C.U.

SHAH POLYTECHNIC
Near Boda Lake, G.I.D.C. Area, Wadhwan, Surendranagar.

SUBJECT

: PROJECT-II

SUBJECT CODE : 2361906 DISCIPLINE : MECHANICAL ENGINEERING

ENROLMENT NO.

: 086090319006

NAME OF STUDENT : BORANA YUVRAJSINH V. DIVISION / BATCH : DIV-II / M5

SUBMISSION: SUBMITTED V SEM SUBMITTED VI SEM : :

CERTIFICATE
THIS IS TO CERTIFY THAT SHRI BORANA YUVRAJSINH V. HAS SATISFACTORILY COMPLETED HIS TERMWORK IN THE SUBJECT PROJECT II (2361906) WITHIN THE PRESCRIBED TIME LIMIT AND PRESCRIBED BOUNDARY.

DATE STUDENT

DATE : GUIDE

INSTITUTE

DATE : OF DEPT.

HEAD.

DATE PRINCIPAL

CHAPTER-1

GUJARAT TECHNOLOGICAL UNIVERSITY

DIPLOMA IN MECHANICAL ENGINEERING SEMESTER- VI

Subject Name: Subject Code:

Project -II 2361906

NOTE: Either OPTION-A or OPTION-B is to be undertaken. (ANY ONE). OPTION- A.

INDUSTRY BASED-IDP SOLUTION Student will continue to work on the same IDP/UDP of V semester. It is to be noted that solution

Should not be:

I. On paper. Ii. In form of only suggestions. Iii. In form of theoretical approach only. iv. Repetitive. To undertake this option, following conditions should be satisfied. 1. It will be absolutely necessary to have feasible and implementable Approach.

2. Industry certificate permitting implementation of IDP. 3. IDP outcome must be physical and must be at related industry Place. 4. IDP outcome must be measurable and acceptable to grant the Term for this subject.

CHAPTER-2

IDP TITLE

To Remove The
Ovality Of Shaft Manufactured by

CNC Grinding Machine.

CHAPTER-3

Description of resources used for solution

Grinding is a process in which desired shape, size and surface finish of the workpiece is obtained by removing unwanted material with the help of grinding wheel manufactured from abrasive grains. In this process the tool is a rotating grinding wheel. Common features of all machine tools: (1) It uses power. (2) It removes unwanted material from the workpiece with the help of cutting tol to give desired shape. (3) It uses workpiece, holding devices, as well as cutting tool holding devices which have definite relative motion with each other. (4) Normally some type of cuting fluid is used. (5) It is stong, rigid, and durable in construction. (6) All its moving parts have definate relative motions which are obtained and contolled by using different drive and control systems. (7) Its main purpose is to get desired shape, size and finish. (8) It is mounted on foundation. (9) It has a very long life compared to its cutting tool.

To ensure the require performance the various components of machine tool must possess:
(1) Strength to withstand forces. (2) Stiffness to resist deformation. (3) Rigidity to sustain vibrations and (4) Provisions for maintaining accuracy of relative location and alignment of all parts throgh out the working range of machinery.

Reference Manufacturing Engineering-II

The quality and acccuracy obtained by this process mainly depends on the following factors:
1. The type of produuct metal 2. The type of Grinding wheel 3. The type and conditon of Grinding Machine 4. The process parameters like a. The speed of Grinding wheel b. The feed of the job c. The depth of cut 5. Personal reasons like skill of the operator

The above discussion reveals that the following thee elements are involved in the grinding process.
1. Product: Whose shape and physical dimensions are as per their requirement. 2. Grinding wheel: Its selection is based upon type of grinding process and product. 3. Grinding machine: Its selection is based upon required accuracy plus the shape and size of the product.

The special features of grinding process are as follows:

1. Operation is intermittent in nature. 2. It produces discontinuous chips. 3. The grain geometry is highly random. 4. The time of contact between chip and an abrasive grain is very small. 5. Grinding wheel has a self sharpening character.

6. The load acting on individual grains is non-uniform. 7. Grinding is associated with high specific cutting energy as compared to conventional cutting operations.
8. The rspid grain wear occurs due to high temperature encountered

in the range of 10,000-14000. 9. The effective rake angle of abrasive grains is highly negative. 10. The grinding action is highly dependent upon the characteristics of the grinding wheel.

Selection criteria of grinding wheels.

The success of grinding process is based on wheel selection.The following factors are considered for selecting a grinding wheel.

(A)Constant factors:
1. Material of the product 2. Quantity of metal to be removed from the product. 3. Contact area.

