FABRICATION OF PLASTIC SHEET CUTTING

Submitted in the partial fulfillment of the requirement for the award of

“DIPLOMA IN MECHINCAL ENGINEERING”

SUBMITTED BY:

1.S.SARAVANAN 28203960
2.J.SATHYA MOORTHY 28203961
3.S.SATHYA RAJ 28203962
4.K.SELVAM 28203963
5.R.SELVAM 28203964
6.K.SENTHIL 28203965

Under guidance of

MR. S.KANDHAN ., B.E

Lecturer of Mechanical Engineering

DEPARTMENT OF MECHANICAL ENGINEERING

PALLAVAN POLYTECHNIC COLLEGE

KOLIVAKKAM – IYYENKARKULAM,
KANCHIPURAM 631 501

MARCH 2007 – 2010

 PALLAVAN POLYTECHNIC COLLEGE
KANCHIPURAM
DEPARTMENT OF MECHANICAL ENGINEERING

BONAFIDE CERTIFICATE
This is to certify that this Project work on

“ FABRICATION OF PLACTIC SHEET CUTTING ”

submitted by _ _ _ _ _ _ _ _ _ _ _ _ _ . Reg. No. _ _ _ _ _ _ _ _ _ _ _ _

is a partial fulfillment for the award of

DIPLOMA IN MECHANICAL ENGINEERING

This is the bonafide record of work carried out by him under our

Supervision during the year 2009 – 2010

Submitted for the Viva - voce exam held on _ _ _ _ _ _ _ _ _ _ _ _

HEAD OF DEPARTMENT PROJECT GUIDE

EXTERNAL EXAMINER INTERNAL EXAMINER

PREFACE
 PREFACE
All the students are imported with theoretical knowledge

and practice to some extend to boost their level of technical knowledge.

They are being imposed to do a certain project work which makes them to

recollect their theoretical Back ground. On various technical subjects such a

scheme was introduced for the students studied diploma course in

engineering by the DIRECTOR OF TECHNICAL EDUCATION Chennai

during 1973 – 1974.

A Project has to be selected by a group of student who will

design and fabricate the same with the guidance of the staffs of the

institution. In the process of doing several working processes and

assembling they encounter problems which may educate them in further

technical knowledge.

In addition to that fabrication of a certain assembly gives

through ideas to the students by which they can do better one at the next

time because of better planning and scheduling.

ACKNOWLEDGEMEN

T
 ACKNOWLEDWENT

We wish to express our profound gratitude of thanks to our

beloved principal Mr.M.SANKAR.M.E., for providing all facilities to carry out

this project work.

We wish to offer our sincere thanks to Mr.V.DAMODARAM

.B.E. ,Head of the Department Mechanical, for his inspiration to do this project

perfectly.

We wish our sense of gratitude to our guide Mr.S.KANTHAN ., B.E.,

Lecturer in Mechanical Engineering for his valuable guidance, constructive

criticisms, effort, encouragement's and suggestions in this project and completing

it successfully.

We have grateful thanks to all other Mechanical Engineering Department

lectures, for their valuable suggestions and kind encouragement through the

entire phase of this work.

 Finally we wish to thank Non-Teaching faculty of

DEPARTMENT OF MECHANICAL ENGINEERING who helped us directly or

indirectly in various stage of this project work.

CONTENTS
S.N TITLE Page.

O No
1. INTRODUCTION
2. SYNOPSIS
3. CONSTRUCTION
4. WORKING PRINCIPLE
5. DRAWINGS
6. DETAILS OF BATTERY CHARGING
7. PRINCIPLE OF DC MOTOR
8. TYPES OF DC MOTOR
9. ADVANTAGE AND DISADVANTAGE
10. APPLICATION
11. PAINTING AND FINISHING
12. SAFETY CARE AND MAINTANANCE
13. FEATURES OF THIS PROJECT
14. COST ESTIMATION
15 CONCLUSION

16. BIBLO GRAPHY

17. PHOTO VIEW
INTRODUCTION

INTRODUCTION

This is a self – assessment test on the part of the students to

assess his competency in creativity.

During the course of study, the student is put on a sound

theoretical foundation of various mechanical engineering subjects and of

course, to a satisfactory extent. Opportunities are made available to him to

work on different kinds of machines, so that he is exposed to various kinds

of manufacturing process.

As a students learn more and more his hold on production

technology becomes stronger. He attains a stage of perfection, when he

himself is able to design and fabricate a device.

This is the project work. That is the testimony for the strenuous

training, which the student had in the institute. This assures that he is no

more a student, he is an engineer.

This report discuses the necessity of the project and various

aspects of planning, design, selection of materials, fabrication, erection,

estimation and testing.

