Introduction

CHAPTER 1 Introduction

1.1 INTRODUCTION OF AREA

In most branches of industry there are processes in which one has the need to remove contaminants from a product, either from the finished product or from some intermediate stage in the production process. Some common methods used are washing with a suitable fluid, brushing, and wiping, polishing, buffing, blow cleaning and vacuum extraction. There is an increased need to make this operation as gentle as possible due to higher demands in quality and at the same time there is a constant battle to reduce Energy consumption making it more complicated to find a suitable process. Polishing and buffing are finishing processes for smoothing a work pieces surface using an abrasive and a work wheel. Technically polishing refers to processes that use an abrasive that is glued to the work wheel, while buffing uses a loose abrasive applied to the work wheel. Polishing is a more aggressive process while buffing is less harsh, which leads to a smoother, brighter finish. A common misconception is that a polished surface has a mirror bright finish, however most mirror bright finishes are actually buffed.

Fig 1.1.1 Buffing is often used to enhance the looks of an item, prevent contamination of medical instruments, remove oxidation, create a reflective surface, or prevent corrosion in pipes. In metallographic and metallurgy, polishing is used to create a flat, defect-free surface for examination of a metal's microstructure under a microscope CCET/MECH/044/011/01 1

Introduction Polishing: - This operation removes surface material, improving the surface and preparing it for buffing. This is generally a coarse operation involving sandpaper and/or coarse compounds. Buffing: - This operation makes the surface smooth producing a high luster and mirror finish if desired. This is done with the use of buffing wheels and buffing compounds. Buffing can be divided into two steps; cut buffing and color buffing.

1.1.1 PROCESS Buffing is usually a multistage process. The first stage starts with a rough abrasive and each subsequent stage uses a finer abrasive until the desired finish is achieved. The rough pass removes surface defects like pits, nicks, lines and scratches. The finer abrasives leave very thin lines that are not visible to the naked eye. Lubricants like wax and kerosene may be used as lubricating and cooling media during these operations, although some polishing materials are specifically designed to be used "dry." Buffing may be done by hand with a stationary polisher or die grinder, or it may be automated using specialized equipment. Sand buffing, when used on German silver, white metal, etc., is technically a buffing operation because it uses a loose abrasive, but removes a significant amount of material, like polishing. Buffing knives and cutlery is known as fine glazing or blue glazing.

For good buffing results, follow the few simple but important rules with some of the buffing terms commonly used:
A SECTION OR SINGLE BUFF, consists of layers of material sewed together in various ways. It is usually about 1/4 inch thick at the face. A BUFFING WHEEL consists of one or more single sections. You can buy ready-made multiple buffs, which are single sections sewed together, or you can assemble any thickness buffing wheel you wish by putting together single or multiple buffs on your spindle. Buffing wheels should always be mounted on your spindle between flanges firmly gripping the sides. CCET/MECH/044/011/01 2

Introduction FLANGES are the metal discs between which buffing wheels are mounted. Each DICO wheel is supplied with a pair of special toothed flanges which bite into the buffing wheel to prevent it from slipping. THE FACE, OR edge, of a buffing wheel is the working surfaces. PREFACED, means that the trued wheel face has a soft nap which prepares it for easy applications of compositions. A COMPOSITION, OR COMPOUND, is the material applied to the face of a buffing wheel to enable you to obtain the finish you desire. It consists of abrasives, which do the work, held in suspension by wax or grease, which acts as a binder to hold the abrasive to the buff. Buffing wheels will not product results without compositions, DICO compositions are specially compounded for easy application and to give dependable results. SPINDLE SPEED is the speed of your spindle expressed in R.P.M., or revolutions per minute When buffing there are two types of buffing motions: the cut motion and the color motion. The cut motion is designed to give a uniform, smooth, semi-bright surface finish. This is achieved by moving the work piece against the rotation of the buffing wheel, while using medium to hard pressure.

