A

PROJECT REPORT
ON

Design and Fabrication of

MULTIPURPOSE MECHANICAL MACHINE
submitted in the partial fulfillment of the award of Degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING

Submitted By University Roll no.

Abhishek Sharma 1414840009
Akshay Sharma 1412840017
Amrendre Chauhan 1412840021
Deepak Negi 1412840037

Under the guidance of

Mr. Murshid Rana

DAPARTMENT OF MECHANICAL ENGINEERING

BHARAT INSTITUTE OF TECHNOLOGY, MEERUT (UP)
2017-18
 CERTIFICATE

We hereby certify that the work which is being presented in the B.Tech . Project
report entitled DESIGN AND FABRICATION OF MULTIPURPOSE
MECHANICAL MACHINE in partial fulfilment of the requirements for the
award of the BACHELOR OF TECHNOLOGY IN MECHANICAL
ENGINEERING and submitted to the BHARAT INSTITUTE OF
TECHNOLOGY, MEERUT (UP) is an authentic record of my own work
carried out during a period from October2017 to April 2018

(8th Semester) under the supervision of

Mr. Murshid Rana Mechanical Department.

SUPERVISOR Prof. Ankur Rajvanshi

Mr. Mr. Murshid Rana (H.O.D.)

Mechanical Engineering

2
 ACKNOWLEDGEMENT
 We feel great pleasure in presenting the report of our project
“Multipurpose Mechanical Machine” which finds application in much
modern equipment and system ,this project is done in partial fulfilment of
B.Tech (Bachelor of Technology) in Mechanical engineering.

 We wish to express our sincere gratitude and thanks to our guide Mr

Murshid Rana. During our whole project work for his inspiration given
by him and guidance showered upon us. He was greatly helpful to us by
solving all our queries and difficulties. We also want to thank our head of
department of Mechanical Engineering and Mr. Brij Nandan (LATHE
OPERATOR) without whom support and guidance this project wouldn’t
be possible.

 Last but not the least we are thank full to all our lecturers who showered
their help and guidance during the project work and also our friends who
always ready to help.

3
 ABSTRACT

This thesis deals with the design, development and fabrication of multipurpose
mechanical machine which perform four operations at a time namely drilling,
angle cutting and grinding and wooden cutting.
Today we see that these operations are the heart of any workshop/machine shop
and they are indispensable, so for the time saving of any organisation four
different operation on four different job can be performed simultaneously,
however jigs and fixtures are required to attain this, but when our need is
specified and particular then this machine can be a time saving equipment.

This machine is automatic and controlled by electric motor and it is based on

the Belt and pulley mechanism. It can be used in small scale
industries/workshop to work upon thin metallic sheets and on wood in carpentry
shop.

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 TABLE OF CONTENT

S.no. CONTENT Page no.

1 Chapter 1: project definition 8

1.1 Problem statement

1.2 Problem identification

2 Chapter 2: mechanism of multipurpose mechanical 9-13

machine

2.1 Objective

2.2 Theory

2.3 Belt and Pulley mechanism

2.4 Bevel gear mechanism

3 Chapter 3: design of model 14-15

3.1 Components

3.2 Calculation

3.3 Advantage

4 Chapter 4 : Calculation 16-18

5 Chapter 5 : operation of machine 19-34

4.1 drilling

4.2 Grinding

4.3 Angle cutting

4.4 wooden cutting

6 Chapter 6: project cost 35

5
7 Chapter 7: Future Implementation 36

8 Chapter 8 : Advantages 37

9 Chapter 9: Conclusion 38

10 Chapter 10: Reference 39

11 Chapter 11 : Help Books 40

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 LIST OF FIGURES

No. Figure Name Page no.

1 Belt and pulley mechanism 9
2 3D view of MPMM 14
3 Actual view of MPMM 15
4 Drilling machine 19
5 Angle cutting machine 22
6 Grinding machine 26
7 Wooden cutter 31

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Chapter 1 : PROBLEM DEFINATION
1.1 PROBLEM STATEMENT

To design and development of MULTIPURPOSE MECHANICAL MACHINE

, a structure which is designed for the purpose of multi-operation i.e.
DRILLING, CUTTING, GRINDING.

1.2 PROBLEM IDENTIFICATION

This machine perform multipurpose operation at same time with required speed
and this machine is automatic which is controlled or operated by motor which is
run with the help of current. This machine is based on Belt and Pulley
mechanism.

