Power Hammer Project Report 2015

POWER HAMMER PROJECT REPORT 2015
USER DEFINED PROBLEM/PROJECT (UDP)
GUIDED BY:
MR. PAVAN M. BHATT
SUBMITTED BY:
1 JAY P. PAREKH 126540319088
2 MITESH A. PRAJAPATI 126540319090
3 PRATIK B. MAHERIYA 126540319091
4 SAHIL I. MANSURI 126540319093
5 KIRTAN TALAVIYA 126540319089
1

CERTIFICATE
This is to certify that project work embodied in this report
entitled “Power hammer” was carried out by
1. Jay P. Parekh 126540319088
2. Kirtan R Talaviya 126540319089
3. Mitesh A. Prajapati 126540319090
4. Pratik B. Maheriya 126540319091
5. Sahil I. Mansuri 126540319093
At V.P.M.P. Polytechnic – Gandhinagar for partial fulfillment of
D.E. semester 6 to be awarded by Gujarat technological University. This
Project work has been carried out under my supervision and is my
satisfaction.
Date:
Place:
Prof. P. M. Bhatt Prof. S. B. Thakkar
Internal Guide HOD, Mechanical Department
V.P.M.P. Polytechnic-Gandhinagar
Department of Mechanical Engineering
2

ACKNOWLEDGEMENT
I wish to express my sincere gratitude to Mr. A. J. Patel, Principal and
Prof. S. B. Thakkar, H.O.D. of Mechanical Engineering Department of
V.P.M.P. POLYTECHNIC for providing me an opportunity to do my
project work on “POWER HAMMER” This project bears on imprint of
many peoples.
I sincerely thank to my project guide Mr. Pavan M. Bhatt, Lecturer in
Mechanical Engineering Department, V.P.M.P. POLYTECHNIC,
GANDHINAGAR for guidance and encouragement in carrying out this
project work.
Last but not least I wish to avail myself of this opportunity, express a
sense of gratitude and love to my friend and my beloved parent for their
manual support, strength, and help and for everything.
Place: Gandhinagar
3

ABSTRACT
To design and fabricate a simple mechanical operated
power hammer by applying the principle of kinematic
arrangement and machine design concepts.
4

INDEX
1. INTRODUCTION……………………………………………..6
2. HISTORY AND DEVLOPMENT OF POWER HAMMER…15
3. EXPERIMENTAL WORK…………………………………...20
4. DESIGN CALCULATIONS……………………………...…..25
5. OPERATION SHEETS……………………………………….31
6. COST ESTIMATION………………………………………....36
7. PART AND ASSEMBLY DRAWINGS……………………...38
8. CONCLUSION………………………………………………..39
9. REFERENCE………………………………………………….40
5

1.INTRODUCTION
ABOUT OF PROJECT WORK
The Aim of course can achieve By learning in classroom and
laboratory. however, Threw the project something extra
Knowledge can achieve.
 To develop planning, designing and manufacturing skill.
 To provide inter disciplinary studies.
 To develop higher-level skill.
 To develop the spirit of the work and be mature.
 To develop ability for teamwork.
We have a chance for applying our knowledge obtained during
diploma program. We have been through many thing like
flexibility study, designing, drafting, process planning, costing,
management and spirit of teamwork. as we make “POWER
HAMMER” to Forging.
6

PREFACE
A project title name-"POWER HAMMER" is most for the
convenience and most of the following for the preface to the Power
hammer electric motor operated my project is based on the
following equipment has been declare for the mechanical
department of the v.p.m.p polytechnic collage of diploma
engineering to planning and well training completed on our project
for the best guidance.
7

APROJECT MEANS
PLANNING BEFORE
CARRYING OUT THE WORK.
ROW MATERIAL REQUIRED
FOR THE WORK.
ORGANIZATION OF THE
WORK.
JOINT EFFORTS PUT
TOGETHER IN THE WORK.
ESTIMATION OF THE MATERIAL
REQUIRED IN THE WORK.
COSTING OF THE WORK.
TECHNIQUES
8