(B) Variable Factors:

1. Speed of the Grinding wheel. 2. Speed of the job or product. 3. Condition of the machine. 4. Personal reasons.

Various grinding wheel operation:

1. Self sharpening action of grinding wheel. 2. Mounting of grinding wheel 3. Loading and glazing 4. Trueing and dressing 5. Grinding fluid

Reference Machine Tool Technology

CHAPTER-4

Details of various solution approaches thought and executed

Below are some of the solution approaches thought and executed: (1) Check machine foundation. As per common features of any machine tool it is mounted on foundation. The foundation should be such that it should resist various forces acting on machine tool. Also it should sustain vibrations produced due to working of machine.if the foundaton of machine is not strong enough than it is possible that the machine may vibrate a lot so that it becomes impossible to work on machine and due to this the accuracy in dimension may also change. It is possible that when a heavy duty job is loaded, the dimension may vary and the cause of taper may be caused. (2) Check shaft alignment in machine assembly. When the machine gets assembled than at that time if the spindl shaft is not properly assembled means not properly aligned than the changes in dimension takes place. So for accuracy in dimension it is necessary that the shaft is properly aligned. The job which is fixed with the spindle will be fixed as per the spindle position and the tool will be fixed as per it should be fixed so when the work starts the difference in the dimension can be seen. So shaft alignment also plays an important role in bringing accuracy in dimension. (3) Check if heavy duty workpiece is loaded. When a heavy duty workpiece is loaded which becomes difficult for a machine to hold and work on it, than the job moves out of control or out of axis and the ovality in dimenson as well as improper surface finish is obtained, so it should be taken into care that the workpiece on which workpiece is loaded should work in safe condition.

(4) Check the lubrication. If lubrication in various machine parts is not done properly tan the wrking condition of a machine gets worst and slowly it is possible that at some stage the machine may break down due to insufficient lubrication and also during working on it the machine parts may not work properly and thus it affects the job dimension as well as the surface finish. So proper care should be taken for lubricating the machne parts when needed or as per schedule. (5) Check quality and quantity of cutting fluid. The quality and quantity of cutting fluid also plays an important role in bringing good surface finish as well as accuracy in dimension. If the quality of cutting fluid is not ok and the quantity of cutting fluid supplied is insufficient than the surface finish is also not ok and it affects the working of cutting tool. The cutting tool does not perform as per requirement and ths the surface finish obtained is low and also if the particles of cutting flid remains on the surface of the jb manufactured then it creates obstruction in working of cutting tool. Hence the quality and quantity of cutting fluid also affects the job manufacturing. (6) Check power supply. If the supply of power to the machine is variable than it affects working of the machine spindle. As per the supply of power the machine spindle stops and starts and thus the work done on it will be like that only. The surface finish is not as per requirement as well as due to frequent stop and start of the spindle or due to change in speed of machine spindle the job does not get required dimension. Thus it also affects the dimension and surface finish of job and it should also be taken into notice when such problem arises.
(7) Check whether proper maintainance is given or not.

Proper maintainance should be given as per needed or as per schedule, so that the working efficiency of machine is maintained. In maintainance of machine attention is paid towards different parts of machine no matter small or big. For example: Suppose in a grinding machine attention is paid towards grinding wheel, balancing of wheel, its working condition, trueing and dressing of wheel, cutting action of grinding wheel, type of grinding wheel is done as per requirement or not, wheels grade is also taken into consideration as it gives surface finish as per requirement, material of product, loading and glazing of

wheel, purification of cutting fluid etc. are taken into consideration during maintenance of a grinding machine. So various factors should be considered while maintainence of any machine.

Above listed factors are responsible for a machine for not working in proper condition.

CHAPTER-5

Details of solution achieved

The solution to our problem ovality in shaft manufactured in grinding machine is due to improper maintainence of grinding wheel. The defect was due to trueing and dressing of grinding wheel and the details of the solution achieved is as listed below:

TRUEING
Trueing is called the process of changing the shape of the wheel, which is resulting due to the loss of original shape when the grinding wheel is wornout as a result of breakin aay of the abrasive grains and bond. The trueing is done to make the wheel true and concentric with its bore. The wheel counter for form grinding can be changed by trueing. The dressing of grinding wheel is done to remove the loading and to break away the glazed surface of the wheel, to bring out the sharp abrasive particles for grinding the work. The trueing and dressing for the following reasons. 1. To regain the shape and efficiency of the wheel. 2. To reduce the heat generated between work & wheel. 3. To reduce the strain on machine and wheel. 4. To improve the surface quality of the work. The trueing and dressing can be easily understood by studying th figure. The tool used for trueing & dressing is called Dresser. The dressers are of the following types. 1. Metal crushers 2. Abrasive sticks/wheels 3. Diamond dresser (a) Single point diamond dresser (b) Single set and matrix diamond dresser (c) Rotary and stationary diamond rolls (d) Crushing rolls