This model of multi operational machine is can be used in industries and

domestic operation which can performed drilling, grinding and cutting of thin
metal and wooden surface.

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Chapter 2: MECHANISM OF MACHINE

2.1 Objective
Our machine will perform four operations at a time namely drilling, angle
cutting, grinding, wooden cutting. So our main aim is to find or use a
mechanism that can fulfil our demand.

2.2 Theory
Requirement of our machine is conversion of rotary motion to reciprocating
motion. Reciprocating motion, also called reciprocation, is a repetitive up-and-
down or back-and-forth linear motion it is found in a wide range of mechanism
including reciprocating engine and pumps. The two opposite motions that
comprises a single reciprocation cycle are called strokes. We are using scotch
yoke mechanism in our machine to provide reciprocating motion to hacksaw
and shaper and bevel gear arrangement for drilling operation. Although not a
common metalworking machine nowadays, crude shapers can use scotch yokes,
almost all those uses a with worth linkage, which gives a slow speed forward
cutting speed and faster return.

2.3 Belt and Pulley mechanism

A belt is a loop of flexible material used to link two or more
rotating shafts mechanically, most often parallel. Belts may be used as a source
of motion, to transmit power efficiently or to track relative movement. Belts are
looped over pulleys and may have a twist between the pulleys, and the shafts
need not be parallel.
In a two pulley system, the belt can either drive the pulleys normally in one
direction (the same if on parallel shafts), or the belt may be crossed, so that the
direction of the driven shaft is reversed (the opposite direction to the driver if on
parallel shafts). As a source of motion, a conveyor belt is one application where
the belt is adapted to carry a load continuously between two points.

9
 Figure 1 : Belt and Pulley mechanism

Belts are the cheapest utility for power transmission between shafts that may not
be axially aligned. Power transmission is achieved by specially designed belts
and pulleys. The demands on a belt-drive transmission system are huge, and this
has led to many variations on the theme. They run smoothly and with little
noise, and cushion motor and bearings against load changes, albeit with less
strength than gears or chains. However, improvements in belt engineering allow
use of belts in systems that only formerly allowed chains or gears.

2.4 Power transfer at some angle :

Bevel gears are used as the main mechanism for a hand drill. As the handle of
the drill is turned in a vertical direction, the bevel gears change the rotation of
the chuck to a horizontal rotatio
Bevel gears are gears where the axes of the two shafts intersect and the tooth-
bearing faces of the gears themselves are conically shaped. Bevel gears are most
often mounted on shafts that are 90 degrees apart, but can be designed to work
at other angles as well. The pitch surface of bevel gears is a cone.

10
Two important concepts in gearing are pitch surface and pitch angle. The pitch
surface of a gear is the imaginary toothless surface that you would have by
averaging out the peaks and valleys of the individual teeth. The pitch surface of
an ordinary gear is the shape of a cylinder. The pitch angle of a gear is the angle
between the face of the pitch surface and the axis.
The most familiar kinds of bevel gears have pitch angles of less than 90 degrees
and therefore are cone-shaped. This type of bevel gear is
called external because the gear teeth point outward. The pitch surfaces of
meshed external bevel gears are coaxial with the gear shafts; the apexes of the
two surfaces are at the point of intersection of the shaft axes.
Bevel gears that have pitch angles of greater than ninety degrees have teeth that
point inward and are called internal bevel gears.
Bevel gears that have pitch angles of exactly 90 degrees have teeth that point
outward parallel with the axis and resemble the points on a crown. That's why
this type of bevel gear is called a crown gear.
Mitre gears are mating bevel gears with equal numbers of teeth and with axes at
right angles.
Skew bevel gears are those for which the corresponding crown gear has teeth
that are straight and oblique
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 Np - Number of teeth on pinion
 Ng - Number of teeth on given gear
 Dg - Pitch diameter of given gear
 Dp - Pitch diameter of given pinion
 F - Face width (length of single tooth)
 γ - Pinion pitch angle (radians)
 Γ - Gear pitch angle (radians)
 Ao - Cone distance (distance from pitch circle to intersection of shaft axes)
 rb - Back-cone radius
 P - Diametrical pitch (teeth per inch of pitch diameter (N/D))
 p - Circular pitch (inches of circumference per tooth (Π/P))
The tooth shape for bevel gears is determined by scaling spur gear tooth shapes
along the face width. The further from the intersection of the gear and pinion
axes, the bigger the tooth cross sections are. If the tooth face were to extend all
the way to the axes intersection, the teeth would approach infinitesimal size
there. The tooth cross-section at the largest part of the tooth is identical to the
tooth cross-section of a tooth from a spur gear with Pitch Diameter of 2* rb, or
twice the Back-Cone Radius, and with an imaginary number of teeth (N’) equal
to times the Back-Cone Radius (rb) divided by the Circular Pitch of the bevel
gear (p). This method of obtaining the dimensions and shape of the largest tooth
profile is known as the “Tredgold” tooth-shape approximation. Refer to the
profiles shown near the Back-cone radius dimension in the drawing above.[3]
Mean radius:

Hp=Tx n/63000 → T = Hp x 63000/n

T = Rm x Wt → Wt = Hp x 63000/ n x Rm

How bevel gear works ?

Bevel gears are useful when the direction of a shaft's rotation needs to be
changed. They are usually mounted on shafts that are 90 degrees apart, but can
be designed to work at other angles as well.

The teeth on bevel gears can be straight, spiral or hypoid. Straight bevel gear
teeth actually have the same problem as straight spur gear teeth -- as each tooth
engages, it impacts the corresponding tooth all at once.

12
Just like with spur gears, the solution to this problem is to curve the gear teeth.
These spiral teeth engage just like helical teeth: the contact starts at one end of
the gear and progressively spreads across the whole tooth.

13
CHAPTER 3: DESIGN OF MODEL
3.1 COMPONENTS OF MACHINE
1. FRAME
2. BEVEL GEAR
3. BELT
4. MOTOR
5. PULLEY
6. BEARING(Ball Bearing)
7. WOODEN CUTTER
8. TOOL POST
9. DRILLING CHUCK
10. DRILL TOOL
11. SINGLE CUTTING TOOL
12. TABLE
13. NUT AND BOLT
14. OTHER COMPONENT

Fig-2 : 3D view of MPMM

14
Fig.3: Actual view of MPMM
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3.2 CALCULATION
T = torque

HP= horse power

N = rpm

D1= driver pulley diameter

D2= driven pulley diameter

Vr = velocity ratio

T1,T2 , T3, T4, T5 and T6 are the torque on the respected pulley P1,
P2,P3,P4,P5 and P6

HP = T * rpm/5252

Torque generate by motor = HP * 5252 /rpm

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HP = 2

rpm = 2800

torque = 2 * 5252/ 2800

T1 = 3.75 N-M

T2 = T1 * velocity ratio

= T1 * D2/D1

T3 = T2 * D2/D1

• Power transmitted between a belt and a pulley is expressed as the

product of difference of tension and belt velocity:

P = (Tt - Ts)v

where Tt = tension in tight side

Ts = tension in slack side

Tt/Ts = e^(µÞ)

where µ = coefficient of friction

Þ = angle (in radians) subtended by contact surface

at the center of the pulley

17
The contact angles (in degrees) of open belt over the smaller (driver) and larger
(driven) pulleys are given below:

dL - Diameter of the larger pulley

dS – Diameter of the smaller pulley
αL- Angle of wrap of the larger pulley
αS – Angle of wrap of the smaller pulley L
C- Center distance between the two pulleys

αL = 180ο + 2β
αS = 180ο - 2β

Where angle β is, β = sin-1 ( (dL - dS)/2)

L0 = Length of open belt

Nomenclature of Cross Belt Drive :

dL - Diameter of the larger pulley

dS – Diameter of the smaller pulley
αL- Angle of wrap of the larger pulley
αS – Angle of wrap of the smaller pulley
C- Center distance between the two pulleys
α L = α S = 180 + 2β
Length of cross belt -

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 CHAPTER 4: OPERATION OF MACHINE
Operation performed by machine :-
1. DRILLING
2. SHAPING
3. CUTTING

4.1 DRILLING
Drilling is the operation of producing circular hole in the work piece by using a
rotating cutter called DRILL.

 The machine used for drilling is called drilling machine.

 The drilling operation can also be accomplished on lathe, in which the
drill is held in tailstock and work is held by the chuck.
 The most common drill used is the twist drill.

DRILLING MACHINE

 It is the simplest and the accurate machine used in production shop.

