Papercuttingrewindingmachine Projectreportsreesanghpghosh 130319004110 Phpapp01

7/21/2019 Papercuttingrewindingmachine Projectreportsreesanghpghosh 130319004110 Phpapp01

1/56


2/56

PAPER CUTTING & REWINDING MACHINE Project Report 2012-13

ACKNOWLEDGEMENT

I am very glad to represent project report on "PAPER CUTTING ANDREWINDING MACHINE" fully designed, fabricated and tested in our polytechnicas part of our curriculum is awarding the Diploma in Engineering. I have tried mylevel best to focus upon each and every parameter. In concern with this topic thedetail, necessary figure, definition, tabular analysis has been enumerated in veryeasy, simple, compact and lucid manner.

I have been able to achieve this task by the dynamic guidance of

honorable SIVARAMAN sir; I have no wards to express my gratitudetowards his kind, persistent inspiration, parent advice and outstanding treatmentwhile clarifying my confusion.

I also extend my sincere thanks to our esteemed Head of MechanicalEngineering Department Mr. M.R JAYACHANDRAN, whose guidance andconstant inspiration where a great use in working of this project. We are alsograteful to our tutor MR. P.P. DEVADAS.

I am also grateful to our honorable work shop superintendent

Mr.N.M.SATHEESAN and members of staff of our workshop for providingnumerous facilities and guidance due to which this difficult task turned in aconvenient task.

The permission granted to us by the honorable principalMr.V.V.SADASIVAN, to do the project work in greatly acknowledged.

Last but not least, I am very thankful to my project partners without whosekind cooperation it was difficult and impossible to go through the leaps and

bounds while preparing this project. Also thanks to them who directly or indirectlyco-operated and contributed during work.

Triprayar SEVENTH BATCH03/13/2013 Mechanical Engineering

Department of Mechanical Engg. S.R.G.P.T.C TriprayarPage 1


3/56


ABSTRACT

Paper Cutting & Rewinding Machine is one of the simplest machine which cuts

rolled paper in needed amount and re-winded form. The conventional paper rewinding

machine has complex mechanism and bulk size. We made some modification to the

conventional machine and eliminating its defects. The main peculiarity of machine is its

simplicity, reduced size, weight. And also reduces floor space. This project can be

directly implemented to paper cutting and rewinding machines in Paper mills. This

machine can also use in textile mills, plastic and rubber sheets cutting and rewinding

process in various industries by changing its cutting components.

By applying these modifications to the conventional machine reduce

maintenance and servicing cost, floor area and overhead expenditures. It is well suited

for small scale industries.



4/56


CONTENTS

TOPIC NO. TOPIC NAME PAGE-NO.

1.

INTRODUCTION 4

2. ORGANISATION FOR FINANCIAL ASSISTANCE 6

3. FINANCIAL MANAGEMENT 12

4. MARKET SURVEY 13

5. SMALL SCALE INDUSTRIES 17

6. SITE SELECTION 20

7. CHARACTERISTICS OF MATERIAL & WELDING 28

8. COMPONENTS OF MACHINE 30

9. MANUFACTURING PROCESS 35

10. WORKING OF MACHINE 42

11. PROCESS OF MANUFACTURING 43

12. ADVANTAGES & DISADVANTAGES 46

13. SPECIFICATIONS OF MACHINE 46

14. DRAWINGS 47

15. MATERIAL REQUIREMENT & COST 52

16. CONCLUSION 54

17. BIBLIOGRAPHY 55



5/56


INTRODUCTION

Definition Of Project :-A project is a group of unique, inter-related activities that are planned

and executed in a certain sequence to create a unique product or service, within a

specific time frame, budget and the clients specifications. Some of the

characteristics of the task that qualify to be projects are:

1) Unique Activities2) Attainment of a specific goal

3) Sequence of activities

4) Specified time

5) Interrelated activities

The success of the project is depending on the ability to strike a balance

between the following interrelated variables or constraints that are:

1) Scope of product

2) Quality of product

3) Cost (design cost, material cost, Service & Transportation charges)

4) Time (lead time, manufacturing time)

5) Resources



6/56


AWARENESS FOR PREPARING A PROJECT REPORT

A project is investment activities where resources are create some capital assets

that will produce some benefits over a spread of time. Every project will definitely have

the following characteristics.

1) It will be specific in its activity, good and planning and performance.

2) A project will be continues process.

3) There will be an effort to identify and quantify in monitory terms for cost

benefits analysis.

The whole cycle of a project has to come through seven different stages

1) Containing of idea (identification of an activity)

2) Formulation of a scheme (here we prepare the project report)

3) Project reports Appraisal

4) Project monitoring

5) Implementation6) Evaluation of the project implementation

7) Taking corrective measures for improvement

A Project Report needs to cover from very general information up to detailed

examination of specific issues relating to entrepreneurs profile with special reference to

these academic qualifications past experience and competence, comprehension and

confidence, market demand and existing sources of supply of the products proposed,technological requirement, plant and machinery, cost of production profitability and

financing pattern etc.



7/56


The important uses of project reports are:

1) It helps in obtaining provisional /registration.

2) It helps com procuring developed land or shed forgot.

3) It helps in securing supply of scarce raw materials.

4) It helps in approaching tank for getting loan (term/working capital)

5) It helps the entrepreneur is establishing techno-economic liability of the project.