SYNPOSIS
 CONSTRUCTION

CONSTRUCTION:

This unit consists of

1) DC Motor 12V DC
2) BATTERY 12V DC

3) CRANK MECHANISM

4) BLADE

5)M.S. fabricated work table

6) M.S. stand
 WORKING
PRINCIPLE

WORKING PRINCIPLE :

This unit consists of

1) DC Motor 12V DC

2) BATTERY 12V DC
 3) CRANK MECHANISM

4) BLADE

Initially the job is placed in the machine unit. Then press the start

switch. The DC Motor starts rotating . The rotary motion of the Motor shaft is

converted to reciprocating motion by the crank mechanism.

The plastic sheet cutting blade is connected to this reciprocating unit.

Hence the blade moves to and fro and thus cut the plastic sheet by feeding plastic

sheet with manual force.

DRAWING
 DETAILS OF
BATTERY
CHARGING

ETAILS OF BATTERY CHARGING

A battery is something that supplies DC power through chemical

reaction. Batteries in different form have existed for over 150 years. The research

work still continues for better performance as the demand increases.

 Battery was developed around 1800 by Alessandro Volta when he found

the generation of electrical current from chemical reactions between different metal of

different properties. The battery now a days we use are divided into the following two

categories,

1. Primary / single use

2. Secondary / Rechargeable

PRIMARY BATTARY

Primary batteries are for single use as the chemical reactions that

produces the electric current in them are irreversible. These batteries are common

primary cells are the common Zinc – Carbon battery, Zinc Manganese Alkaline

battery etc. These are used for domestic purpose like watches, tape recorders, torch

etc.

SECONDARY BATTERY:

Secondary batteries are rechargeable batteries i.e they can be sued

multiple times, after using the charge stored in them, they can be recharged and

reused. These batteries are mainly; used in industries and automobiles where higher

initial current is required. Disadvantages of these batteries are they are costly and

require regular maintenance. Some of the common examples of secondary batteries

are Nickel – Cadmium battery, Lead Acid battery etc,.

CELL COMPONENTS:
 Let us now see the different components of a cell

1. The electrolyte

2. The positive electrode

3. The negative electrode

4. The separator

Electrolyte:

The electrolytes may be acidic solution, which provide the positive ions,

or the alkaline solution which provides the negative ions. These ions are used to

conduct the charge flow from positive to negative electrode.

The Positive Electrode:

The positive electrode accepts the electrons from external circuit during

discharge and the negative electrodes supplies the electrode circuit when oxidized

during discharge.

The Negative Electrode:

In alkaline electrolyte the negative ions are created at positive electrodes

and absorbed at negative electrodes and in acidic electrolyte the positive ins are

created at negative electrode and are absorbed at positive.

The Separator:
 In the cell a separator is used to electrically isolate the electrodes and save cell

from internal short circuit.

LEAD – ACID CELL:

The Lead Acid cell consist of

1. Lead dioxide as positive electrode

2. Sponge metallic lead as negative electrodes

3. Sulphuric acid as electrolyte

During discharge the active material of positive electrode react with

Sulphuric acid to form lead sulphate and active material of negative electrode react

with sulphuric acid to form water

When this cell is recharged, during recharge the lead sulphate converts

back to lead dioxide and metallic lead.

Battery Types:

Commonly the following four types of batteries are used with the inverter

system,

1. Automobile Batteries

2. Tubular / Industrial Lead acid batteries

3. Sealed Maintenance Free (SMF) Batteries

4. Nickel Cadmium Batteries

5. Automobile Batteries

These batteries are commonly used in the automobile, cars, truck etc.
Battery Rating:

The backup time provided by a Inverter depends very much on the rating

of the battery used with them.

Commonly batteries are available in 6 and 12 and 24 Volts rating. Other

than the voltage rating, the ampere – Hour rating is used to define the power

availability or capacity of the battery.

The backup time provided by a battery connected to Inverter depends on

the

DC bus voltage of the Inverter. This depends on their design. It could be

24V, 48V, 72V 120V and so on.

Normally more than one 6Volt or 12 V battery is used in series for higher

voltages requirements.

Charger Design:

The life of a battery used in inverter very much depends on the charging
methods used to charge the battery. These types of charging circuit are used in

Inverter to charge the battery

• Constant voltage

• Constant current

• Constant voltage constant current

Constant Voltage:

This type of charging method using series regulators is suitable in SMF

batteries, but they are not useful in automobile and industrial lead acid batteries.

Constant Current:

This charging method using shunt regulators is good for the automobile

and industrial lead acid batteries but it can damage the SMF batteries by overcharging

them.

Constant Voltage Constant Current:

This charging method is suitable for automobile and industrial lead acid

batteries and also for the SMF batteries.

 PRINCIPLE OF DC
MOTOR

PRINCIPLE OF DC MOTOR

A DC motor is a dc machine working as a motor to convert dc electrical

energy into mechanical energy (dc) motor are very commonly used in cars, trucks,
aircrafts, etc. They are also used in large ratings, where wide range of speed control is

necessary.

When a conductor is carried a current and in lying in magnetic filed.

Force acting on the conductor. This is the principle of a Dc motor. The conductor is

housed in armature slots and current is applied from the dc source through brushes and

commentator. The field poles provide the magnetic field.