Concept of degrees of freedom
In the design or analysis of a mechanism, one of the most
important concerns is the number of degrees of freedom (also
called movability) of the mechanism. It is defined as the number of
input parameters (usually pair variables) which must be
independently controlled in order to bring the mechanism into a
useful engineering purpose.
Degrees of Freedom of a Rigid Body in a Plane
The degrees of freedom (DOF) of a rigid body are defined as
the number of independent movements it has. Figure 1.2 shows a
rigid body in a plane. To
determine the DOF of this body we must consider how many
distinct ways the bar can be moved. In a two dimensional plane
such as this computer screen, there are 3 DOF. The bar can be
translated along the x axis, translated along the y axis, and rotated
about its centroid.
Fig 1.2 Fig 1.3
Degrees of Freedom of a Rigid Body in Space
An unrestrained rigid body in space has six degrees of
freedom: three translating motions along the x, y and z axes and
three rotary motions around the x, y and z axes respectively in the
as shown in the fig 1.3
9

Kutzbach Criterion Equation
Consider a plane mechanism with υnumber of links. Since in
a mechanism ,one of the links is to be fixed, therefore the number
of movable links will be (υ -1)and thus the total number of
degrees of freedom will be 3(n-1) before they are connected to any
other link. In general, a mechanism with υnumber of links
connected by j number of binary joints or lower pairs (i.e. single
degree of freedom pairs) and h number of higher pairs (i.e. two
degree of freedom pairs), then the number of degrees of freedom of
a mechanism is given by
n = 3(υ-1)-2j-h
This equation is called Kutzbach criterion for the movability
of a mechanism having plane motion.
If there are no two degree of freedom pairs (i.e. higher pairs),
then h= 0,substituting h= 0 in equation 1, we have
n=3(υ-1)-2j
Four bar chain mechanism
The simplest and the basic kinematic chain is a four bar chain
or quadratic cycle chain, as shown in below fig. It consists of four
links p, q, l and s, each of them forms a turning pair. The four links
may be of different lengths. According to Grasshof’s law for a four
bar mechanism, the sum of the shortest and longest link lengths
should not be greater than the sum of the remaining two link
lengths if there is to be continuous relative motion between the two
links.
10

According to Grasshof’s law for a four bar mechanism, the
sum of the shortest and longest link lengths should not be greater
than the sum of the remaining two link lengths if there is to be
continuous relative motion between the two links.
A very important consideration in designing a mechanism is
to ensure that the input crank makes a complete revolution relative
to the other links. The mechanism in which no link makes a
complete revolution will not be useful. In a four bar chain, one
of the links, in particular the shortest link, will make a complete
revolution relative to the other three links, if it satisfies the
Grasshof’s law. Such a link is known as crank or driver.
Single Slider Crank Mechanism
A single slider crank chain is a modification of the basic four
bar chain. It consists of one sliding pair and three turning pair. It is,
usually, found in reciprocating
Steam engine mechanism. This type of mechanism converts rotary
motion into reciprocating motion and vice versa. In single slider
crank chain, as shown in below fig the links 1 and 2, links 2 and 3,
and links 3 and 4 form three turning pairs while the links 4 and 1
form a sliding pair.
11

The link 1 corresponds to the frame of the engine, which is
fixed. The link 2 corresponds to the crank; link 3 corresponds to
the connecting rod and link 4 corresponds to cross- head. As the
crank rotates the cross-head reciprocates in the guides and thus the
piston reciprocates in the cylinder.
Applications:-
Forging
Forging refers as the process of plastically deforming metals
or alloys to a specific shape by a compressive force exerted by
some external agency like hammer, Press, rolls, or by an upsetting
machine of some kind. The portion of a work in which forging is
done is termed the forge and the work is mainly performed by
means of heavy hammers, forging machines, and presses. Forging
processes are among the most important manufacturing techniques
since forging is used in small tools, railroad equipment,
automobile, and aviation industries.
A number of operations are used to change the shape of the
raw material to the finished form. The typical forging operations
are:-
1. Upsetting.
12