6) It helps the entrepreneur to plan the sequence of operation youre the

implementation of the project.

Once a project has been identified the first step is to find out the price of

machinery and raw materials. Get the latest quotations for the machineries.

After ascertain the price of plant, machinery and raw materials. Find out the mages of

employees prevalent in the area. Now calculation regarding the profit return and break-

even point etc. has to be done.

A detailed market study had to be conducted and the same should be

incorporated into the project report (it is a must when the project cost is over 20 lakhs).

The market study should certain in the total demand for the product and presentmanufacturers of the product, their installed capacities. Marketing arrangement

including channels of distribution, logistics, etc.

The financial institutions on the receipt of project report are interest in

appraising the project from the following angles.

I. Technical area

II.

Economic areaIII. Commercial area

IV. Financial area

V. Managerial area and

VI. Social area



8/56


GENERAL ASPECTS OF A PROJECT

Up on the completion of the project the students will be able to:

1) Practice in machine drawing

2) Practice in selecting the right materials

3) Practice in are welding

4) Practice in painting

5) Practice in turning operation

6) Practice in thread cutting

I. Topic covered:

1) Selection of the materials

2) Arc welding

3) Types of fits

4) Types of threading

5) Estimating and costing6) Quality control

7) Production drawing

II. Equipment and tools:

1) Machine shop tools

2) Fitting shop tools

3)

Arc welding equipment4) Painting equipment

5) Gas cutting equipments



9/56


Procedure for Design of Machine Elements :-

The design of machine element is the most important step in thecomplete procedure of machine design. In order to ensure the basicrequirement of machine elements, calculations are carried out to find outthe dimensions of the machine element. These calculations form anintegral part of the designing of machine elements. The basic procedure o fthe design of element is as follows:

1) Determine Forces Actin on Element.

2) Select Suitable Material for Element.

3) Determine Failure Mode Of Element.

4) Determine Geometric Dimensions of Element.

5) Modify Dimensions for Assembly and Manufacturing.

6) Prepare Working Drawing of Element.



10/56


ORGANISATION

FOR FINANCIAL

ASSISTANCE



11/56


FINANCIAL ASSISTANCE AVAILABLE TO SMALL SCALEINDUSTRIES IN KERALA

For healthy growth of small scale industries it is necessary that theyadequate financial assistance may be made available to them at appropriate time.They are number of agencies at centered and state level providing financialassistance to small scale industries in Kerala- some of them are,

1) KERALA FINANCIAL CORPORATION LIMITED

They provide financial assistance for setting up new industry or forexpansion, diversification, modernization or renovation of existing onesassistance from the corporations available for the following activities.

1. They require testing or servicing of machinery of any descriptionvehicles vessels, motor boats and trailers tractors.

2. Mining, hotel industry etc.

2) TECHNOCRAFT ASSISTANCE SCHEME

Under the scheme financial assistance to the extent of 90% of the fixedcost of this. Project subjected to a maximum of Rs.20 lakhs one in the case of

techno craft is available to technically qualified entrepreneurs who set theirunits.

3. KERALA STATE DEVELOPMENT CORPORATIONFOR SCHEDULED CASTE AND SCHEDULED TRIBES LTD.

1. Loan for small business trade or industry2. Margin money loan for starting industries3. Supply of machineries for productive purpose4. Loan to encourage traditional industries



12/56


BANK

State bank of India operates a scheme of coordinate credit assistance tosmall scale industries. The financial assistance is provided to craftsman andtechnical qualified entrepreneurs who have sound project and are not able to

provide what is called owner equity of minimum capital usually required tosecure loan.

Other facilities available to the small scale industries in Kerala facilitiesfor incentives available from the state governments are :-

1. Subsidiary to meet the cost of project reports2. Subsidiary to meet the cost of technical knows how3. Modernization subsidy4. Assistance of development of prototypes5. Electricity duty concession

FACILITIES AVAILABLE FROM CENTRALGOVERNMENT

The small scale industries assistance mainly from the following financial bodies,

1. Kerala financial corporation (KFC)2. District industrial Centre (DIC)3. National small scale industries corporation (NIC)4. Industrial cooperative bank



13/56


FINANCIAL MANAGEMENT



14/56


INTRODUCTION

Every business enterprise erective of its nature and scale of businessneeds finance to carry out its activities and accomplish certain businessobjectives. No business venture can assure can succeed unless it has enoughmoney to take advantage of any opportunities that may arise. Finance is the life

blood of any business.The management of finance therefor plays a key role in the anticipation

of financial needs, acquiring financial resources and allocating funds in the business. In fact it determines the success or failures of any business activity.The economic objectives of a business organization are profitable, growth andsurvival. The attainment of these objectives largely depends up on the efficientmanagement of finance.

Financial management basically deals with procurement of funds needed by the enterprises on the most favorable terms in the light of their objectives. Itis only concerned with effective procurement of funds but also on the efficientutilization of funds.

DEFINITION

The finance function is concerned with the process of acquiring andefficiently utilizing the funds of a business system, with the objective ofmaximizing the value of firm. Financial management involves the application ofgeneral management principles to the financial function.

According to hog land, financial management deals with how thecorporation obtains the funds and how it uses them.

