device design.

Bipolar and multipolar field

In the early years of generator development, the stator

field went through an evolutionary improvement from a single

bipolar field to a later multipole design.

Bipolar generators were universal prior to 1890 but in

the years following it was replaced by the multipolar field

magnets. Bipolar generators were then only made in very small

sizes.

The stepping stone between these two major types was the

consequent-pole bipolar generator, with two field coils arranged

in a ring around the stator.

This change was needed because higher voltages allow

current to flow greater distances over small wires.

To increase the output voltage, a DC generator must be

spun faster, but beyond a certain speed this is impractical for

very large power transmission generators.

By increasing the number of pole faces surrounding the

Gramme ring, the ring can be made to cut across more magnetic

lines of force in one revolution than a basic two-pole generator.

Consequently a four-pole generator could output twice the

voltage of a two-pole generator, a six-pole generator could

output three times the voltage of a two-pole, and so forth. This

allows output voltage to increase without also increasing the

rotational rate.

SALIENT FIELD BIPOLAR GENERATOR

CONSEQUENT FIELD BIPOLAR GENERATOR

CONSEQUENT FIELD FOUR POLE SHUNT WOUND DC GENERATOR

FIELD LINES OF A FOUR POLE STATOR PASSING THROUH A RING OR DRUM ROTOR

In a multipolar generator, the armature and field

magnets are surrounded by a circular frame or "ring yoke" to

which the field magnets are attached. This has the advantages of

strength, simplicity, symmetrical appearance, and minimum

magnetic leakage, since the pole pieces have the least possible

surface and the path of the magnetic flux is shorter than in a

two-pole design

Field coils are usually wound with enameled copper

wire. Sometimes cotton insulation is used. The north and

south pole depends upon the direction of current flow

through the field coil

ARMATURE

In electrical engineering, an armature generally

refers to one of the two principal electrical components of an

electromechanical machine–generally in a motor or generator,

but it may also mean the pole piece of a permanent magnet or

electromagnet, or the moving iron part of a solenoid or relay.

The other component is the field winding or field

magnet. The role of the "field" component is simply to create a

magnetic field (magnetic flux) for the armature to interact with,

so this component can comprise either permanent magnets, or

electromagnets formed by a conducting coil.

The armature, in contrast, must carry current so it is

always a conductor or a conductive coil, oriented normal to both

the field and to the direction of motion, torque (rotating

machine), or force (linear machine).

The armature's role is two-fold. The first is to carry

current crossing the field, thus creating shaft torque in a rotating

machine or force in a linear machine. The second role is to

generate an electromotive force (EMF).

In the armature, an electromotive force is created by

the relative motion of the armature and the field. When the

machine is acting as a motor, this EMF opposes the armature

current, and the armature converts electrical power to

mechanical torque, and power, unless the machine is stalled, and

transfers it to the load via the shaft.

When the machine is acting as a generator, the armature

EMF drives the armature current, and shaft mechanical power is

converted to electrical power and transferred to the load. In an

induction generator, these distinctions are blurred, since the

generated power is drawn from the stator, which would normally

be considered the field.

The Armature core is keyed to the machine shaft and it

rotates between the field poles

It consist of slotted steel laminations

The laminations are insulated from each other by thin

coating of varnish

The laminations are slotted to accomodated the

armature winding

Armature winding is wound in two ways

Lap winding- for low voltage high current machine

Wave winding- for high voltage low current machine

COMMUTATOR

The emf induced in the armature is ac in nature

Commutator converts this ac to dc

The commutator is made of copper segments insulated

from each other by mica sheets and is mounted on the shaft

of the machine

BRUSHES

A brush is a device which conducts current between

stationary wires and moving parts, most commonly in a rotating

shaft. Typical applications include electric motors, alternators

and electric generators

Brushes are made of carbon and rest on the commutator

The brushes are put inside the brush holder

The brush holders are kept pressed against the commutator

by a spring

Types of carbon brushes

There are distinguished basically 3 types of carbon brushes:

1. brushes for automotive applications: DC current, voltage 12-48 V

2. brushes for household applications: AC current, voltage 110 / 220 V

3. brushes for industrial motors: both AC and DC current, various voltages

Starter solenoid

In a car or truck, the starter solenoid is part of an

automobile starting system. The starter solenoid receives a large

electric current from the car battery and a small electric current

from the ignition switch.