 The work piece is held stationary i.e. clamped in position and the drill
rotates to make a hole.
Components of drilling machine
1. Spindle
The spindle holds the drill or cutting tools and revolves in a fixed position
in a sleeve.
2. Sleeve
The sleeve or quill assembly does not revolve but may slide in its bearing
in a direction parallel to its axis. When the sleeve carrying the spindle
with a cutting tool is lowered, the cutting tool is fed into the work; and
from the work. Feed pressure applied to the sleeve by hand or power
causes the revolving drill to cut its way into the work a fraction of an mm
per revolution.
3. Column
The column is cylindrical in shape and built rugged and solid. The
column supports the head and the sleeve or quill assembly.
4. Head
The head of the drilling machine is composed of the sleeve, a spindle, an
electric motor and feed mechanism. The head is bolted to the column.
5. Worktable
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 The worktable is supported to an arm mounted to the column. The
worktable can be adjusted vertically to accommodate different heights of
work or it can be swung completely out of the way. It may be tilted up to
90 degrees in either direction, to allow long pieces to be end or angle
drilled.
6. Base
The base of drilling machine supports the entire machine and when bolted
to the floor, provides for vibration free operation and best machining
accuracy. The top of the base is equipped with similar to the worktable
and may equipped with t-slot for mounting work too larger for the table.

Figure 4: Bench drilling machine

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Types of drilling machine according to feed
Hand feed
The hand-feed drilling machine are the simplest and the most common type of
drilling machines in use today. These are the light duty machine that are
operated by the operator, using a feed handled, so that the operator is able to
feel the action of the cutting tool as it cuts through the workpiece. These drilling
machine can be bench or floor mounted.

Power feed
The power feed drill machine are usually larger and heavier than the hand feed
drills. They are equipped with the ability to feed the cutting tool into the work
automatically duty work or the work that uses large drills that require power
feed larger, work piece is usually clamped directly to the table or base using t-
bolts and clamps by a small work places are held in a vice. A depth-stop
mechanism is located on the head, near the spindle, to aid in drilling to a precise
depth.

Specification
Drill size in mm Feed in mm/rev.
3.2 and less 0.025-0.050
3.2 to 6.4 0.050-0.10
6.4 to 12.7 0.10-0.18
12.7 to 25.4 0.18-0.38
25.4 and large 0.38-0.64

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4.2 Angle CUTTING

Angle cutter

An angle cutter, also known as a side cutter or disc cutter, is a

handheld power tool used for cutting the availability of an
interchangeable power source has encouraged their use with a wide
variety of cutters and attachments.
Angle cutter can be powered by an electric motor . The motor drives a
geared head at a right-angle on which is mounted an disc or a thinner
cut-off disc, either of which can be replaced when worn. Angle grinder
typically have an adjustable guard and a side-handle for two-handed
operation. Certain angle cutter, depending on their speed range,

22
 The following properties are required for cutting tool
materials:
 hardness, hot hardness and pressure resistance.
 bending strength and toughness.
 inner bonding strength.
 wear resistance. oxidation resistance. small prosperity to diffusion and adhesion.
abrasion resistance. edge strength.

What are cutting discs?

Cuttings disc are expendable tools used on angle grinders or stationary devices
for cutting a variety of materials - from metal alloys (steel, stainless steel,
aluminum), to wood, stone, concrete and other materials. They are round, thin
and flat panels, like CD or DVD. They are basically divided into classical
cutting discs using a synthetic resin as a binder and diamond discs.
They were invented because sometimes it was impossible to cut particular
material or the procedure was too demanding regarding time or costs. Cutting
discs on angle grinders allowed great mobility, ease of use and availability.

How are the cutting discs used?

Cutting discs are used by being installed on the angle grinder or a stationary
device and then cutting required material like steel pipes, stainless steel rods
aluminium.
Unlike cutting with knife or scissors, in which case the cut parts connected
together again obtain full length, cutting with cutting disc causes a reduction in
the total length of the product. This happens because the cutting with discs
actually removes material from a particular point to make a hole that will
separate the product in pieces of desired length. If we take a thin hand sander
and abrade the same place numerous time, we would get the same result. It
means that cutting process is actually extremely fast honing of material (several
thousand revolutions per minute) on a very small area (0.8 to 3 mm).
It is important to note that this method of cutting creates a lot of friction that
develops high temperature at the point of cutting and can lead to undesirable
changes in structure and colours. In order to prevent this, it is advisable to use
the disc as thin as possible, and cut carefully so the product wouldn't get
warmed up.