Financial management may also be defined as that part of management,which is concerned mainly with raising the funds for the enterprises in the mosteconomical manner, utilizing those funds are profitably as possible for a givenrisk level, planning future investments and controlling current performance andthe future development through financial statistics and other means.

FUNCTIONS OF FINANCIAL MANAGEMENT

The financial management begins a strategic and key area ofmanagement involves variety of functions form the view point of effectivemanagement of finance, the finance function can be categorized as1. Executive finance functions.2. Routine finance functions.



15/56


EXCECUTIVE FINANCE FUNCTIONS

1) DETERMINING FINANCIAL NEEDS

The anticipation of the total finance need of the organization is alsoknown as the capitalization division. It means determining total financialrequirements of an organization in terms of long term requirements. This keyis a division, which decides the size of the organization and the scale of anoperation. Sometimes the top management prescribes the maximum limit on thetotal financial requirement should be very carefully anticipated, otherwise it islikely that the organization may face a situation of over capitalization (i.e.;available of more funds with little chance of their profitable investment) orunder capitalization (i.e.; sacrifice of profitable channels of investment due to in

adequate funds)

2) DETERMINING CAPITAL STRUCTURE AND SOURCE OFFUNDS

The capital structure and source decides the blending owned and borrowed funds in the total financial requirements. It also implies determinationof the sources, timing and procedure to obtain funds, which an enterprise needsfor its long terms and conditions of different financial resources verysignificantly depending up on the financial image of the enterprise. The financial

management should have full knowledge of the different sources of funds alongwith their advantages and limitations to make use of them in the best interest ofthe enterprise. Different types of securities and debentures may raise the fundsor they could be borrowed from financial institution or banks.

3) INVESTMENT DECISION (ALLOCATION FUNDS)

Allocation of funds in business means investing them between thedifferent components of fixed and current assets. The investment in fixed andcurrent assets must yield reasonable returns. The returns from the businessoperations using fixed and current assets must be sufficiently high to meet thecase of raising funds. Assets are balanced by weighting their profitability againstthe liquidity; profitability depends up on the factors such as cost, control,

pricing, forecasting, future profits and measuring the cost of the capital, liquiditycash.



16/56


4) MANAGAMENT OF FIXED ASSETS

The investment in fixed asset as like land, building, machinery,equipment, furniture, fixture etc. 60% to 80% of total investments. It involveslong term commitment of funds for their purchase or replacement. This needscareful decisions after evaluating their utility and productive capacity. Theinvestment in fixed asset is governed by the top level policies like owning theasset, to hire or to get it on lease, to make or buy the components etc. it alsoformulate the appropriate depreciation policies for the replacement of fixedassets.

5) ROUTING FINANCE FUNCTIONS

These are certain routine functions, which are falling within the jurisdiction of the financial management. Generally, these functions aredelegated to the subordinate staff in the finance department some of theimportant routine functions are,

Control on cash Custody and safe guard of the document Record keeping Management reporting

OBJECTIVES OF FINANCIAL MANAGEMENT

The objective of financial management may be such that they should be beneficial to the owners, management, employees and the customers. Theseobjectives can be achieved by maximizing the value of the firm. Some of theimportant objectives of the dynamic management are:

INCREASE IN PROFILES

A firm should increase its revenues in order to maximize its value. The profits of the firm are maximized, when the firm is in the equilibrium. At stagein the average cost and the revenues are equal.

REDUCTION INCOST

A firm should make efforts to reduce the cost of the capital and to launchits economy in its operation.



17/56


SOURCES OF THE FUNDS

A firm should make a judicious choice of funds so that they maximize itsvalue. The financial should carefully evaluate the financial risk involved beforemaking an investment decision when achieving the goal of maximization of

project or value of the firm.

LONG RUN VALUE

The financial management should not only maintain the business insound financial health but also strive to produce a rate of earning which willreared the owners adequately for their investment and keep the business insufficient liquidly for the confidence of its creditor and investors.

CAPITAL

In order to start to run a business i.e.; to produce and to sell goods orservices, money has to be invested the money invested in the business in order toyield an income is known as capital.

Capital is needed for the following purposes;

o Purchasing fixed assets (building, equipment, machinery, tools,furniture etc.)

o Purchase raw materials and other supplieso To meet the day expenditure such as wages of workers, selling

and distribution expenses, equipment and plant maintenance costetc.

IMPORTANCE AND SCOPE OF CAPITAL

Capital plays a vital role in the life of modern productive system. Capitalis the life blood of any business production without capital is not possible.

Nature cannot furnish goods and materials to man unless he has the tools and

machinery, for mining, farming, forecasting, finishing etc. with the growth oftechnology and specialization, the capital has to play a vital role. Productivity ofthe modern economy is mainly due to the extensive use of the capital, i.e.;machinery tools or equipments in the productive system.

Capital is one of the important factors of production. It plays a strategicrole in raising productivity. Economic development is not possible withoutmaking and using machinery, construction of irrigation work, the production ofagricultural tools and implements, building dams, bridges and factories, railway,airports ships, harbors, etc. which are all capital.