2. Fullering.
3. Drawing down.
4. Setting down.
5. Punching.
6. Bending.
7. Welding.
8. Cutting.
All these operations are carried out with the metal in a heated
condition, which must be maintained by taking a ‘fresh’ heat when
the work shows sign of getting cold.
Forging Processes
The processes of reducing a metal billet between flat-dies or
in a closed impression die to obtain a part of predetermined size
and shape are called smith forging and impression-die forging
respectively. Depending on the equipments utilized they are further
sub-divided as hand forging, hammer forging, press forging, drop
forging, mechanical press forging, upset or machine forging.
Press
Press working involves production of final component from
sheet metal in cold condition. The machine which is used to apply
the required pressure of force in a short duration is called press.
The press consists of a frame, supporting bed and ram. The ram is
equipped with special punches and moves towards and into the die
13

block which is attached to a rigid body. The punch and die block
assemble are generally referred to as a die set or simply die.
A disadvantage of press working is that the operations are
carried out at room temperature and the metal is less deformable of
strain hardening.
Classification of Presses
Presses are classified in various ways as listed below.
(i) Mechanical press.
(ii) Hydraulic press.
Press Tool Operations
A large number of operations can be performed by using
press tools, and all press tool operations can be broadly classified
into two types,
1. Cutting operations.
(i) Blanking,
(ii) Piercing
(iii) Lancing,
(iv) Cutting off and Parting,
(v) Notching,
(vi) Shaving, and
(vii) Trimming.
2. Shaping operations
(i) Forming (embossing, Beading and Cutting, etc.),
(ii) Drawing, and
(iii) Bending.
14

2.PROBLEM DEFINITION
The conceptual design was based on the principle of design
by analysis [Norton, 2006]. The methodology adopted was to
examine the most critical defects of conventional hammer mills
and provide solutions. Thus the following defects or problems
were identified and corresponding solutions were proffered.
Problem 1
As a result of wear and corrosion the sieve screen holes enlarge or
burst thereby allowing larger than desired particles to pass through.
Solution 1
Eliminate sieve screens. Introduce an endless sieve that is a
dimensionally controlled “open gate”.
Problem 2
After several hours of hammer mill operation, the sieve screen
holes are clogged thereby reducing its efficiency and capacity.
Solution 2
The solution to problem 1 eliminates problem 2
Problem 3
Wet materials become elastic and therefore absorb most of the
impact energy of the hammer without breaking. This reduces the
efficiency of conventional hammer mills.
reduces the efficiency of conventional hammer mills.
Solution 3
Introduce a fan to induce forced convection and rapid drying of
material
Problem 4
Adequately broken particles can be collected when they fall
through the sieve hole by gravity. Due to the relatively large gap
between the hammers and the screen, this will be inadequate and
therefore clearly inefficient.
15

Solution 4
Solution 3 eliminates problem 4 as pressurized air can lift particles
of sufficient sizes through great distances. This is observed in
tornadoes and cyclones.
Problem 5
Materials being crushed by conventional hammer mills cannot be
recycled until they are reduced to the required size before trying to
force them through the sieve holes. This is probably the greatest
cause of burst holes.
Solution 5
A mechanical separator, which rotates at the same speed as the
shaft ensures that all solid particles above certain sizes are blown
back into the hammer mill chamber until they are ground or broken
by impact into fine particles.
Problem 6
Some of the particles produced by hammer mills are in the form of
dust. They usually constitute 5- 10% of the raw materials and are
lost as dust into the atmosphere. They constitute serious health
hazard to the human operators of the hammer mills as they enter
the lungs (which can lead to cancer) and ears (which can lead to
hearing loss), eyes (which can lead to blindness), et cetera
2The dust particles escaping into the atmosphere would eventually
settle on roofs of buildings, leaves of trees, and on animals thus
causing pollution and damaging the ecology of the immediate
environment.
Solution 6
Install a large sedimentation chamber with long tubes so as to
virtually remove all the dust at the point of generation. This is
greatly aided by solution 3 as the fan generates the required suction
pressure. The design factors considered to be of utmost importance
in this design were function, maintenance, reliability, safety and
cost (Norton, 1999). The introduction of a sieve less screen for
separating the right size of particles from the unwanted ones
ensures that most of the maintenance and reliability problems of
16

