Project Report

on
Submitted in partial fulfilment for the award of degree of Bachelor of
engineering
In
Mechanical engineering

Visvesvaraya Technological University, Belgaum

By
VARUN B R 1BM13ME120

BHASKAR CHAWDHARY 1BM13ME137

KEWIN PALOCAREN 1BM13ME142

VISHAY RAINA 1BM13ME128

Under the guidance of
Dr Raghu sharma
Assistant professor
Department of mechanical engineering
B.M.S College of Engineering
Bangalore-560019

Department of Mechanical Engineering

Accredited by NBA for five years (2014-2019), Under Tier-1,
B.M.S College of Engineering
Autonomous College under VTU
BANGALORE-560019
April-2016
Certificate
Department of Mechanical Engineering
Accredited by NBA for five years (2014-2019), Under Tier-1.
B.M.S College of Engineering
Autonomous College under VTU
1
 BANGALORE 560019

This is to certify that this Project Report titled

A STUDY ON THE EFFECT OF SAND BLASTING ON SURFACE FINISH OF ABS

PLASTICS

Has been successfully carried out by

VARUN B.R 1BM13ME120

BHASKAR CHAWDHARY 1BM13ME137

KEWIN PALOCAREN 1BM13ME142

VISHAY RAINA 1BM13ME128

As a part of 7th semester curriculum in Bachelor of Engineering in Mechanical Engineering.

B.M.S. College of Engineering during the academic year 2016-2017

Guide

Dr Raghu Dr. L. Ravi Kumar

Assistant Professor Professor and Head
Department Of Mechanical Engineering Department Of Mechanical Engineering
B.M.S. College of Engineering, Bangalore-19 B.M.S. College of Engineering,
Bangalore-19

Dr K. Mallikharjuna Babu
Principal
B.M.S. College of Engineering, Bangalore-19

Contents
Certificate 2

Abstract 4

List of figures, tables and nomenclature 5

Chapter 1 Introduction 6
2
1.1 Blasting Technology 6
1.2 Air blasting 6
1.3 Types of air blast delivery systems 7
1.4 Terminology used in surface texture 8
1.5 Nozzle specifications 9

Chapter 2 10

1 2.1 Aim
2 2.2 Scope
3 2.3 Relevance

Chapter 3 11

Methodology adopted

Chapter 4 Equipment specifications 12

1 4.1 Properties of 3D printer used

2 4.2 Property of compressor used
3 4.3 Blast gun properties 13
4 4.4 Property of test material 14
5 4.5 Instrument used to measure the surface roughness

Chapter 5 Commercial survey of compressors 15

5.1 Air requirement

5.2 Commercial compressors for blasting

Chapter 6 Experiments conducted 18

1 6.1 Sieve analysis

2 6.2 Tests on ABS models

Abstract
This project aims to design a device which enables easy patient handling and transportation
on staircases. Presently the state of patient handling in the congested areas, which restricts the
mobility of the ambulance, is unacceptable. They violate the safety regulations of patient
handling. This device will be capable of negotiating a staircase like a ramp and thus facilitate
transporting patients residing in multi-storeyed houses without lifts, to the ambulance. The
mechanisms for negotiating a staircase like a ramp were studied and concepts were
generated,in order to achieve the design of the same. A thorough strength analysis will be
performed on all the components of the design. Alternatives for each component were
assessed to decide on the feasibility of the mechanism that is compatible with the structure.

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 List of figures
1.1 Venturi nozzle 7
1.2 Surface texture 8
1.3 Variation of the nozzle size with the stand-off distance 9

2 4.1 Aha protocentre 999 3D printer-3D printing lab, BMSCE. 12

3 4.2 Multistage air-compressor in Energy Conversion Engineering (ECE) Lab 13
4 4.3 Blasting gun
5 4.4 Taylor-Hobson Profilometer 14

5.1 Compressor 1 16
5.2 Compressor 2
5.3 Compressor 3
4
 5.4 Compressor 4 17

6.1 Sieve analysis 18

List of tables
Table 1.1 9
Table 4.1 14
Table 5.1 15
Table 7.1 19

Nomenclature
SCFM Surface cubic feet per minute
PSI - Pounds per square i
1. Rust removal
2. Mould cleaning

Factors that affect blast finishing are:

1. Media delivery systems

2. Blast containment enclosures, media recovery and dust collection systems.

3.Media used in industrial blasting systems

Media delivery systems:

There are three media delivery systems that propel and deliver media for high speed impact
to the part being processed.