18/56


SMALL SCALE INDUSTRIES



19/56


SMALL SCALE INDUSTRIES

Everybody knows that the major problem in our country is to give employmentfor the unemployment youth. In order to create substantial employment opportunities,the new industrial policy lays stress on executive promotion and development of collegeand small-scale industry in the college and small-scale industry in the country. This willnot only solve the unemployment problem. It also help to utilize the local resourceswhere ever available. But unfortunately due to lack of proper knowledge among theentrepreneurs, the small scale industries get up by them may not be workingeconomically due to various reasons.

One of the identification and selection suitable entrepreneurs are according toour opinion, the entrepreneurs starting small scale industries should be selected only bya component agency and proper project should be identified to him rather than going itfor this opinion.

ROLE AND SCOPE OF SMALL SCALE INDUSTRIES

The role of small scale industries in the national economy has been greatly appreciatedand it has in to distinct entity of its own. The small scale industries provided rest scopeof increasing employment. They are labor intensive and comparatively little capital tostart with. They help production on prices, and they accelerate the rate of industrialgrowth. This help in equitable distribution of national wealth.

PROCEDURAL STEPS TO SET AND MANAGE A SMALL SCALEINDUSTRY

The steps involved to start small scale industry are conduct market survey andstudy the products as regard their demands in the market and select one of them.The selection of production is guided by,

MARKET ABILITY

It is very essential to know

Present users and prospective users of the proposed products. Demand for the product in the state and side the state. Study the similar products available in the market that can be competitors.

analyses them as regards their utility, quality and cost. Check whether it is seasonal product or it has throughout the year. Find whether the product can be exported.



20/56


PROFITABITITY

Any product proposed to be manufactured should ensure reasonable return on

investment the manufacture of the product should be economical viable. The proposed product should have come out from the laboratory levels to exploitation.

TECHNICAL FEASIBILITY

The proposed product should be technically feasible. It should be within thetechnological competency of the entrepreneur.

STABILITY

The proposed product should have stable sails all the year round otherwise thecost of production may go up and make product unstable. This may cause difficult to

plan May production and procurement program. In such cases it necessary to find outalternatives uses for man machinery and equipments during the slack season.

REASONABLE GROWTH OVER TIME

The proposed product should give reasonable growth over a period of time inorder to ensure a progressive return to the entrepreneurs.

PROJECT CAPACITY

After conducting market survey the capacity of the project must be decidedconsidering the amount of money can be arranged i.e.; by partnership, through banks,financial corporation or shares. While deciding the capacity of the project following arethe factors which should also be considered.

1) Demand product2) Whether the demand is regular or fluctuating3) Quality of powder, water, land, material available4) Nature of product



21/56


SITE SELECTION



22/56


SITE SELECTION

Having taken a decision to start a factory it is important to select a suitable siteor location. The site has great effect on the success or failure of the operation of thefactory, so maximum importance should be given to the site selection. Therefore whileselecting a site the owner or management must consider technical, commercial andfinancial aspects and then to select a site the owner or management must considertechnical. Sometimes it is not an easy affair to find a place where possess allrequirements. In such cases we have to analyses the merits and demerits of the place to

be selected and taken a favorable decision.

The problem of site selection of factory can be solved in the following twostages

A. The selection of actual siteB. General location of factory

A. GENERAL LOCATION OF FACTORY

The following factors must be considered this regard. They are

1. NEARER TO THE RAW MATERIAL

As far as possible, the site selected should be nearer the source of raw materials.This will reduce the cost of transportation of raw materials from the place to the plant.Further if the raw materials are bulky and heavy it becomes very essential to select thesite near it. This why the most of the iron and steel located in Orissa and Bihar due to

proximity of the raw material such as coal and iron ore.

2. NEARER TO THE MARKET

The cost transportation of the finished goods and distribution cost etc. will bereduced if the factory is situated near the market. The goods can be sold at cheaper rateand moreover it will be help in quick service to customer. Their requirements alsostudied.

3. TRANSPORTATION FECILITIES

Transportation costs play a very important role then we have to see that the cost oftransportation should remain fairly small in production to the total cost depending uponthe order of raw materials and finished goods. A suitable method of transportation likeroad, rail, air and water is selected and accordingly the plant location is decided.



23/56


4. AVAILABILITY OF CHEAP AND EFFICIENT LABOUR

It is necessary to consider that whether right kind of labor cost is an important

item of the total production cost in manufacturing a product.

5. AVAILABILITY OF PURE WATER

All factories need soft and pure water for various uses as chemical industryrequire a large quantity of water for processing, so should not be set up at a locationwhich is famous for storage, if pure water is not available in one location of water to thelocation.

6. AVAILABILITY OF POWER AND FUEL

Due to development of electricity this factor has not much effect. Even then wehave to see that where the electricity is cheaper but most of the steel industries arelocated near the source of fuel.

7. CLIMATIC CONDITIONS

It is governing factor for fuel several industries, textile factories require moistclimate that is why most of the textile mills have been located at Bombay andAhmadabad but now a days with the use of air conditioning facilities it has been

possible to control the atmospheric moisture content in the factory according to therequirements.

8. LAND

Topology, area and shape of the site, cost drainage and other facilities are also to be considered at the time of the site selection.

9. COMMERCIAL FACILITIES

Availability of the financial and banking facilities is an important factor, sincethe factories require a constant feeding of working capital this is considered to the most.

10. EXISTANCE OF RELATED INDUSTRIES

Specially, increase of small scale industries, repairing is a problem if suchfacilities are in the existing area repairs are carried out immediately without affecting

production target.The factors like local bylaws, fire production, hospital, school and security etc

should be considered.