constant sieve de-clogging, checking and servicing, repair and
changing are virtually eliminated as the machine functions as
designed. Elimination of the sieves usually associated with
conventional hammer mills also eliminates their greatest running
costs which constitute of stockpiling of very expensive sieves that
cannot be manufactured in Nigeria or repaired locally, machine
down time and idle time due to clogged or burst sieve holes that
reduce its availability, reliability and effectiveness.
17

2.HISTORY AND DEVLOPMENT OF POWER
HAMMER
Until now we have confined ourselves to study of hand tools
used in smithy work. They certainly perform very well so far as the
hand- forging is concerned, but their use for satisfactory
production is limited to small forging only. It would not be
difficult to understand that the intensity of blows, however great
one may try to achieve through hand hammering, will not be
sufficient enough to effect the proper plastic flow in a medium
sized or heavy forging. For this, a power hammer is usually
employed. The capacity of these hammers is given by the total
weight of their falling parts i.e., tup or ram and die. A 200 kg
hammer will be one of which the falling parts weigh 200 kg. The
heavier these parts and greater the height from which they fall. The
higher will be intensity of blow the hammer will provide. Power
hammers in common use are of different types e.g. spring power
hammers, pneumatic power hammers, Steam hammers and Drop or
Forge hammers and six bar slider crank power hammers. These
hammers are named partly after their construction, partly
according to their way of operation. Apart from these, a large
number of forging presses and machines are used in forging work.
In the following articles these hammers and
machines will be discussed in detail.
Types of Power Hammers
Helve hammer
Helve hammers are well adapted for general engineering
work where the size of the stock is changed frequently. They
consist of a horizontal wooden helve, pivoted at one end with a
hammer at the other end. An adjustable eccentric raises the
hammer which when falls strikes a blow. They are made in sizes
from 5 to 200kg.
18

Trip Hammer
Trip hammers have a vertically reciprocating ram that is
actuated by toggle connection driven by a rotating shaft at the top
of the hammer. Trip hammers are also built in sizes from 5 to 200
kg. The stroke range of both helve and trip hammers ranges from
about 400 per minute for small sizes to about 175 for large size.
Lever-Spring Hammer
They are mechanical driven hammers with a practically
constant lift and an insignificantly variable striking power. It only
increases with increasing operating speed and thus has increases
number of strokes per minute. The ram is driven from rocking
lever acting on an elastic rod. The rocking lever consists of a leaf
spring so that an elastic drive is brought about.
They are suitable for drawing out and flattening small
forgings produced in large numbers. Their disadvantage is the
frequent breaking of springs due to vibrations when in operations.
Spring hammers are built with rams weighing from 30 to 250
kg. The number of strokes varies from 200 to 40 blows per minute.
Pneumatic hammer
The hammer has two cylinders compressor cylinder and ram
cylinder. Piston of the compressor cylinder compresses air, and
delivers it to the ram cylinder where it actuates the piston which is
integral with ram delivering the blows to the work. The
reciprocation of the compression piston is obtained from a crank
drive which is powered from a motor through a reducing gear. The
air distribution device between the two cylinders consists of rotary
valves with ports through which air passes into the ram cylinder,
below and above the piston, alternately. This drives the ram up and
down respectively.
19