A. Air Blasting (Pneumatic)

B. Mechanical Wheel (airless blasting)
C. Hydro blasting (pumped water)

1.2 AIR BLASTING

The process utilizes an air compressors energy to deliver air/media mix at speeds and
volumes to impact the parts being processed. The air speed or pressure of an air
compressor is controlled by a pressure regulator. The regulator can increase or decrease
the speed of the media delivery. Air pressure is measured by pounds per square inch (psi),
industrial blasting is effectively done between 20 and 90 PSI. The higher the PSI, the
higher is the air speed. The volume delivered of the air/media mix is determined by the
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orice or opening diameter of the nozzle with pressure blast systems or air jet diameter of
the suction blast gun body. Air volumes are measured by surface cubic feet per minute
(scfm). The larger the orice ID opening, larger is the volume of air/media. Other factors
that affect volume of air into the blast system is media and air hose diameter. Increased air
pressure (PSI) also increases the SCFM with a given size orice. .
Industrial blasting gun bodies of suction cabinet blast systems range between 12 to 38
SCFM. The pressure blast cabinet systems range between 12 to 68 scfm and the pressure
blast room systems use up to 254 scfm. Industrial air compressors produce approximately
4.5 SCFM per horse power (hp). Blasting cabinets require 3 to15 hp compressors.

1.3 Types of air blast delivery systems:

1. Suction (used in blast cabinets)
2. Pressure (used in blast cabinets, blast rooms, and outdoor blasting)
SUCTION blasting uses the venturi principle sucking media from a hopper. The air jet is
1/2 the ID of the nozzle and as the air stream is passed through both, it creates a low
pressure which sucks the media from the hopper into the air stream. The media
acceleration distance is very short ( from the nozzle to the workpiece-approximately 4 to
14). The suction systems work ne and can be continuously blasted as long as there is
blasting media in the hopper. Suction systems do not deliver media well at very low air
pressures (5 to 25 psi) and they have limits on how long the suction feed hose can be.
Very heavy blasting (large steel media) cannot be conveyed into the air stream with
suction blasting. Most industrial blast cabinets are suction systems and work well with
most media.

6
Figure 1.1 :Venturi nozzle: Features a converging entry and a diverging exit and suction feed
system
1.4 Terminologies used in surface texture

Figure 1.2 Surface texture image source www.mfg.mtu.edu/quality/sfinish/terminology

1) Surface: The area which is confined by a boundary which separates the part
from the surrounding
2) Nominal Surface: The surface which is free from any roughness or waviness.
In other words its a theoretically and geometrically perfect surface, which is
impossible to obtain in practice.
3) Profile: The contours present on the surface of a manufactured part.
4) Roughness height: Its the arithmetic average deviation of the surface
measured in micro meters.
5) Roughness width: distance parallel , to the normal surface between successive
peaks or ridges that constitutes the predominant pattern of the roughness
6) Roughness width cutoff: The maximum width of surface irregularities that is
present in the measurement of roughness height. It is always greater than roughness
width.

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 1.5 Nozzle specifications
The Blast nozzle spray obtained from the work-piece , is affected by factors such as
orice size, air pressure, and distance from the work-piece. As the distance from the
blast pattern is increased, the total diameter of the blast pattern also increases. The hot
spot (Region of effective blasting) can be at larger distances from the work-piece
using pressure blast systems.

Figure 1.3 Variation of the nozzle size with the stand-off distance

Distances from work-piece

GUN ID 6 12 18
1/4" 1-3/8 2-5/8 - 2-3/4 - 1
5/16 1-1/2 3-1/2 1-3/4 4-1/2 - 3-3/4
7/16 2 3-3/4 2 4-1/2 - 3-3/4

Table 1.1 : Variation of the nozzle size with the stand-off distance.

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 Chapter 2

2.1 Aim

To design a structure that facilitates transport of a patient from the site of trauma to the
ambulance in a safe way adhering to the patient handling regulations. The USP of the
structure is that it can negotiate staircases like a ramp while keeping the patient immobilised
on the structure bed. It is also designed for use in narrow stairways and congested landings,
without discomforting the patient.

The following objectives have been identified as critical components in design of the
structure:

1. Strength analysis of the structure.

2. Analysis of track mechanism and load bearing capacity of chassis

3. Selection of Gas spring

4. Design of auxiliary wheel

5. Braking mechanism for the structure

6. Design of rear legs

7. Selection of immobilisation devices

2.2 Scope

Alterations could be made to the design of the structure to have variable length and width of
the bed in order to adapt to the different staircase dimensions that the structure may
encounter.

2.3 Relevance

In congested residential layouts, ambulances are unable to reach the site of trauma and
usually are forced to stop on the main roads. In these cases, the patient is brought to
the ambulance in ways which are against the safety guidelines of patient handling
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techniques. In an attempt to make patient transition a smooth and safe process, this
structure finds relevance in its development. In broad perspective, it is a structure that
can negotiate a narrow staircase like a ramp and may be used in applications that have
similar requirements.