24/56


B. THE SELECTION OF ACTUAL SITE

The most important factors in this aspect are as follows

1) The availability of cheap land to build and expand the plant in future.2) The cost of leveling the land and providing foundation subsoil and drainage.3) Cost of building materials like granite, bricks, literate sand and cement, lime.4) Facilities for transport in getting and sending materials.5) Facilities for housing the workers and if necessary,6) Cost of installation of electricity, gas and other facilities.7) Cost laying the water supply and providing the sewage.8) Cheap possibilities of disposing of trade waste efficient treatment.

REGISTRATION OF PLANT

The next step is to ensure the implementation of the project. If in case, theentrepreneur is interested in getting financial assistance from institutional agencies, it isnecessary for him to prepare and submit a feasible project report for their acceptance.

To apply and avail of the various facilities, incentives and assistance available fromvarious instructions like district industrial Centre, national small scale IndustriesCorporation and various financial institutions. It is necessary for the unit to itselfregistered with director of industries and commerce. The registration of the unit is donein two stages via

1) Provisional registration2) Regular registration

PROVISIONAL REGISTRATION

Provisional registration is meant to enable party to make necessary steps during the unitinto existences. A provisional registration is valid up to six months and it can convert toregular registration later on. The provisional registration entities the part to

i. Apply for a shed in an industrial state, developed site in an industrial area/

material for the construction of the shed, as the case may be.ii. Apply to corporation, municipal/ panchayath other local authorities for constructthe establish a unit.iii. Apply for power connectioniv. Apply for the financially institution on the basis of a project may require bythemv. Apply to the N.S.L.C/S.S.L.C/ other institution for procuring machinery in hire

purchase basis.vi. Obtain sales tax, exercise, and duties etc. registration whenever required.



25/56


REGULAR REGISTRATION

When the party has taken all steps for establishing the unit, i.e.; when the factory

building is ready, power connection is given the machinery has been installed etc. andhe can apply for the machinery has been installed etc. and he can apply for the regularregistration of the unit. Within the seven days on the receipt of application, the districtindustries officer or other designed officer will inform the party to the date and time forinspection of the unit. On being satisfied that the unit is capable of production activity, aregistration certificate is issued by the directorate of industries and commerce.

MANAGEMENT

It is easier to a new unit, than to manage it successfully managing a unit is acontinuous process; the entrepreneur should have initiative, drive clarity of ideas andshould be in a position to enlist the cooperation of the workers to achieve the commongoals in order to achieve this goal, the entrepreneur must be in a position to manage allthis firm i.e. manage all the things come in action successfully. His success dependsupon the attention that the entrepreneur pays to the various things, problem likearrangement of raw materials, scheduled production, proper management of labor,timely arrangement of finance, to the scheduled and asserting to cost of production.



26/56


MARKET SURVEY



27/56


INTRODUCTION

Market survey is a scientific study of all problems relate to the transferand sale of goods produced from producers to consumers. Market survey

provides necessary statistics helpful for forecasting and planning a project beforestarting a business, market survey is very essential to know about what must be

produced, how much be produced, who are the purchasers, and where they arelocated, margins of profit etc.

Thus the main object of market survey is find out the future of the proposed products in the initial stage preliminary survey is done by someexperienced analyst and if this preliminary survey supplies sufficientinformation that there is no profitable market for the product to be manufacturedthen further detailed survey is not required. If preliminary survey provides somehope then only detailed survey is done.

The following points area of the most importance while making marketsurvey.

1) Demand for product in the market.2) Selling method to be adopted.3) Possible new market for the products.4) Comments of customers for the product.5) To see that existing size, quantity and design suit the consumers or not.

USEFULNESS OF MARKET SURVEY Helps the entrepreneur to know the market potential for his products(s). To know other competitions producing the same product(s). Fix the production rate proportional to consumers demand. Helps in fixation of price in accordance with demand. Accelerate sales. Helps to discover new market opportunities Induces confidence in entrepreneur to make investments in production. Helps in predicting changes in market. I.e. Sales position or

expansion/shrinkage for a particular product.

Reveals customers requirements, tastes, purchasing capacity, preferences for a particular brand, buying motives and habits etc.



28/56


STEPS IN MARKET SURVEY

Typically a market survey consist of the following steps

1. Define the target group or population.2. Selection of sampling scheme and sample size.3. Preparation of questionnaire.4. Recruiting and training field investigators.5. Obtaining information from responses by target group in the questionnaire.6. Security of information gathered in the survey.

MARKET RESEARCH

All industries enterprises it develops product for direct market applicationswithout having any idea in advance of consumer acceptance of the product takesquicker risk.On the country another concern lends to learn consumer action to product priorto manufacturing the same.it does not involve any risk associating highexpenditures.Market research may be defined as organized approach which includes all ourresearch activities involved in the market.

1) Gathering recounting and analyzing the activity and marketability of the

Product.2) The nature of the demand3) The nature of completion4) The method of marketing5) Other aspects of movements of problems from the stage of production to the

point where they consumed.

Market research provides an effective sales forecast. It also promotes soundnessof marketing decisions.