When the ignition switch is turned on (i.e. when the

key is turned to start the car), the small electric current forces

the starter solenoid to close a pair of heavy contacts, thus

relaying the large electric current to the starter motor.

Starter solenoids can also be built into the starter itself,

often visible on the outside of the starter. If a starter solenoid

receives insufficient power from the battery, it will fail to start

the motor, and may produce a rapid 'clicking' or 'clacking'

sound.

This can be caused by a low or dead battery, by

corroded or loose connections in the cable, or by a broken or

damaged positive (red) cable from the battery.

Any of these will result in some power to the solenoid,

but not enough to hold the heavy contacts closed, so the starter

motor itself never spins, and the engine does not start

OUR PROJECT IS REPLACEMENT OF

ADVANVANCED DE-BURRING MACHINE IN

MANUFACTURING YOKE LINE:

BURR(EDGE):

A burr is a raised edge or small pieces of material

remaining attached to a workpiece after a modification process.

It is usually an unwanted piece of material and when removed

the process is called deburring.

Burrs are most commonly created after machining

operations, such as grinding, drilling, milling, engraving or

turning. It may be present in the form of a fine wire on the edge

of a freshly sharpened tool or as a raised portion of a surface;

this type of burr is commonly formed when a hammer strikes a

surface. Deburring accounts for a significant portion of

manufacturing costs.

In the printmaking technique of drypoint, burr, which

gives a rich fuzzy quality to the engraved line, is highly

desirable - the great problem with the drypoint medium is that

the burr rapidly diminishes after as few as ten impressions are

printed.

TYPES OF BURRS:

There are three type of burrs that can be formed from

machining operations:

Poisson burr

Rollover burr,

Breakout burr.

The rollover burr is the most common. Burrs may be

classified by the physical manner of formation. Plastic

deformation of material includes lateral flow (Poisson

burr), bending (rollover burr), and tearing of material from

the workpiece (tear burr). Solidification or redeposition of

material results in a recast bead. Incomplete cutoff of

material causes a cutoff projection.

Burrs can be minimized or prevented by considering

materials, function, shape, and processing in the design and

manufacturing engineering phases of product development.

Burrs in drilled holes cause fastener and material

problems. Burrs cause more stress to be concentrated at the

edges of holes, decreasing resistance to fracture and shortening

fatigue life.

They interfere with the seating of fasteners, causing

damage to fastener or the assembly itself. Cracks caused by

stress and strain can result in material failure. Burrs in holes also

increase the risk of corrosion, which may be due to variations in

the thickness of coatings on a rougher surface.

Sharp corners tend to concentrate electrical charge,

increasing the risk of static discharge. Burrs in moving parts

increase unwanted friction and heat.

Rough surfaces also result in problems with lubrication.

As wear is increased at the interfaces of parts, making it

necessary to replace them more frequently. Electrical charge

buildup can cause corrosion.

DE-BURRING:

There are many deburring processes, but the most

common are: mass-finishing, spindle finishing, media blasting,

sanding, grinding, wire brushing, abrasive flow machining,

electrochemical deburring, electropolishing, thermal energy

method, machining, and manual deburring.

Manual deburring

Manual deburring is the most common deburring process

because it is the most flexible process. It also only requires low

cost tools and allows for instant inspection.

A MANUAL DE-BURRING TOOL

Electrochemical deburring

Electrochemical deburring is the use of electrochemical

machining to deburr precision workpieces and edges that are

hard-to-reach, such as intersecting holes. The process uses a salt

or glycol solution and electricity to dissolve the burr.