Hydraulic hammer
In this hammers instead of air oil was used. The cost
hydraulic hammer is high as compared to the pneumatic hammers.
Hydraulic hammer is used in high force applications. These are
noise less.
Power hammers
Unfortunately, using presently available power hammers and
formers can subject users to a number of inherent disadvantages.
Generally, presently available power hammers and formers are
expensive and may cost on the order of tens of thousands of dollars
putting them out of reach of all but the largest metalworking
operators. Presently, available power hammers and formers tend to
be bulky and occupy large footprints making them unsuitable for
small-scale operations. In addition, presently available power
hammers and formers can require precise, custom machined die
sets, which may be unusable with other machinery, in order to
provide proper operational clearance. Finally, presently available
power hammers and formers can be operated by linkage drives that
have the capacity to literally destroy the machines if proper die set-
ups and clearances are not maintained.
Recent research of power hammer
The present disclosure addresses a power hammer assembly
providing users with the metal forming advantages associated with
power machinery at a reduced expense and in a smaller footprint
than presently available power hammer systems. In general, the
power hammer assembly of the present invention provides three
dimensional shaping capabilities, which have application in the
forming of custom metal products such as, for example,
customized motorcycle and automotive parts. The power hammer
assembly of the present disclosure can be fabricated and assembled
in a kit fashion with commonly available tools to reduce costs.
20

Alternatively, the power hammer assembly of the present
disclosure can be purchased in an assembled configuration. In one
aspect, a power hammer assembly of the present disclosure
provides powered forming capabilities while remaining
economical with respect to performance, vibration, and footprint
size and acquisition costs. In some embodiments, the power
hammer assembly can comprise a power assembly for providing a
single stroke speed and/or a single set stroke with respect to the
striking of die assemblies against a piece of metal. In some
embodiments, the power hammer assembly of the present
invention can comprise a larger throat area and/or a larger die gap
than presently available power hammers to facilitate ease of use. In
some embodiments, the power hammer assembly of the present
invention can comprise adjustment features allowing for the use of
die sets of varying configurations such as, for example, shank size,
shank length or alternatively, die sets fabricated for use with other
machinery. In some embodiments, the power hammer assembly of
the present invention can comprise a belt transmission assembly
designed to slip in the event of die interference during set-up or
operation so as to avoid damaging the power hammer assembly. In
some embodiments the power hammer assembly of the present
invention includes fine adjustment means for spacing between the
upper and lower die.
Mechanism
Four bar parallel linkage mechanism for toe movement
21

In recent research the four bar linkage mechanism is used for
the humanoid robots for the free movement of their toe. Using this
mechanism the major part of the force acts on the non-movable
portion of this link rather then on the toe tip. Because of this it is
possible to decrease the constraint on the
joint. At the same time the following multiple roles of the toe are
expected. One it to generate a large kicking force at the toe pad and
another is to maintain multiple contact with the floor by the toe
joint control.
22

3. EXPERIMENTAL WORK
Construction
As shown in above diagram it consists of 5 links, and one
fixed link. The five links are crank (link 1), link 3. Connecting rod
(link 4), Crank (link 5) and Ram die
(link 2).Column can be considered as a fixed link. The link 1
rotates about a turning pair F, it is rotated by a pin joint axis, the
link 3 and link 1 is connected by a turning pair E. The connecting
rod (link 4) and link 3 are connected by a turning pair D. The crank
(link 5) is fixed at a turning pair A and oscillates about the pin joint
axis. Crank(link 5) and connecting rod (link 4) are connected by a
turning pair B.
23