29/56


CHARACTERISTICS OF MATERIALS AND WELDINGPROCESS

Plain Carbon Steels :-

Depending upon the percentage of carbon, plain carbon steels are classified intofollowing three groups:

a) Low carbon steel b) Medium carbon steelc) High carbon steel

Low carbon steel : -

They contain less than 0.3% carbon. It is popular as 'mild steels'. Low carbonsteels are soft and very ductile. They can be machined and welded easily.However, due to low carbon content, they are unresponsive to heat treatment.So M.S is used for project.

Strength of Welded Joints:-

Welded joints are classified into following two categories:-

a) Where strength of weld is more than the strength of parts joined together. b) Where strength of weld is less than strength of parts joined together.

In first category the failure occur in the parts joined together by weld whilein second one it will occur in the weld deposit. Strength of weld deposit is more thanthe strength of connected parts under the following conditions:

a) The components are mead up of mild steel with less than 0.3% of carbon. b) The welding electrode contains 0.15% carbon.c) Electrode is coated resulting in shielded wilding.

During the welding process coating on the electrode gives off an inert gaswhich acts as a shield, protecting the arc from the surrounding atmosphere. Coatingalso forms the slag on the molten metal and protects it during cooling process. Whencomponents are mead up of material such as high carbon steel or alloy steel the welddeposits is weaken than the strength of connected components.



30/56


WELDED JOINTS OFFER FOLLOWING ADYANTAGESCOMPARED WITH OTHER JOINTS:

a) Riveted joints required additional cover plates, gusset plates, straps, clipangles and a large number of rivets that increase weight.

b) Due to elimination of these components cost of welded assembly is lowerthan that of riveted assembly.

c) Welded structures are lighter than corresponding iron casting by 50% andsteel casting by 30%.

d) Welded structure has smooth and pleasant appearance; the projection ofrivet head adversely affects the appearance of riveted structure.

e) Strength of welded joint is high, very often the strength of weld is more thanthe strength of the plates that are joined together.

f) Machine components of certain shape such as circular steel pipe finddifficult in riveting, however they can be easily welded.

Stress Reliving Of Welded Joints:-

Welded joints are subjected to residual stresses due to non-uniformheating of parts being joined. There is always possibility that localizedthermal stresses may result from uneven heating and cooling during fusionand subsequent cooling. This is also results in distortion. The magnitude ofresidual stresses cannot be predicted with any degree of certainty. This is themajor disadvantage of welded joints. Following two methods can reducesthe residual stresses.

a) Preheating of the weld area to retarded cooling of the metal in thevicinity of the joint.

b) Stress reliving of weld area by using proper heat treatment such as

normalizing and annealing in temperature range of 550 C to 675 C.

One of the methods of stress reliving is 'hand peening'. It consists ofhammering the weld along the length with peen of hammer while joint ishot. It reduces residual stress and induced residual compressive stress onsurface. This improves fatigue strength of joint.



31/56


COMPONENTS OF PAPER CUTTING &

REWINDING MACHINE



32/56


33/56


4) PLUMMER BLOCK

The roller is supported at the twoends with the help of Plummer block fittedwith 40 mm diameter Ball bearings. The

bearings are cleaned and greased for easyrotation of roller.

5) BEARINGS

Ball bearing is a type of rolling-element bearing that uses balls tomaintain the separation between the bearing races.

The purpose of a ball bearing is to reduce rotational friction andsupport radial and axial loads. It achieves this by using at least two races tocontain the balls and transmit the loadsthrough the balls.

In most applications, one race isstationary in Plummer block and the other isattached to rollers journal. As one of the

bearing races rotates it causes the balls torotate as well. Because the balls are rollingthey have a much lower coefficient of frictionthan if two flat surfaces were sliding againsteach other.

Ball bearings tend to have lower load capacity for their size than otherkinds of rolling-element bearings due to the smaller contact area between the

balls and races. However, they can tolerate some misalignment of the inner andouter races.



34/56


6) INDUCTION MOTOR

An induction or asynchronousmotor is an AC motor in which allelectromagnetic energy is transferred byinductive coupling from a primary windingto a secondary winding, the two windings

being separated by an air gap.

The machine is powered by 1 Hp motor with 1440 rpm. This makesone roll rotates and rotating roll makes other rollers to rotate and not onlywound the paper but also pull the paper to make the operation going.

7) SINGLE V-BELT AND PULLEY SYSTEM Vee belts (also known as V-belt or wedge rope) solved the slippage

and alignment problem. It is now the basic belt for power transmission. They provide the best combination of traction, speed of movement, load of the bearings, and long service life. They are generally endless, and their generalcross-section shape is trapezoidal (hence the name "V").

The "V" shape of the belt tracks in a mating groove in the pulley (orsheave), with the result that the belt cannot slip off. The belt also tends towedge into the groove as the load increases-the greater the load, the greater

the wedging action, V-belts may be homogeneously rubber or polymer.

Belts are looped over pulleys. The belt drives the pulleys in the samedirection. As a source of motion, the belt is one application where the belt isadapted to continuously carry a load between the motor and pulley fitted onthe roller.



35/56


8) CUTTER CLAMP (C-CLAMP) WITH BOLTS

C-clamp with the two bolts are used to clamp the cutter to the frameand one extended piece of flat for mounting of cutter.

9) NUT AND BOLTS

Bolt, is a type of fastener characterized by a helical ridge,known as an external thread or just thread, wrapped around a cylinder.