The construction of dc motor and generator are similar. However their

external appearance may be somewhat different. A motor has a rather closed frame

because it is may be operating in dusty environment and unskilled workers may be

working in its vicinity.

 TYPES OF DC
MOTOR

TYPES OF DC MOTOR

DC Shunt Motor:

This motor has medium starting torque, a speed regulation of 5 – 10 %

and excellent adaptability to adjustable speed service. It can be used for constant
speed drives like pumps, fans blowers, etc,. However for all these applications, a 3

phase induction motor is preferable, because it ;is cheaper, more rugged and requires

lesser maintenance than dc motor. However a dc shunt motor is cheaper for low speed

drives. Moreover, whenever a wide range of speed control is required, dc shunt motor

is used. The main application of dc shunt motor is in steel and aluminium, rolling

mills and ward – Leonard speed control system.

Dc Series Motor:

This motor has a very high starting torque. Moreover it speed decreases

with increase in load torque. So that its power input remains more or less constant. It

is best suited for hoist cranes and traction. Speed control is generally obtained through

armature control. They are used for battery-powered vehicles.

Compound Motor:

A differential compound is rarely used. The characteristics of a

cumulative compounds motor depend on the relative strength of series and shunt

fields. It has good starting torque and dropping speed – load characteristic. They can

be used for pulsating loads needing flywheel action, viz. shears, conveyors, crushers,

hoists, plunger pumps, etc., Whenever the supply voltage is likely to vary

considerably, a compound motor is preferred. Because its induction and contribution

to back emf, the series field helps in reducing the fluctuations of current drawn from

mains.
 ADVANTAGES
&
DIS ADVANTAGES

ADVANTAGES

1. Single person is enough to operate this efficiently to cut the plastic sheet..

2. Easy and efficient handling of this unit without wastage or damage to the plastic

sheet, machine and to any other parts.

3. low maintenance cost and life of equipment also increased..

 4. Least maintenance of the equipment.

5. Need not require any individual work place.

6. Can be worked in the work spot.

7. Suited for cutting plastic sheets of minimum thickness sheet..

DISADVANTAGES

• Manual power required to operate .

• The time taken for loading and unloading the kit is more when Compared to

pneumatic controlled unit.

• It cannot be used for more than 5mm thickness plastic sheet..

 APPLICATION

APPLICATIONS
By using this device many numbers of plastic sheets are cut and the cutting

operation can be performed very easily. It is very much useful in making name board

for advertisement This device is used to cut the various thickness ranging from

1mmto 5mm .
 PAINTING AND
FINISHING

FINISHING AND PAINTING

JOB PREPARATION

Before welding, remove any bend in the L angle with the sludge hammer on the

anvil block. Then it is cut to the required length with the hacksaw blade and fabricated

to required dimensional shape with arc welding.

FINISHING OPERATION BEFORE PAINTING

 After welding, any slag on the welded area is removed with the chipping

hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed with

the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the metal

primer, the second coating is applied with the paint

 SAFTY,CARE AND
MAINTENANCE

SAFTY,CARE AND MAINTENANCE

Before starting the machine, some of the points to be noted for safety purpose,

1. Before starting the operation, check the following items

(1) Check the mechanism for proper operation .

(2) Check the alignment of blade in the machine

(3) Don’t insert the any material or object between the during operation

of machine

(4) Check the lifting alignment and handle in the machine

(5) Wear gloves and shoe for proper handling .

 FEATURES OF
THIS PROJECT

FEATURES OF THIS PROJECT

 It is compact in size

 It can be move

 Low electrical power consumption

 It can be utilized at our work shop

 It is simple in construction

 Low cost

 Less weight and easy to handle

 It reduces the man power

 It is simple in operation..
 COST

ESTIMATION

COST ESTIMATION

S.NO ITEMS RUPEES

1. CUTTER AND HOLDING UNIT 500.00

2. MOTOR UNIT 3000.0

0

3. MECHANISM FOR OSCILLATION 600.00

4. M.S. FABRICTED HOUSING UNIT 600.00

5. BATTERY COST 300.00

6. TRANSPORT COST 700.00

7. REPORT 800.00

TOTAL 6500.

00
CONCLUSION
 CONCLUSION

We make this project entirely different from other projects. Since concepts

involved in our project is entirely different that a single unit is used to various

purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of fabrication work and

how the welding is doing and material selection for particular components etc.,

It is concluded that any fabrication work can be done with the help of

welding.

We have successfully completed the project work on using welding work

at our Institute.

Once again we express our sincere thanks to our staff members.

 BIBLIOGRAPHY

BIBLIOGRAPHY

1. WORKSHOP TECHNOLOGY - HAJRA CHOWDRY

2. PRODUCTION TECHNOLOGY - R.S. KHURMI

3. MACHINE SHOP TECHNOLOGY - S.S.MANIAN

4. JIG AND FIXTURE DESIGN - R.K.JAIN

5.FLUID POWER BY - E.SUNDRAMOORTHY

PHOTO VIEW
PHOTO VIEW