Ram Die (link 2) and connecting rod (link 4) are connected
by a sliding pair C. Ram Die and composite bush are connected by
a sliding pair G.
Crank (link1) is joined at turning pair F to the column and
also crank (link 5) is joined at turning pair A. Column is welded to
the base, vice (not shown in above fig) is fitted to the column for
holding the work piece. All the links, Column, Base and Vice are
made up of Mild Steel, they are rigid enough to absorb the
vibrations and shocks produced during work. Composite bush is
made up of two materials outer one is of Mild Steel and the liner is
made up of Gun Metal to prevent from wear, tear and corrosion
resistance. A handle is provided at point E, with the help of the
handle the crank (link 1) is rotated.
Working Principle
The Crank (link 1) rotates at a fixed axis at F it is joined to
link 3. As the link1 is rotated the motion is transmitted to the link 3
which is connected at point E. The motion is further transmitted to
the connecting rod which is joined with the link 3 at D. Finally the
connecting rod transmits the motion to the Ram Die (link 2) which
reciprocates at a fixed path G. The Connecting rod (link 4) and
Ram Die (link 2) are connected at C, Where a slot is provided for
getting a straight line motion of the ram Die. The crank (link 5) is
provided for oscillating the connecting rod at a fixed path.
Manufact
uring Process
Cranks (link 1 and 5)
A mild steel material of the required dimension is cut on the
power hack saw machine. After cutting process is over the fillet is
provided over the edges by using a hand grinder. After a drill of
diameter 6 mm is made. Finally the filing was done on the bench
vice.
24

Connecting Rod
A mild steel material of the required dimension is cut on the
power hack saw machine. After cutting process is over the fillet is
provided over the edges by using a hand grinder, after providing
fillets drilling operation of required diameter is done after
completing this process now we proceed towards milling the slot
of 65 x 8 x 6 mm3 by using an end mill cutter. Finally filing was
done on bench vice to remove unnecessary sharp corners.
Ram die
Mild steel material of required dimension is cut on power
hack saw. The material was fixed on the chuck in a lathe machine
for doing facing and turning operations. Polishing was done for
good surface finish. Chamfers were made for removing sharp
corners. A hole was drilled at the end of the ram of the required
size for fixing the slider pin. A slot was milled on the rod to insert
the connecting rod in the slot and fixing it in the slider pin. At the
other end of
The ram a hole of required size was made and then later it was
taped at the same end to make the fixing adjustment of the punch
with the help of a screw.
Composite Bush
It was manufactured by two different materials one of Mild
steel and other was liner made up of Gun metal. The outer one is
made up of Mild steel on which facing and turning operations were
done on a lathe and then the inner one was made up of Gun metal
on which facing and turning were carried out of the required size
then the liner was inserted in the outer bush by the application of a
press fit.
25

Column
The Column is made up of Mild Steel of required dimension.
First the marking for the holes to fix the links were done on the
column. The outer profile was marked and then made to cut on a
gas cutter, and then it was milled to the required size and then
finally chamfering was done to remove unnecessary sharp corners
and edges. Drills were drilled on the column for bearings, turning
pairs F and A. Then the composite bush was welded on the
column. Vice was fitted on the column by the application of
welded joints for holding the work piece.
Determination of Degrees of Freedom
The formula for finding the degree of freedom from the
Kutzbach equation is given below,
n = 3(υ-1)-2j-h
Where,
n = Degree of freedom
υ= no of links
J = no of lower pairs
h = no of higher pairs
Links:
a) Fixed link
b) Crank (link 1)
c) Crank (link 5)
d) Link 3
e) Connecting Rod
f) Ram Die
Therefore, number of links = 6
Lower pairs:-
Number of higher pairs = 0
Therefore, n = 3(-1)-2j-h
h = o
26

n = 3(υ-1) -2j
n = 3(6-1) -2 x 7
n = 3 x 5 – 2 x 7
n = 15 – 14
n = 1
Therefore, the mechanism has single degree of freedom.
27

4.DESIGN CALCULATIONS
1. Determination of length of the links
For evaluating the length of the links we made prototype,
Length of the links is proportionally taken according to the
diagram of the Six bar Slider crank Power hammer mechanism. By
checking the movability after more and more trails of link lengths
we finalized the dimensions as shown below,
1. crank (link 1) = 120mm
2. Ram die link2 = 420mm
3. link3 = 440mm
4. connecting rod(link4) = 655mm
5. crank (link 5) = 120mm
2. Design calculation for finding the width and thickness of
the links
This mechanism is designed for applying a compressive force of
0.6 tonnes for forging or press operation.
Minimum cross sectional area required to transmit is 0.6
tonnes load (A):
Load = P
Permissible shear stress [σ ]
Taking M.S for link design yield stress
(σy) = 300N/mm²
Adopting factor of safety = 4
Permissible shear stress [σ] =300/4=75N/mm²
Minimum area required = P
[σ]
=6000/75
∴Effective area (A) =80 mm²
28