A nut is a type of fastener with a threaded hole. Nuts are almost alwaysused opposite a mating bolt to fasten a stack of parts together. They aremade up of Mild Steel. Nuts and Bolts of different size is used for fixingthe Plummer block to the main frame and to install the cutter clamp.



36/56


MANUFACTURING PROCESS



37/56


MANUFACTURING PROCESS

I. STRUCTURE FABRICATING PROCESS :-

For structure fabrication, the c-channel of size 75 X 40 mm is used. Theapproximate wt. of it per meter is 6.8 kg. Steps in fabrication of structure are given

below.

Step One:

First cut the c-channel in pieces of length 71" (i.e. 6 feet [180 mm]- two pieces)and in 36" (i.e. 3 feet[91.5 mm] - three pieces). Then Put the two lengths of 6 feet

parallel to each other at a distance of 3 feet from each other. Then put the lengths of 3feet on either end of two parallel lengths and weld them as shown below. The twodiagonals must be same.

Step Two:

Then cut four pieces of c-channel of length 24" (i.e. 2 feet[61 mm]) and weldtwo of them on one end of rectangular structure vertically using engineers block. Thenweld remaining two pieces vertically at a distance of 30" from previous pieces.

Step Three:

Then brought the two pieces of flat of size 75 X 12 X 760 mm and weld them onthe top of four columns as shown.



38/56


Step Four:

Then cut another two pieces oflength 48" (i.e. 4 feet[122 mm]) andweld them vertically at a distance of16" from previously welded columns.Afterwards weld the previously cut

piece of 36"[41 mm] on top and in between the upper ends of thesecolumns.

Step Five:

Then cut two pieces of C-channel oflength 15". And four pieces of 4" length. Then

at a distance of 4.5" from nearest end weldthem to form a frame as shown below.



39/56


II. ROLLER MACHINING PROCESS

Roll is mead up of hollow pipe, solid circular plates & solid shaft journal.

So we have to manufacture each part as per required size and then assemble it asa roll. Steps in this task are:-

Step one:

First, brought the hollow pipe of required dimensions. I.e. of required outer,inner and length. If it not available, then cut it on hacksaw machine.

Step two:

Then brought two circular plates of 10 mm thickness, face them from bothsides by holding them on lathe machine. And turn out to the diameter as equal toinner diameter of hollow pipe so they can fit into pipe for welding purpose.

Step three: Take solid bar of M.S. of 50 mm diameter cut it to length 110 mm. Hold

this bar on lathe chuck and turn it out up to the diameter 38 mm so that it can be fit

in pedestal self-aligning bearing block.

Step four: Now, weld the turned solid bar to each of two s o l i d circular plat es axially.



40/56


Step five:

Now, weld these plates in the bore of hollow pipe.

Step six:

The roll is completed , but because of welding different parts itneed to be turned again using lathe machine. Hold the journal on oneside in chuck and turn the other journal as well as hollow pipe part ofroll . Do the same operation by holding other journal in chuck so the rollwill rotate along its axis accurately.

GROOVE FOR WELDING THE M.S ROD AT CENTRE-



41/56


III. CUTTER CLAMP MAKING PROCESS

The c-clamp with the two bolts to clamp and one extended piece of flat formounting of cutter is welded. It is used to hold the cutter.

Step One:

First take the flat of 25 X 10 and cut it by bend saw in size of 90 mm,65mm, 60 mm and 40 mm.

Step Two:

Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of 40 mmin length and weld it on the 65 mm side of clamp.

Step Three:

By using drilling machine, make three holes of 10 mm at the points shown below inthe complete assembly of cutter. Afterwards perform the tapping operations usingtap of inch.



42/56


IV. DRIVING MECHANISM

As our project as a demo and also designed for small weightwe use the 1 Hp A.C . motor. It is having the 1440 rpm speed. We usetwo pulleys of three [7.62 mm] & eight [20.32] inch diameterrespectively on motor and roller. One on the motor shaft and anotheris on the shaft of roll. The numbers of belts required for givenapplication is one. V-belt is used forthis purpose.



43/56


V. WORKING OF MACHINE

As we give number of modifications it is necessary to brieflyexplain working procedure of machine. When the paper beingmanufactured in paper mill it is not of standard size an also get torn out atthe edges. And here is the need of re-winding machine. The roll of papermanufactured is mounted on the roll (A). In our machine we have given theself-aligning bearing with inner extended ring for ease in mounting and urn-mounting.

Then paper is passed around roll (B) to ensure that paper remainstraight and tight. Then it passed through the cutter and grooved roll on topof machine, where it is cut. Because of our modification to this cutter roll thewt. of machine is decreased.

Then the paper which is cut is come to the roll at bottom, The roll is powered by 1 Hp motor with 1440 rpm. This rotating roll makes other roll(C) to rotate and not only wound the paper but also pull the paper to make theoperation going.



44/56


PROCESS OF MANUFACTURING



45/56


Various manufacturing process combines together in the productionof this machine. Each product however, has its own place and can

particularly be adopted to get a certain specifications. The followingoperations are adoptedfor the manufacturing of Paper Cutting & Rewinding Machine.

Marking :-

This is the process of dimensioning the raw material to the requiredsize. This is usually done by scriber and steel rule. After marking, the linesare punched by using a dot punch.