FIG 1.1.2

CCET/MECH/044/011/01

Introduction The color motion gives a clean, bright, shiny surface finish. This is achieved by moving the work piece with the rotation of the buffing wheel, while using medium to light pressure.

FIG 1.1.3

1.1.2 CHOOSING THE RIGHT WHEEL There are different types of wheels and these have different effects on the compound they are used with. For example, the SISAL wheel is a coarse 'rope like' fiber, which frays out to make a sort of brush. These fibers have a very beneficial effect on scratched and rougher surfaces, almost stroking them smooth. When used with a course 'EMERY' compound, they 'cut' the metal down very rapidly. You could use this compound on a SPIRAL SEWN wheel and it would work, but the job would take much longer because the softer SPIRAL SEWN wheel is not going to thrash the metal so aggressively. As you progress through the buffing compounds, you will change your buffing wheel, ending up using a soft polishing wheel, such as the CANTON FLANNEL with the least abrasive BLUE or RED compound which only polishes, it has no cutting action. So, depending on the job in hand, you will determine which

abrasive compound and wheel you are going to use first, then step down through the stages until YOU are satisfied with the results. Compounds are made from a mixture of fine abrasive fillers and a sort of greasy wax. The compound is melted, by friction heat, as the bar is pressed to the revolving wheel. This applies a thin layer of abrasive, 'glued' onto the cloth wheel, making it similar to an emery paper, only much faster!

CCET/MECH/044/011/01

Introduction Do not apply the compound after the work piece, or on its own. This wastes material and is much less efficient. By applying the material before the work piece, you actually use the work piece to force the compound into the buff. This is much less wasteful, more efficient and will actually speed up your buffing times.

1.1.3 APPLYING THE COMPOSITION TO YOUR BUFFING WHEEL On a new wheel: Be sure the wheel is revolving toward you and has attained full speed. Then pass tube of composition lightly across wheel face in front of, and a little below spindle, until face is slightly coated. Now hold a clean piece of old metal lightly against wheel face for a few seconds to spread coating. Do this several times until face is uniformly coated. After face has been adequately charged with composition, you are ready to buff. It will be necessary to apply more composition from time to time as you buff, and the best way to do this is with a wiping motion, being careful not to overload the wheel. Never use a wheel for coloring which has previously been used for coarse buffing or cutting down. Particles of grit remaining in the face may scratch your final finish. You will save time and avoid costly mistakes by using a separate wheel for each type of composition.

CCET/MECH/044/011/01

Introduction 1.1.4 APPLICATIONS Automotive & Truck: The automotive industry is facing fierce competition that adds cost constraints to finishing operations. The high quality/low cost requirements of the automotive industry continues to push manufacturers of finishing materials to find new strong, flexible materials to drive down the overall cost of metal finishing

FIG 1.1.4 Aerospace: Metal finishing in the aerospace industry is dominated by two very different applications: Jet Engine Turbine Blades and Airframe Skin Finishing. The process for Polishing Jet Engine Turbine Blades is purely functional whereas Airframe Skin Finishing is both aesthetics.

FIG 1.1.5 Plumbing Fixtures: There are three primary base materials used the manufacture of plumbing fixtures: Brass, Zinc and Plastic. The wide range of product designs, unique finishes and different base materials pose a unique challenge to the finishing process for plumbing fixtures.

CCET/MECH/044/011/01

Introduction

FIG 1.1.6 Door & Decorative Hardware: Although door knobs, levers and lock sets have been the mainstay of this industry it also includes other components such as hinges, kick plates and door knockers. These parts are most often made of brass and zinc and require specific buffing methods.

FIG 1.1.7 Cookware: Whether the outside of the cookware is made of aluminium or stainless steel the simple round shape of most cookware is most often buffed with the fast, efficient tangential buffing methods. Although for aluminum parts care should be taken to minimize the amount of heat that can build up in tangential buffing.