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Diamond cutting discs

Diamond discs are a completely different story. Their production technology,

using diamonds, and the way of using discs makes them much more expensive
than classic cutting discs.. It is clear that these are not discs completely made of
diamonds, but they have cutting edge covered with a thin layer of diamond
grains.
Diamond cutting discs were mainly used for cutting stone, concrete, reinforced
concrete and asphalt, but with the development of technology they price became
more available so they are used also for cutting ceramic, steel, stainless steel,
plastic, etc.

The influence of disc thickness on cutting

The thickness of disc has a crucial impact on speed and quality of cutting. In
theory, you can also cut some material with grinding disc. The only question is
how much power, time and material will you spend. (In the ideal case where
angle grinder will not bounce or move to the left to the right during cutting).
The thinner disc is, the cutting is quicker and more accurate, less material is
being used, likelihood of sparking is less and considerably lower temperatures
are developed. Thickness of 3.00 mm was the standard for years. It was thick
enough to withstand safety requirements and lateral straining, but also being
thin enough for reasonable cutting. Since the standard grinding discs where
manufactured in thickness from 6.00 to 12.00 mm, thickness of 3.00 mm for
cutting disc proved to be ideal former production capabilities.
As technology of abrasives progressed, innovation began, so the thickness of
cutting discs decreased to 2.5 mm, 1.9 (1.8) mm, 1.5 mm, 1 mm and 0.8 mm.
Today, all discs produced by the leading European and world manufacturers are
safe for use in any thickness, and there is no reason for the mistrust that still
exists towards thin cutting discs. Two protective safety nets are minimum
prescribed by European and world standards, but some manufacturers made a
step further by producing discs with three safety nets..

Durability and quality of cutting disc

All cutting discs have their durability, so each manufacturer is obliged to print

24
year when validity ends, clearly and indelibly on the cutting disc. It can vary
from one up to the maximum of 3 years. It is not recommended to use cutting
disc after the expiration date.
As for the quality of cutting disc, it is a very sensitive subject. There are various
manufacturers, as well as different product lines of the same manufacturers with
big differences in their prices and performance. Also some reputable
manufacturers supply their cheapest lines from China – either they have a
separate business units or some other companies work on their behalf. So be
careful when you're buying discs and take enough time for proper testing. Good
test could ultimately save you a lot of money and time.
It is important to know that nowadays, tools and technology are changing
almost daily. You must have a time and a will to test new products on the
market every few years.

Safety of cutting discs

Because of the strong centrifugal forces, discs must be manufactured according
to strict safety requirements prescribed in standards EN 12413 - Safety
requirements for bonded abrasive products and EN 13236 Safety requirements
for super abrasives. Besides, leading manufacturers meet the additional
requirements prescribed by the Organization for the safety of abrasives – OSA.

When working with cutting discs we should pay particular attention to handling
them. Do not throw them or drop something on them. They are designed for
maximum possible safety during operation, however, they are not indestructible.
Before use a disc should be inspected visually for any cracks or chips. The
cutting discs are spinning at the speed of 80 m / s, or little slower than the
average speed of F1 cars. At that speed, each chip can cause serious life-
threatening injuries. We shouldn't kid ourselves - as in everything else, there are
high-quality products and the ones of low quality. Lower price cutting discs is
usually a consequence of worse contexture. The result can be rapid wearing of
the discs, low quality of cut, difficult controlling, odors, increased sparking.
Unfortunately, the safety of the disc itself is sometimes questionable. Cases
where the disc busted during work are not uncommon.
As with any other product, the balance should be found between the price and
the quality. Joining the European Union, employers are obliged to provide safe
working environment and safe tools for their employees.

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4.3 grinding-

Grinding

Sketch of how abrasive particles in a grinding wheel remove material from a work piece .

Grinding is an abrasive machining process that uses a grinding wheel as

the cutting tool.
A wide variety of machines are used for grinding:

 Hand-cranked knife-sharpening stones (grindstone)

 Handheld power tools such as angle grinders and die grinders
 Various kinds of expensive industrial machine tools called grinding
machines
 Bench grinders
Grinding practice is a large and diverse area of manufacturing and tool making.
It can produce very fine finishes and very accurate dimensions; yet in mass
production contexts it can also rough out large volumes of metal quite rapidly. It
is usually better suited to the machining of very hard materials than is "regular"
machining (that is, cutting larger chips with cutting tools such as tool
bits or milling cutters), and until recent decades it was the only practical way to
machine such materials as hardened steels. Compared to "regular" machining, it
is usually better suited to taking very shallow cuts, such as reducing a shaft’s
diameter by half a thousandth of an inch or 12.7 μm.
Grinding is a subset of cutting, as grinding is a true metal-cutting process. Each
grain of abrasive functions as a microscopic single-point cutting edge (although
26
of high negative rake angle), and shears a tiny chip that is analogous to what
would conventionally be called a "cut" chip (turning, milling, drilling, tapping,
etc.). However, among people who work in the machining fields, the
term cutting is often understood to refer to the macroscopic cutting operations,
and grinding is often mentally categorized as a "separate" process. This is why
the terms are usually used separately in shop-floor practice.