The electrical current is applied with a specialized tool to

reach the burr location. Burrs are removed in 5 to 10 seconds,

while the rest of the workpiece is unaffected.

Thermal energy method

Thermal energy method (TEM), also known as thermal

deburring, is a deburring process used to remove hard-to-reach

burrs or burrs from multiple surfaces at the same time.

The process uses an explosive gas mixture to provide

thermal energy to burn off the burrs. It is the fastest burr

removal process, requiring only 20 milliseconds to remove a

burr.

The process starts by loading the workpiece into an explosion-

proof chamber, which is then sealed and clamped with

approximately 220 metric tons (240 short tons). The chamber is

then evacuated of air and filled with an oxygen and fuel mix;

this mixture is pressurized to 0.5 to 1.9 MPa (73 to 280 psi).

An electrical igniter then ignites the mixture, which burns

for approximately 2 milliseconds, causing all of the sharp

corners and burrs to burn away. The peak temperature reaches

3,000 °C (5,430 °F).

Cryogenic deburring

Cryogenic deburring is a cryogenic process used to

remove burrs and flash from plastic and die cast workpieces.

The process works by tumbling and/or abrasively blasting the

workpieces at cryogenic temperature levels.

The low temperatures (approximately −195 °C

(−319.0 °F)) are achieved using liquid nitrogen, liquid carbon

dioxide, or dry ice.

This low temperature brings the material below its

embrittlement temperature, which causes the flash or burrs to be

easily removed via tumbling or media blasting. This process has

been around since the 1960s to deflash plastic and rubber

INTRODUCTION:

De-burring machine is a machine which is mainly used to

remove remaining burs in the internal surface of the component

after drilling operation is done.

The operation is done semi automatically with the help of

de-burring tool which is in the holder.

The power for the tool spindle is from the motor which is

connected by means of gear train. The whole set up is placed in

the vertical column which slides vertically on the LM Guide

ways with re-circulating ball inside.

The work in which the burs is to be removed is placed on

the bed which is made with v-slot horizontally for the effective

hold of cylindrical type jobs.

Main Objectives :

The main objectives of the de-burring machine are listed:

It is used to clean the surface of inner part of yoke.

It is used to remove burs in the internal surface of the yoke.

It is operated semi automatically with the help of set of

bevel gears and a motor.

Need for the Project

As it is the re-model of existing de-burring machine it has to overcome the following problem existed in old machine

Fully manually operated.

Difficulties in operating.

More wear and tear.

Maintenance cost is high.

operation is noisy.

The construction is tedious and difficult.

Occupies more space.

No shock absorber.

No linear guide ways.

More spare cost for the whole set up.

More complicated in construction.

More damage to gear and bearing.

Employee feel to operate the machine in rough manner.

Mean time between failure is low.

Mean time to repair is high.

Works To Be Done:

Following are the works should be done to implement the

advanced machine:

Have to overcome all the difficulties.

Construction should be made simple.

Gears and bearings should be reduced.

Operation should me made as noiseless.

Wear and tear should be reduced by red Machine is made

as compactable.

Operation should be made as semi automatic .

Maintenance cost must be reduced.

Shock absorber should be placed.

Linear guide ways should be placed .

Less damage to gears and bearings.

Gears and bearings should be reduced by means the size of

the machine is reduced.

Should use simple drives in order to reduce the workers

stress and strain.

Mean time between failure must be high.

Construction of existing deburring machine

It consist of a motor ,pulley ,spline shaft self alignment bearing ,bevel gears and a cutter

Motor

The motor is connected to a pulley which is in turn is connected to another pulley attached to a spline shsft as seen in fig

Spline shaft

The other end of the spline shaft is connected to a bevel gear

Bevel gear

This bevel gear is in turn connected to another bevek gear

Tool

This bevel gear is connected to the cutter(deburring tool)

This is basic construction of the deburring machine as shown in fig.