The formula for the minimum effective area is obtained as bt –
(dt) it can be observed in the link as in the fig2.1
Fig 2.1
In fig 2.1 hatched portions indicates minimum effective cross
sectional area in the entire mechanism. We know that stress is
inversely proportional to the area, so the minimum area leads to
increase the stress. So it is always preferred to design any machine
by taking minimum cross sectional area as effective area.
Effective area (A) =bt - (d t) mm²
where,
b=breadth of the link in mm
t=thickness of the link in mm
d=diameter of pin hole in mm
∴Effective area (A) =80 mm²
For safe design bt - (d×t) ³80 mm²
29

From the design of bolt we obtained diameter of pin as 6mm, by
keeping the diameter of pin constant and by trial and error method
we obtained the breadth and thickness of the link as 20mm and
6mm respectively.
Design calculation for bolt diameter
3.1 Calculation of Stress Concentration
Stress concentration factor is given by,
Kt = Nominal stress
Maximum stress
Nominal stress is given by,
σnom= P
(w - a)h
The below diagram is for the finite width plate with a transverse
hole.
We know that width of the plate W = 20mm
Thickness of the plate h = 6mm
Nominal stress is given by,
σnom= P
(w - a)h
Where,
P=tensile force
= 0.6 tonne
30

=0.6×1000×9.81
= 5886N
Therefore,
σnom=5886
(20 - a)6
Kt = σnom
σmax
σnom=σ max
k t
5886 =150
(20 - a)6 2.3
5886 =65.22
(20 - 6a)
5886 = 65.22(120-6a)
5886 = 7826.5 – 391.32a
5886 – 7826.5 = - 391.32a
- 1940.5 = - 391.32a
Therefore, a=1940 .5
391 .32
a = d (diameter) = 4.99mm
Due to dynamic characteristics of links the diameter of pin is
selected as 6 mm.
Calculation for bearing stress.
For M.S material σy= 300 N/mm²
Factor of safety = 2
Permissible bearing of crushing stress =σb=σy
n
= 300/2 = 150N/mm²
31

Bearing stress(σ)= P
d+n
P = 0.6 + 1000×9.81N
d = 6mm
t = 6mm
n = 2
(σb) ≥0.6 ×1000 ×9.81
6×6×2
≥81.75 N/mm²
The bearing stress is greater than 81.75 N/mm² , so the design is
satisfactory
4Design for punching operation
Permissible shear stress is given by,
σY =0.6σy
=0.6 × 300
= 180 N/mm²
τY ≥load
shear area
τY ≥6000
shear area
32

Shear area for punching operation can be observed from above
diagram is p dt Where,
d = diameter of blanking or piercing hole in mm.
t = the thickness of the blank in mm.
Shear area=πdt=6000
180
πdt =33.3 mm²
Therefore, t =33.3 =1.5mm
π ×7
33

5. OPERATION SHEETS
1. CRANK (LINK 1)
Description : Crank 1
Part No : 1
Material : Mild Steel.
Required size : 120mm x 20mm x 6mm
SL.
NO
MACHINE OPERATION TOOL GAUGE
1 Power saw Cutting Hacksaw Vernier
caliper,
steel
rule
2 Grinding Fillet Grinding
Wheel
-
3 Drilling
Drillɸ6 x 6
Drill bit Vernier
Caliper
4
Drilling Drillɸ6 x 6
Drill bit Vernier
Caliper
5 Bench vice Filing Flat file -
2. RAM DIE
Description : Die
Part No : 2
Required size : 20mm x 420mmɸ
34