Grinding wheel
A grinding wheel is an expendable wheel used for various grinding and abrasive
machining operations. It is generally made from a matrix of coarse abrasive
particles pressed and bonded together to form a solid, circular shape, various
profiles and cross sections are available depending on the intended usage for the
wheel. Grinding wheels may also be made from a solid steel or aluminum disc
with particles bonded to the surface.

Processes
Selecting which of the following grinding operations to be used is determined
by the size, shape, features and the desired production rate.
1. Surface grinding
Surface grinding uses a rotating abrasive wheel to remove material, creating a
flat surface. The tolerances that are normally achieved with grinding are
±2×10−4 inches (5.1 μm) for grinding a flat material and ±3×10−4 inches
(7.6 μm) for a parallel surface.
The surface grinder is composed of an abrasive wheel, a work holding device
known as a chuck, either electromagnetic or vacuum, and a reciprocating table.
Grinding is commonly used on cast iron and various types of steel. These
materials lend themselves to grinding because they can be held by the magnetic
chuck commonly used on grinding machines and do not melt into the wheel,
clogging it and preventing it from cutting. Materials that are less commonly
ground are aluminum, stainless steel, brass, and plastics. These all tend to clog
the cutting wheel more than steel and cast iron, but with special techniques it is
possible to grind them.
2. Cylindrical grinding
Cylindrical grinding (also called center-type grinding) is used to grind the
cylindrical surfaces and shoulders of the workpiece. The workpiece is mounted
on centers and rotated by a device known as a drive dog or center driver. The
abrasive wheel and the workpiece are rotated by separate motors and at different
27
speeds. The table can be adjusted to produce tapers. The wheel head can be
swiveled. The five types of cylindrical grinding are: outside diameter (OD)
grinding, inside diameter (ID) grinding, plunge grinding, creep feed grinding,
and centerless grinding.
A cylindrical grinder has a grinding (abrasive) wheel, two centers that hold the
workpiece, and a chuck, grinding dog, or other mechanism to drive the work.
Most cylindrical grinding machines include a swivel to allow the forming of
tapered pieces. The wheel and workpiece move parallel to one another in both
the radial and longitudinal directions. The abrasive wheel can have many
shapes. Standard disk-shaped wheels can be used to create a tapered or straight
workpiece geometry, while formed wheels are used to create a shaped
workpiece. The process using a formed wheel creates less vibration than using a
regular disk-shaped wheel.
Tolerances for cylindrical grinding are held within ±0.0005 inches (13 μm) for
diameter and ±0.0001 inches (2.5 μm) for roundness. Precision work can reach
tolerances as high as ±0.00005 inches (1.3 μm) for diameter and ±0.00001
inches (0.25 μm) for roundness. Surface finishes can range from 2 micro inches
(51 nm) to 125 micro inches (3.2 μm), with typical finishes ranging from 8 to 32
micro inches (0.20 to 0.81 μm).
3. Creep-feed grinding
Creep-feed grinding (CFG) was invented in Germany in the late 1950s by
Edmund and Gerhard Lang. Unlike normal grinding, which is used primarily to
finish surfaces, CFG is used for high rates of material removal, competing with
milling and turning as a manufacturing process choice. Depths of cut of up to
6 mm (0.25 inches) are used along with low workpiece speed. Surfaces with a
softer-grade resin bond are used to keep workpiece temperature low and an
improved surface finish up to 1.6 µm.
With CFG it takes 117 s to remove 1 in3 (16 cm3) of material, whereas precision
grinding would take more than 200 s to do the same. CFG has the disadvantage
of a wheel that is constantly degrading, requires high spindle power (51 hp or
38 kW), and is limited in the length of part it can machine.
Continuous-dress creep-feed grinding (CDCF) was developed in the 1970s. It
dresses the wheel constantly during machining, keeping it in a state of specified
sharpness. It takes only 17 s to remove 1 in3 (16 cm3) of material, a huge gain in
productivity. 38 hp (28 kW) spindle power is required, with a low to
conventional spindle speeds. The limit on part length was erased.
High-efficiency deep grinding (HEDG) uses plated super abrasive wheels,
which never need dressing and last longer than other wheels. This reduces
capital equipment investment costs. HEDG can be used on long part lengths and