(1)

Metal crusher: for roughing operation and it is also known as StarThis type of dresser is rotated on the wheel face by

It is used Dresser.

keeping it sloping at 3 to 5 to the wheel axis. This dresser removes the dull graiins from the bond material of the wheel. (2) Abrasive sticks/wheels:

The abrasive sticks are used for the grinding wheel used for grinding tool and cutter. It is also used to remove loading and glazing of the diamond wheel. The abrasive wheels are used for trueing and dressing of the diamond and cubic boron nitridng wheels. The black or green silicon carbide is used in this type of dresser. The diameter of the abrasive wheel is kept to times the diameter of grinding wheel.
(3) Diamond dresser:

The single point diamond dresser is generally sed for dressing of the grinding wheels used for precision operation like surface grinding, cylindrical grinding, centreless grinding and thread grinding. It is kept at 14 to 15 angle to the wheel axis as shown in fig. The improved form of single point dresser is called matrix type dresser. It can be used for large & wide wheel dressing without fading. Crushers are used for profile dressing but now a days rotary and form diamond rolls are used in its place, which can provide better geometrical shape to the wheel. There are two methods of trueing & dressing. They are (1) grinding and (2) Crushing. In crushing slow flow is given to the rollers against the rotating grinding wheel. Due to this effect abrasive breaks and leave the wheel face. In crushing the rise of temperature is less but it generates more rough surface in comparison to the diamond dressing. In both these methods sufficient amount of coolant is necessarily used. If treng and dressing of grinding wheel is done properly when needed than the ovality in shaft will not form. So this is the solution to our problem.

CHAPTER-6

Description/ specifications/ parameter of processes/ etc.of resources (specifically materials, methods and machines) used for solution. Description
The solution of trueing and dressing proves correct when points listed below are taken into consideration: Swing over table dimension should be 1100 mm.

Z Axis: Table motor power 13 Nm.

XAxis: Table motor power 13 Nm.

WHEEL UNIT: Diameter of grinding wheel 1100 mm,

Standard grinding wheel thickness 120 mm. Min grinding wheel thickness 25 mm.

 Wheel rotation motor power 22 KW.

WORKHEAD: Step less rotation speed rpm from 0 to 40 rpm. Diameter of chucks 630 mm. Headstock rotation motor power 27 Nm.

Machine type 600 1000 Main specifications

Distance between centre mm 800 1000

Grinding length RS // URS mm 400 800 R // UR mm 600 1000 Centre height mm 175
Weight of workpiece between centre kg 100

Load on chucked work Nm 100 Mains voltage required 3 x 400 V / 50 Hz // 3 x 460 V / 60 Hz Power consumption depending on equipment A 35 80 Space required / length x width mm 2400 x 2000 3000 x 2000 Table / slide: Z-axis Travel mm 750 1150
Rapid traverse speed m/min 20

Resolution um 0.1 Swiveling range of upper table degree 9 Wheel slide: X-axis Travel mm 350
Rapid traverse speed m/min 10

Resolution um 0.1 Peripheral grinding wheel speed m/s 35 / 45

 Parameter of processes:
The parameter of processes for our solution is as given below: (1) First of all start the process of manufacturing the shaft which is to be done on grinding machine. (2) Then after the manufactured shaft should be inspected and the ovality of shaft should be considered well in mind as to solve our problem of shaft ovality.
(3) When the problem of shaft ovality comes into sight than at that

time as per our solution the condition of wheel should be checked i.e inspection of grinding wheel should be done. (4) After the inspection of grinding wheel the process of trueing and dressing which is been suggessted should be done so that the problem of shaft ovality gets reduced. (5) It is also necessary to inspect the grinding wheel after the process of trueing and dressing so that we come to know about the condition of wheel and can bring it to a situation of perfection for our process of grinding.
(6) After the grinding wheel has been inspected and proved OK, the

process of shaft manufacturing should be started so the condition of the solved problem can be verified. (7) When the solution successfullly gets implemented, than the work should be started again.

CHAPTER-7

Photographs/clips of work in progress.

CHAPTER-8

Problems encountered during execution of IDP/UDP project solution and solution adopted.
1) Availabilty of computer created a problem.
2) Waste of time as the cyber cafe is far from college as well as from

home. 3) To find the company for our project work is a problem as if most of the student request a single company to share their problem than the students coming late dont get a problem as the problems have been distributed. 4) To find problems to prepare this chapter is also a problem. 5) The solution to the problem which experienced and educated person were unable to bring was asked us to solve which is out of our capacity as we need to gain much knowledge as well as experience to solve that.