FIG 1.1.8 CCET/MECH/044/011/01 7

Introduction

1.2 MOTIVATION / AIM & OBJECTIVE

During the visit of Fieldsman Engineers Pvt. Ltd. At Rajkot We had seen spray painting booth in the assembly department in which worker was painting pump body through spray gun. Because of very high pressure of paint flowing through nozzle there was spreading of paint in atmosphere. For that problem they hold a water wash painting booth. The WATER WASH SPRAY PAINTING BOOTH provides an extremely efficient means of removing paint particles from the exhausted air by using water as a filtration media, have designed the WATER WASH SPRAY PAINTING BOOTHS for many finishing applications. We also offer both pump as well as no-pump versions in open type model, enclosed type model and convey rise models. Standard WATER WASH SPRAY PAINTING BOOTHS are utilized for high volume paint usage, medium or large sized components and batch processes.

1.2.1

WATER WASH SPRAY PAINTING BOOTH contains special features like water tank or over spray paint collection disposal tank, specially designed eliminators (baffles), saw tooth plates, washing chamber and high pressure exhaust blower. This

CCET/MECH/044/011/01

Introduction type of painting booth is more popular where the paint consumption is 10-100 liters/shift, heavy paint consumption, high production and / for any component. Working of WATER WASH SPRAY PAINTING BOOTH is very simple. When the paint is sprayed on the component the over spray is sucked rapidly by the high pressure centrifugal blower through the saw tooth plate and the eliminator. During the above process the paint waste particles get cut at the saw tooth plate thereby separating the thinner to the exhaust blower and paint waste into the tank. More finer spray dust is eliminated in the washing chamber. Paint is actually washed in this chamber. The best advantage of WATER WASH SPRAY PAINTING BOOTH is that lumps of waste paint are collected in the collection tank thereby helping the user to dispose it easily.

Filtering Air All paint spray booths should have some method of filtering the exhausted air from the enclosed space. The fume and paint-filled air can not only be a severe toxin but also clog up any type of mechanical movements, such as fans. The paint exhaust may also pose a fire hazard. The airborne paint particles can quickly build up on fan blades, ruining the air movement efficiency. The built-up paint can also create a fire hazard as a small spark or high heat built up from a restricted fan can create a devastating fire. Many local pollution regulations may also prohibit the exhausting of certain types of paint into the surrounding atmosphere. This calls for some type of filtration device for the exhausted air from most paint booths.

Water as a Filter Water filter systems are generally placed inside the exhausted air vent. The spray water system must be placed well before the exhaust fan so the suction of the fan does not draw water into the moving fan blades. Another consideration for the water spray booth exhaust system is the accessibility for adding fresh water to the water box and the proper disposal of the paint water waste. The water spray booth is an efficient method for removing the paint

CCET/MECH/044/011/01

Introduction particles from the exhausted air. The water filter or spray effectively catches the particles in a stream of water and then flushes them through a water filtration system.

The Spray or Water Fall The spray or waterfall that catches the particles can be fashioned in any number of ways. Generally, a separate circulation pump moves water from a basin and flow the water through a series of nozzles. These nozzles are configured in such a way as to create a full spray or stream area in which the exhausted air must past through. As the exhausted air passes through this waterfall or spray, the larger paint particles are caught by the water and held in the stream. The water then falls into a catch basin to be reused. Generally, the basin is equipped with a series of overflow containers in which the heavier particles can be removed from the water before reentering the circulation pump. A series of simple flow filters can also be employed to capture and remove the paint particles from the water. These filters can then be properly disposed of through the waste stream system from the municipality

We get the motivation from this industry that we will create eco friendly dust collector for the industry. With the help of this dust collector, all the dusts are collect and store at one place. We will fabric one metal cover around the buffing wheel, so that all the dusts removed due to the buffing process will be collected at the particular area. After that collected dusts will be transferred to the dust sink, with the help of transferred pipe which connect collected dust area and dust sink. The dust sink contains water at specific level, so that dust will be dry and collected in it. With the help of this project the environment of the industry will be eco friendly and the health of the worker as well as the quality of product will be increase.

CCET/MECH/044/011/01

10