28
removes material at a rate of 1 in3 (16 cm3) in 83 s. It requires high spindle
power and high spindle speeds.
Peel grinding, patented under the name of Quick point in 1985 by Erwin Junker
Maschinenfabrik, GmbH in Norrish, Germany, uses a thin super abrasive
grinding disk oriented almost parallel to a cylindrical workpiece operates
somewhat like a lathe turning tool.
Ultra-high speed grinding (UHSG) can run at speeds higher than 40,000 fpm
(200 m/s), taking 41 s to remove 1 in3 (16 cm3) of material, but is still in the
R&D stage. It also requires high spindle power and high spindle speeds.

Form grinding is a specialized type of cylindrical grinding where the

grinding wheel has the exact shape of the final product. The grinding wheel
does not traverse the workpiece.
Internal grinding is used to grind the internal diameter of the workpiece.
Tapered holes can be ground with the use of internal grinders that can swivel on
the horizontal.
Centerless grinding is when the workpiece is supported by a blade instead
of by centers or chucks. Two wheels are used. The larger one is used to grind
the surface of the workpiece and the smaller wheel is used to regulate the axial
movement of the workpiece. Types of centerless grinding include through-feed
grinding, in-feed/plunge grinding, and internal centerless grinding.
Pre-grinding When a new tool has been built and has been heat-treated, it is
pre-ground before welding or hard facing commences. This usually involves
grinding the OD slightly higher than the finish grind OD to ensure the correct
finish size.
Electrochemical grinding is a type of grinding in which a positively
charged workpiece in a conductive fluid is eroded by a negatively charged
grinding wheel. The pieces from the workpiece are dissolved into the
conductive fluid.

Work holding methods

The workpiece is manually clamped to a lathe dog, powered by the face plate,
that holds the piece in between two centers and rotates the piece. The piece and
the grinding wheel rotate in opposite directions and small bits of the piece are
removed as it passes along the grinding wheel. In some instances special drive
centers may be used to allow the edges to be ground. The work holding method
affects the production time as it changes set up times.

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Work piece materials
Typical workpiece materials include aluminum, brass, plastics, cast iron, mild
steel, and stainless steel. Aluminum, brass and plastics can have poor to fair
machinability characteristics for cylindrical grinding. Cast Iron and mild steel
have very good characteristics for cylindrical grinding. Stainless steel is very
difficult to grind due to its toughness and ability to work harden, but can be
worked with the right grade of grinding wheels.
Work piece geometry
The final shape of a workpiece is the mirror image of the grinding wheel, with
cylindrical wheels creating cylindrical pieces and formed wheels creating
formed pieces. Typical sizes on work pieces range from 0.75 in to 20 in (18 mm
to 1 m) and 0.80 in to 75 in (2 cm to 4 m) in length, although pieces from
0.25 in to 60 in (6 mm to 1.5 m) in diameter and 0.30 in to 100 in (8 mm to
2.5 m) in length can be ground. Resulting shapes can be straight cylinders,
straight-edged conical shapes, or even crankshafts for engines that experience
relatively low torque.
Effects on work piece materials
Mechanical properties will change due to stresses put on the part during
finishing. High grinding temperatures may cause a thin martensitic layer to form
on the part, which will lead to reduced material strength from micro cracks.
Physical property changes include the possible loss of magnetic properties on
ferromagnetic materials.
Chemical property changes include an increased susceptibility to corrosion
because of high surface stress.

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4.4 wooden cutter
The multi operation machine is a type of mechanical material cutting machine
which is made to cut wooden articles. It operation consists a rotating shaft fitted
with a cutter, which rotates in opposite direction to that of wood movement. The
machine is made from a rigid mild steel table standing on strong legs. The table
consists of a rectangular slot below which the shaft embedded with sharp cutter
along the length and a front cutter at its end. The machine also provides the
provision of grinding the cutter sharp edge when it is worn out. A grinding
wheel made of abrasive material is fitted on another shaft on to which the power
is transmitted with the help of a pulley and belt mechanism

4.4.1 construction
The wood cutting machine consists of the following parts, which forms the
main elements of the machine.
1) Saw fence with bracket
2) C-plate
3) Motor pulley and tool kit
4) Cutter
5) Rip fence
The machine is built over a rigid steel structure taking in view of the sever
vibrations that will generate during the cutting operation. The machine consists
of a flat high surface finish table over which the wood work pieces are placed
for cutting.