SL.NO MACHINE OPERATION TOOL GAUGE
1 Power saw Cutting Hacksaw
Blade
Vernier
caliper,
steel rule
2 Lathe Facing Single
point
cutting
tool
Vernier
caliper
3 Lathe DrillingØ10x
2
5
Drill Ø20 Vernier
caliper
4 Drilling DrillØ4.5 x 5 DrillØ4.5 Vernier
caliper
5 Drilling DrillØ6 x 6 DrillØ6 Vernier
caliper
6 Tapping M6 internal
thread
Tap -
7 Milling Slot End mill
cutter
Vernier
caliper
3. LINK 3
Description : LINK 3
Part No : 3
35

SL. NO MACHINE OPERATION TOOL GAUGE
caliper,
steel
rule
Wheel
-
3 Drilling Drillɸ6 x 6 Drill bit Vernier
caliper
caliper
4. CONNECTING ROD
Description : Connecting Rod
Part No : 4
caliper,
steel
rule
Wheel
-
caliper
caliper
5 Milling Slot End mill
cutter
Vernier
caliper
6 Bench vice Filing Flat file
36

5. CRANK (LINK 5)
Description : Crank (link 5)
Part No : 5
caliper,
steel
rule
Wheel
-
caliper
caliper
6. COMPOSITE BUSH
Description : composite bush
Part No : 6
Bush.
Material : Mild steel
Required size : 38mmx 100mmɸ
caliper,
steel
rule
point
cutting
Vernier
caliper
37

tool
3 Lathe Drilling25 Drill Bit Vernier
caliper
4 Lathe Reaming Reamer Vernier
caliper
Liner
Material : Gun metal
Required size : ɸ 25mm x 105mm
caliper, steel
rule
point
cutting
tool
Vernier
caliper
3 Lathe Drilling 25ɸ Drill Bit Micrometer
4 Lathe Reaming Reamer Micrometer
5 Lathe Step turning Single
point
cutting
tool
Vernier
caliper
38

6. COST ESTIMATION
Cost of Standard components
Name of
component
Quantity Cost/piece Cost in Rupees
Bearing (6mm) 4 15 60
M6 bolt and nut 5 8 40
½ inch bolt and
nut
1 26 26
M5
Countersunk
bolt
and nut
8 1.5 12
M6
Countersunk
bolt
and nut
2 3 6
TOTAL COST 144
Material Cost
Name of
component
Quantity Cost in Rupees
M.S Flat for links 1 150
M.S Rod for ram 1 100
M.S sheet for base 1 2000
Bush (M.S and
gunmetal)
1 156
TOTAL COST 2406
Machining Cost
Machine Cost in Rupees
Lathe 500
Drilling 300
Gas Cutting 170
Welding 200
Milling 660
39

Total Cost 1830
Total Cost of Six bar Slider Crank Power Hammer
Mechanism
Particulars Cost in Rupees
Transportation and
Allowances
1220
Painting and Name Plate 800
Cost of Standard Components 144
Material Cost 2406
Machining Cost 1830
Total Cost 6400
40

7.PART AND ASSEMBLY DRAWINGS
41

1. CRANK (LINK 1)
42

2. RAM DIE
3. LINK 3
4. CONNECTING ROD
43

5. CRANK (LINK 5)
44

6. COMPOSITE BUSH
45

7. ELECTRIC MOTER
46

DETAIL DRAWING
47

NUT BOLT USED IN POWER HAMMER
48

ASSEMBLY DRAWING
49

8.CONCLUSION
During working on project we have been gone through
learning of many feasibility study production process and
controlling with team work.
We have come across the practical and the
manufacturing world. We have gained theoretical as well practical
knowledge so far through study workshop and completed our
project.
This experience and knowledge will be further helpful
to our professional career.
50

9.REFERENCE
• www.slideshare.com
• www.wikipedia.org
• www.nptel.in
• www.google.com
51

Power Hammer Project Report 2015

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Power Hammer Project Report 2015