018 fab indexing table for vertical milling 2010mc

7/30/2019 018 Fab Indexing Table for Vertical Milling 2010MC

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DESIGN AND FABRICATION OF INDEXING TABLE

FOR VERTICAL MILLING MACHINE

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

DIPLOMA IN MECHANICAL ENGINEERING (MTMR}

SUBMITTED BY:

1. A.GOVINDASWAMY 4. S.MAHALINGAM2. S.KARTHIK 5. S.MANIKANDAN3. P.MADHAIYAN 6. R. RAJKUMAR

Under guidance of

Mr. N.RAMU, M.E

OCTOBER 2008.

DEPARTMENT OF MECHANICAL ENGINEERING{MTMR}A M K TECHNOLOGICAL POLYTECHNIC COLLEGE

CHEM BARAMBAKKAM, CHENNAI 602 103


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BONAFIDE CERTIFICATE

This is to certify that this Project work on

DESIGN AND FABRICATION OF INDEXING TABLE

FOR VERTICAL MILLING MACHINE

submitted by . Reg. No.

in 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 2008

Submitted for the Viva-voce exam held on ..

PROJECT GUIDE

INTERNAL EXAMINER EXTERNAL EXAMINER


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ACKNOWLEDGEMENT

At the outset, we would like to emphasize our sincere thanks to the

Principal Mr. R. J. KUMAR, B.E., M.E., MISTE., Ph.D., encouragement

and valuable advice.

we thank our Esquired Head of Department Mr R. RAJKUMAR,

A.M.I.E, M.E., for presenting his felicitations on us.

We are grateful on our Entourages Mr. N.RAMU, M.E., for guiding

in various aspects of the project making it a grand success.

We also owe our sincere thanks to all staff members of the

Mechanical Engineering Department.

Ultimately, we extend our thanks to all who had rendered their co-

operation for the success of the project.


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1. INTRODUCTION

2. SYNOPSIS

3. CONSTRUCTION DETAILS

4. WORKING PRINCIPLE

5. SPARE PARTS DRAWING

6. ADVANTAGES AND DISADVANTAGES

7. FEATURES OF THIS PROJECT

8. SAFTY,CARE AND MAINTENANCE

9. PAINTING AND FINISHING

10. COST ESTIMATION

11. CONCLUSION

12. BIBLIOGRAPHY

13. PHOTO VIEW


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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.


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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


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SYNOPSIS

In vertical MIilling machine the end mill cutter is used to make a slot

in a component . Only straight slot maching is done on the job. For curved

and circular slot machining , a separate device or attachment is

necessary for this machining.

We select our project DESIGN AND FABRICATION OF

INDEXING TABLE FOR VERTICAL MILLING MACHINE can be used


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to rotate the job for circular slot machining. In this indexing table

mechanism consists of worm gear and worm wheel is used to rotate the

job.

This worm gear attachment is used on speed reducer of 10 ;1 . The

job is machined effectively by the slow rotational movement of indexing

table


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CONSTRUCTION

This project consists of

(1) M.S. L angle Fabricated base

(2) Worm and worm wheel gear box mechanism

(3) Indexing disc for holding the job

(4) Hand wheel for indexing the job

1) M.S. L angle Fabricated base ;

The base is made of 25 mm X 25 mm L angle to a size of 250 mm

x250 mm . The worm and worm wheel gear box is mounted on this base

with elevated position of 75mm from the base in order to rotate the hand

wheel. This base can be mounted in the machine table with the help of holes

in the attachment.

2)Worm and worm wheel gear box mechanism;

This gear box reduces the input 10;1 ratio .The Hand wheel for

indexing the job is screwed to the input of the worm. The output of the


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worm wheel shaft is screwed to bush which is welded to the indexing disc

plate.

3) Indexing disc for holding the job;

This disc is made in M.S.Plate of 4mm thickness of 200mm in

diameter size.This plate is welded centrally with a M.S. bush This plate has

4 slots on the surface for clamping the job with the help of bolt and nut.

4)Hand wheel for indexing the job;

A hand wheel is screwed to the worm shaft for the purpose of indexing.


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WORKING PRINCIPLE

This project consists of

(5) M.S. L angle Fabricated base(6) Worm and worm wheel gear box mechanism

(7) Indexing disc for holding the job

(8) Hand wheel for indexing the job

The base is made of 25 mm X 25 mm L angle to a size of 250 mm

x250 mm . The worm and worm wheel gear box is mounted on this base

with elevated position of 75mm from the base in order to rotate the hand

wheel. This gear box reduces the input 10;1 ratio .The Hand wheel for

indexing the job is screwed to the input of the worm. The output of the

worm wheel shaft is screwed to bush which is welded to the indexing disc

plate.

For 10 revolution input , the indexing disc rotates one revolution

only. Hence for one revolution of input, the indexing disc rotates only 36


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degree only. For half revolution of input, the indexing disc rotates only 18

degree only . . For 45 degree revolution of input, the indexing disc rotates

only 9 degree only . . For 5 degree revolution of input, the indexing disc

rotates only 1 degree only .

By using above arrangement , we can set the indexing in the order of

9 degree output. This base can be mounted in the machine table with the

help of holes in the attachment. The disc plate has 4 slots on the surface for

clamping the job with the help of bolt and nut.


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SPARE PARTS DRAWING


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SPARE PARTS DRAWING


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This is more efficient in the technical field

Quick response is achieved

Simple in constructions

Easy to maintain and repair

Cost of the unit is less when compared to other indexing devices


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No fire hazard problem due to over loading

Comparatively the operation cost is less

The operation of arm is faster

Continuous operatio n is possible without stopping.


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1) Compound indexing cannot be done with this unit.

2) Indexing can be done in steps of 9 degree only.

3) Indexing ratio is very low

4) Chances of Manual error can be occur

5) Used for light machining only.


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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;


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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.


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SAFTY,CARE AND

MAINTENANCE

1) Wear gloves during machining.

2) Should not cleaned with hand for removal of chips


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3) Dont apply for heavy cut

4) Clamp the unit well properly in the machine table.


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COST ESTIMATION

1. worm and worm wheel 1 3300.00

2. Base unit 1 1000.00

3. hand wheel 1 100.00

4. Indexing plate -- 900.00

5. paint & emery 200 ml 200.00

6. M.S. Bush for disc plate 1 200.00

7. Transport cost -- 200.00

--------------------------------------------------------------------

Total cost ------------------------------------5900.00

---------------------------------------------------------------------


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The test carried out on cooling tower indicates that the apparatus has given

correct values comparable to apparatus manufactured by professionals

This apparatus can be easily manufactured and marketed

Cost of this apparatus is reasonable

The experience gained in this project will give self confidence to design

simple machines and apparatus on similar lines under entrepreneurs scheme

of the Government.


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018 fab indexing table for vertical milling 2010mc

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