4.4.2 LAYOUT AND PARTS

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4.4.3 SHAFT & CUTTER ASSEMBLY

 A high surface finish mild steel shaft is used for embedding the cutter at its
counter for cutting purpose. The shaft is rigidly fixed with the cutter to avoid
any accidental failure of its assembly.

4.4.4 PULLEY & V – BELT

A pulley and v – belt mechanism is used for the transfer of torque
power from the motor to shaft containing cutter. Two pulleys are used
one at the motor output and another at the main shaft. The v belts are
used with a size of 30’x 10’ for connecting these pulleys.

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4.4.5 WORKING PRINCIPLE

The operation of the machine is simple as there is no any complexity

of assembled parts. The machine is made ON by pressing the Power
button and by adjusting the length of cut and depth of cutter over table
surface.
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4.4.6 THE FOLLOWING STEPS DEMONSTRATE THE
OPERATING PROCEDURE.
1. First connect the main switch to the alternate current c supply.
2. Then start the motor from the on/ off switch.
3. Electric motor will starts the motor shaft is connected to the cutter
by help of pulley and v- belt are connected pulley both motor shaft
and cutter shaft.
4. Check the direction of cutter block pulley as per allotment on
pulley.
5. Then starts the system unit and absorb the direction of rotation
shaft rotation should be anticlockwise when viewed from pulley side.
6. Take the wooden piece to require cutting.
7. Put on the opposite of the cutter on the table. 8. Then push the
wood opposite direction to the cutter.
9. For a different depth take different cutters. Then the cutting
operation is completed.
10. Then check the surface cutter uptown wheel. If it’s correct leave
it. If it is not correct it.
11. Then start to push the wood piece to opposite direction of surface
cutter to make a smooth surface finish on wooden piece.
12. Then our operation will be completed.
13. Then switch off the machine and remove the main supply.

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CHAPTER 6: COSTING OF PROJEC`T
S.no. Particulars Total quantity Cost rest/unit Total cost
1 Motor 2800 rpm 1 3500 3500

2 Pillow block 8 150 1200

bearing
3 Bevel Gear and 1 200 200
pinion
4 Drill chuck 2 290 290

5 Wooden cutter 1 170 170

6 Steel shaft 2 160 320

7 Nut and bolts 3 kg 200 200
8 Pulley 6 500 500
9 Belt 3 150 150

10 3-phase interpolator 1 310 310

11 Paint 3 40 120
12 Flange 1 15 15
13 Grinding wheel 1 170 170

14 Cutting wheel 1 60 60

15 Single point cutting 2 75 150

tool
16 Wire 15m 180 180

17 Transportation and 500 500

miscellaneous
18 Kerosene 1l 32 32

19 Angle 1500 1500

Total 9567

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CHAPTER 7: FUTURE IMPLEMENTATION
 We can perform various operations like cutting drilling and shaping
individually by introducing coupling (engagement and disengagement)
between them.
 We can perform grinding operation by introducing a grinding tool at the ain
shaft.
 We can perform boring operation by introducing a boring tool by replacing
drilling tool.
 We can change the motor speed by regulator.

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Chapter 8: ADVANTAGE

 Multi operation can be performed at one time.

 The return stroke is utilized for cutting.
 All operation is performed by only one motor.
 Size is compact and require less space.
 Time saving
 Less man power is required.
 Low manufacturing and maintenance cost.

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CHAPTER 9: CONCLUSION
After completing the major project on “MULTIPURPOSE MECHANICAL
MACHINE” we are much happy and would like to thank our professor , guide
and the lecturers of the concerned department who have guided us.

While making this project we have been able to learn a lot and understand the
various aspect of “multipurpose mechanical machine” we can use our
knowledge , which we get during our study .

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REFERENCES

The websites
 www.technologystudent.com
 www.terry-eng27.blogspot.in
 www.en.wikipidea.org
 www.ask.reference.com
 www.dictionary.reference
 www.community.machinedesign.com
 www.sciencedirect.com

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THE HELPFUL BOOKS
 Workshop technology (hazra choudhary)
 Theory of Machines (R. S. KHURMI)
 Machine design
 Production technology

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