Cutting :-

Cutting is used for the separation of parts. This operation has been adopted on the following items:

C-Channel, M.S Flat, M.S Rod, G.I Pipe, M.S Circular Plate,Cast Iron Block.

Grinding :-

Grinding operation are used for finishing the surfaces which are

previously file or cut by a hack saw. Grinding is also for removingexcess material and foe smoothing the sharp curves of the welded

portion. A grinding machine which is either fixed or flexible is used forthe above operations.

Welding :-

Welding is the process of making a permanent joint byestablishing inters atomic bonds between two or more pieces of metal

by using heat and pressure, with or without using filler metal. It is the

essential part of our project.

Welding is used to make the frames, clamps, rollers andinstalling blocks etc.

Drilling :-

It is the process of making holes in the desired position. Forfixing clamp to the frame by bolts has been done.



46/56


Lathe operations :-

The most essential part of the manufacturing of Paper Cutting &Rewinding machine is the lathe work. The roller making and boring

pulleys are done by lathe work. The main operations included in thelathe work are turning, drilling, chamfering etc.

Cleaning :-

Cleaning consist of removing the chips, Fluxes, Scraps andmany other waste particles from the production area.

Inspection :-

After the manufacturing of various parts it requires inspection onwhether it is within the limit or not. For this gauges and other precisioninstruments are used.

Assembling :-

This is the process of joining all the components together to getthe complete product. That includes fixing bearing to the roller,installing Plummer block & clamp etc.

Painting :-

This is the process of polishing and finishing work of the product. It prevents the corrosion of the parts of a machine. This formsthe final phase of production.



47/56


Advantages

1) It is more compact as compared with conventional one.2) Operation is simple Because of eliminating complex mechanisms.3) Saving of floor space as motor is adjusted inside the structure.4) New cutter clamping assembly given will eliminate the biggest

disadvantage of machine i.e. high weight.

Disadvantages

6) When the winding and cutting operation is going on there is noway to find that how much paper had been wound and howmuch is remained.

SPECIFICATIONS OF MACHINE

Length 6 feet ( 152.4")= 387.096 mm

Width 0.914 feet ( 36") = 91.44 mm

Height 4 feet ( 48" ) = 121.92 mm

Components4 Hollow rolls, 8 Plummer

blocks,8 bearings

Motor1 Hp, 3 phase, induction

motor



48/56


DRAWINGS



49/56




50/56




51/56




52/56




53/56


MATERIAL REQUIREMENTS & COSTANALYSIS



54/56


MATERIAL REQUIREMENTS & COST

SL No. DESCRIPTION QTY. RATE AMOUNT

1 760 X 89 mm G.IPipe(4 Nos ) 25 Kg. Rs. 81 per Kg. Rs. 2025.00

2 M.S. Rod

135 mm X 50 mm 24 Kg. Rs. 58 per Kg. Rs. 1392.00

3M.S Circular Plate12mm X 90 mm

(8 No.)

7 Kg. Rs.58 per Kg. Rs. 406.00

4 M. S. Flat 12 X 75 X

760(2 No

11 Kg. Rs. 58per kg. Rs. 638.00

5 C-channel 75 X 40 ( 12.2 meter ) 76 Kg. Rs. 58 per kg. Rs.4400.00

6 Plummer Blocks

No 208 i .e. 40 mm 8 No. Rs .200 per block Rs.1600.00

7 Bearings 40 mmInner8 No. Rs.30 per Bearing Rs. 240.00

8 Pulleys 3"

Pulley 8"

1 No.

1 No.

Rs. 240 per Pulley

Rs. 540 per Pulley

Rs. 150.00

Rs. 540.00

9 V- Belt of B-type 1 No. Rs.180 per Belt Rs.180.00

10 Paper 4.1 kg Rs. 35 per kg. Rs.131.00

11 Moto r 1 Hp InductionMotor 2 nd Hand 1 No. Rs. 2500 Rs. 2500

12 Travelling Charge --- ------ Rs.1,160.00

Total Rs.14,962.00



55/56


CONCLUSION

The matters discussed in the earlier pages just have a broad outline for startingand managing an industry in small scale sector. We have tried our level best to give a

clear picture about the needs, and requirement of industries which produces. We have

been made an attempt to reduce handling cost and material movement. The main

consideration in the layout and planning is practical rather than the accuracy of facts and

figures. It is hoped that the report will be an immersed us to all investigator Interested in

preparing the project. However it shall be always born business and practical standpoint

We hope that we can be proud of the efforts. We employing in getting this

project work completed. It helped us to study a lot of things and practice in various

techniques. We hope that this project will helpful to the students in polytechnic to

understand the working of Paper Cutting & Rewinding Machine. We will be grateful

those who have co-operated with us once again thanking them.



56/56


BIBLIOGRAPHY

Forbes Marshall- Engineering Data Book

Workshop Technology- B.S. R aghuwanshi (Vol. I & II)

Production Management- ICFAI University

Elements of machine design- V. B. Bhandari

Strength of materials- R. K. Bansal

Papercuttingrewindingmachine Projectreportsreesanghpghosh 130319004110 Phpapp01

Documents

Transcript of Papercuttingrewindingmachine Projectreportsreesanghpghosh 130319004110 Phpapp01