10
 Chapter 3

Methodology adopted

11
 Chapter 4
Equipment specifications
4.1Properties of 3D printer used:

Figure 4.1 Aha protocentre 999 3D printer-3D printing lab, BMSCE.

Make: Aha 3D ProtoCentre 999

Technology: Fused Deposition Modeling
Build volume: 9 x 9 x 9 cubic inches (228 X 228 X 228mm)
Build material: All thermoplastics (ABS)
PC/Tablet connectivity: USB, Micro SD card
Extruder nozzle bore: 0.5 mm
Positional accuracy: 50 microns
Power consumption: 250W
Dimensions: 500 x 500 x 500 mm

4.2Properties of compressor used:

Input pressure source obtained through compressor: A multistage compressor was used to
obtain the compressed air. The outlet of the compressor was connected to the blast gun via
tube. A pressure gauge was connected to this tube to measure the output pressure. Flow
control valve was used to control the out flow of the pressurized air.

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 Figure 4.2 Multistage air-compressor in Energy Conversion Engineering (ECE) Lab

4.3 Blast gun properties

1. Nozzle diameter used was 4mm.

2. Blast gun is of siphon feed type system.

3. The blast gun was connected to the reservoir via a tube with the help of 3/8 BSP male
(brass) and 3/8 BSP hose nipple.

13
 Figure 4.3 blasting gun

4.4 Properties of test material

Acrylonitrile Butadiene Styrene

Sl. No Properties Units Range
1. Tensile strength MPa 22
2. Youngs modulus MPa 1627
3. Flexural strength MPa 41
4. Flexural modulus MPa 1834
5. Notched izod impact strength J/m 107
6. Unnotched izod impact strength J/m 214

7. Heat deflection temperature C at 0.45 MPa: 90

at 1.81 MPa: 76

8. Density g/cm 1.05

9. Elongation at break % 6
10. Color Blue, red, yellow, steel grey, green, black,
white, grey
Table 4.1: Data sheet of Standard Acrylonitrile Butadiene
Styrene (source: FDM material properties-Materialise).

4.5 Instrument used to measure surface roughness:

Figure(4.4) Taylor-Hobson Profilometer Talysurf is an instrument

working on carrier modulating principle. It consists of a sharply pointed diamond
stylus about 0.002mm tip radius and 0.1micron least count.

Chapter 5

14
 Commercial survey of compressors
Conforming with the projects long term goal to make a table-top sand blasting machine,
determining the size of the compressor is an important step.

5.1 Air requirement

Below is a chart of air volume (SCFM) used in blasting with suction systems utilizing
pressures (PSI) and orice sizes.

Suction-Blast Air Requirements ( scfm )( Table 5.1)

Pressure (psi) 30 40 50 60 70 80 90 100
1/4 nozzle 3/32 jet 6 7 8 10 11 12 13 15

1/4 nozzle 1/8 jet 10 12 15 17 19 21 23 26

5/16 nozzle 5/32jet 15 19 23 27 31 37 38 42

7/16 nozzle 7/32 jet 31 38 45 52 59 66 73 80

5.2Commercial compressors for blasting:

Parameters for selecting a compressor:

1. Air volume
2. Lubrication type
3. Horsepower
4. Portability
5. Power source

Following are the compressors primarily used in sand-blasting units:

Ingersoll-Rand SS3F2-GM Garage Mate Oiled Wheeled Single Hot Dog Compressor

(Figure 5.1)
They are one of the top brands in air compressors and air tools as well as other tools. The
tank is horizontal and holds 30 gallons. This particular unit is multi-faceted in terms of its

15
portability and has indoor/outdoor usage feasability. This has a max pressure of 135 PSI.
This unit weighs about 185 pounds(84 kgs).

NorthStar Belt Drive Single-Stage Portable Air compressor

(figure 5.2)
This unit is powered by a
two horsepower air
compressor. This unit
weighs 207 pounds(94
kgs). The noise decibels on
this are 80.

California Air Tools CAT- 263DLH Steel Tank Oil-

Lubricated Air Compressor

(figure5.3)

This unit has a powerful 2.0 horsepower motor. This is a portable unit. This unit weighs
about 52 pounds(24 kgs). This is a corded electric unit. This unit has a max PSI of 125 and
is an 85 decibel unit.

Porter-cable pancake compressor:

16
 (figure 5.4)

Features:

a) 2.0 SCFM delivered @ 90 PSI pump, 3.5 gallon tank and 135 max PSI for longer run
time and quicker recovery.

b) Durable oil-free pump for long life and no maintenance.

c) Low Amp 120V motor.

d) Only 26 lbs(11.7kgs) for easy portability.