The cutter is moved up and down using a mechanical lever

Working

The deburring machine has a complete mechanical operation and the working of the deburring machine is as follows

The motor runs at a constant rpm and it is connectrd to a pulley which is used to rotate a spline shaft attached to one of the pulley as shown in construction fig

When the spline shaft rotates it turns the bevel gear attached to its other end

This bevel gear is attached to another bevel gear using a spline shaft and the rotation of the first bevel gear is directly transmitted to the second bevel gear via the spline shaft

This bevel gear is in turn the cutter which is used in the deburring operation

A mechanical lever is attached to the side of the machine which is used to place the cutter on the part where the deburring is to be done

This mechanical lever when pushed down moves the whole deburring assembly down and this places the cutter at the hole where deburring is done

A spring attached brings the whole construction back to the original position once the deburring is done

This represents the working of the existing deburring machine

Construction of new deburring machine

The new deburring machine was simplified and the construction of the machine is shown in figure

It consist of a motor which is attached to a pulley as shown in figure

This pulley is attached to another pulley via a belt drive(V belt used)

This pulley is then connected to a bevel gear via a spline shaft

This bevel gear is connected to the cutter which is used to remove burr from the machine part

In this in order to move and place the cutter on the hole to be deburred the whole assembly moves up and down with the help of a pneumatic cylinder controlled by PLC and is activated by pressing two switches

Comparison with the earlier machine

The new machines construction is very simple when compared to the old machine ,in this

In this machine one of the spline shaft is removed and the bevel gear attached to it is also removed ,so the new machine has just one spline shaft and one bevel gear as shown in the construction

In this the movement of the cutter up and down is governed by a pneumatic cylinder controlled using PLC and activated via two switches in the centre console thus the mechanical level of the earlier one is removed and this makes the new machine completely automatedThe machine consists of the following subsystem

Mechanical sub systems Control sub systems Pneumatic sub systems

Mechanical sub system

The basic structure is fabricated out of square tubes and electrical panel mounted on the back side top of the machine. All the co ordination movements are performed with the help of pneumatic actuator

Control sub systems

The control system is based on industrial standard and highly reliable programmable logic controller (PLC). It controls the operating sequence of the various operating elements with the help of feedback signal from various sensors “ESTIC controller are also controlled by PLC through the feedback from torque transducer and its controller output

Pneumatic sub system

This pneumatic subsystem features double acting cylinders, single acting cylinders solenoid valve pack,pressure switch, non return valves with pilot control, pressure regulator with filter, A11 the interconnections are done through pneumatic tubing.

Working

The basic working principle of the new deburring machine is similar to that of the earlier one

The motor runs at a constant rpm and the motor turns the pulley attached to it

This in turns the pulley attached to the pulley connected to the shaft of the motor via a belt drive as shown in construction figure

This pulley then turns the spline shaft attached to it, this in turn rotates the cutter which is used to remove the burr

The cutter is moved up and down using a pneumatic cylinder which is activated by pressing two switches on the centre console simultaneously

Specifications: Component : yoke No of component : 3 NOS Operation : 1 No of drilling heads : 1 No of spindle : 1 Spindle power : 0.75 KW, 1400rpm Spindle speed : 320 rpm Drilling spindle drive : belt drive Drilling feed :

0.2mm/rev(variable by feed cyl.) Drill tool : HSS Head movement : by LM GUIDE

with hydraulic cylinderFixture:

Component clamping : manual Component rotary/linear indexing : by manual/with

pneumatic stopper No of rotary indexing : 4/8 times Angle of indexing : 90

Conclusion

The REMODEL DEBURRING MACHINE was designed and manufactured. The deburring machine eliminated all disadvantages associated with the earlier machine is automated making the work much easier and stress free

The safety factor of the new machine was also improved requiring the worker to use both his hands for the operation eliminating injuries that was frequent with earlier machine