Chapter 6
Experiments Conducted
6.1 Sieve analysis

17
In order to obtain the varying grit sizes, sieve analysis tests were performed on Silicon
dioxide abrasive. The sand was separated in sieves of British standard setup and the
following sizes were obtained:

1. Mesh size 30
2. Mesh size 44
3. Mesh size 60
4. Mesh size 100

Figure 6.1

6.2 Tests on the ABS model

Step 1: Procured the ABS model from the college 3D printing lab.

Step 2: Measured their initial surface roughness using Talysurf.

Step 3: Conducted sand-blasting with varying combinations of grit size and pressures.

Step 4: Measured final roughness of the sand blasted parts.

Chapter 7
Results & Discussions
18
The experiment was carried out as planned by varying the grit sizes and pressure. The
results obtained are as shown in table 7.1

1. Pressure ranges

Sl Range Pressure in Pressure in MPa

No. Kg/cm2
1 Low 4 0.3922
2 Medium 5 0.4903
3 High 6 0.5833

2. Duration of blasting
per trial- 2 minutes.

Sl Pressure Grit Stand- Initial Roughness Final % Decrease

No. Off (in microns) Roughness In
Distanc (in microns) Roughness
e (in
mm)
1 Low 30 40 No Result No Result No Result
2 Medium 30 40 No Result No Result No Result
3 High 30 40 No Result No Result No Result
4 Low 44 40 No Result No Result No Result
5 Medium 44 40 No Result No Result No Result
6 High 44 40 No Result No Result No Result
7 Low 100 40 No Result No Result No Result
8 Medium 100 40 No Result No Result No Result
9 High 100 40 No Result No Result No Result
10 Low 30 50 22.66 6.87 69.71
11 Medium 30 50 No Result No Result No Result
12 High 30 50 23.53 5.93 74.7
13 Low 44 50 31.84 13.7 56.94
14 Medium 44 50 25.99 8.61 66.88
15 High 44 50 23.55 4.36 81.42
16 Low 100 50 22.27 9.84 55.81
17 Medium 100 50 No Result No Result No Result
18 High 100 50 34.83 11.53 66.89
19 Low 30 60 No Result No Result No Result
20 Medium 30 60 No Result No Result No Result
21 High 30 60 No Result No Result No Result
22 Low 44 60 No Result No Result No Result
23 Medium 44 60 No Result No Result No Result
19
24 High 44 60 No Result No Result No Result
25 Low 100 60 No Result No Result No Result
26 Medium 100 60 No Result No Result No Result
27 High 100 60 No Result No Result No Result

Table 7.1 Results obtained after sandblasting the specimen by varying parameters.

X-axis = pressure in MPa

Y-axis= percentage decrease in surface roughness

20
X-axis= Grit size
Y-axis= percentage decrease in roughness

X-axis= Grit size

Y-axis= percentage decrease in roughness

21
Conclusions:
1. When the grit size is
maintained constant, the percentage decrease in surface roughness increases with
increasing temperature.
2. When the pressure is
maintained constant, the percentage decrease of surface roughness decreases with
increasing mesh size.

The above results are validated from the graphs. There is a slight discrepancy in
values due to the slight variations in stand-off distance.

Future scope:

The results obtained as part of this mini project have helped in our overall
understanding of how the parameters influence the sand-blasting process.

The identification of the right compressor and nozzle specifications has been studied
in this project to help facilitate the development of a table-top sand blasting
machine.

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 References
[1] Alhubail, Mohammad (2012) Statistical-Based Optimization Of Process Parameters Of
Fused Deposition Modeling For Improved Quality. Ph.D. Thesis, University of Portsmout.

[2] Pandey,P.M., Reddy, N.V. and Dhande, S.G.(2003) Improvement of surface finish by
staircase machining in fused deposition modeling, Journal of Materials Processing
Technology, Vol. 132, pg. 323-331.

[3] Rao, A.S., Dharap, M.A.,Venkatesh, J.V.L. and Ojha, D. (2012) Investigation of post
processing techniques to reduce the surface roughness of fused deposition modeled parts,
International Journal Of Mechanical Engineering And Technology, Vol. 3, No. 3, pg. 531-544.

[4] Gurpal Singh Bual, Parladkumar,Methods to Improve Surface Finish of Parts

Produced by Fused Deposition Modeling, Manufacturing Science and Technology
(2014) 2(3): 51-55

[5] Srinivas Athreya1 , Dr Y.D.Venkatesh2, Application Of Taguchi Method For

Optimization Of Process Parameters In Improving The Surface Roughness Of Lathe Facing
Operation 1 (Mechanical Department, Fr. C. Rodrigues Institute of Technology,
University Of Mumbai, India) 2 (Principal, Xavier Institute of Engineering,
University Of Mumbai, India)

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