International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 05 | May 2024 www.irjet.net p-ISSN: 2395-0072
Design and Development of a Special Purpose Machine with PLC Control for Face Milling of Connecting Rod
Abhijeet Sambhaji Shinde
Department of Mechanical Engineering
Ashokrao Mane Group of Institutions
Vathar Tarff Vadgaon, Kolhapur, MAH(INDIA)
Abstract - Special purpose machines are extremely productive machines that are used to create the same part in huge quantities on a daily basis. Theyhavefixtures andtooling that are specifically developed for them. A carefully selected collection of limit switches, sensors, logic controllers, automatic job clamping, etc., form the foundation of an SPM. SPM only finishes the designated tasks for which it is designed. Consequently, the SPM grinds the connecting rod's face simultaneously on both sides. This will ultimately lead to a decrease in the long and energy-intensive cycle time of the existing standard milling machine. unit is made and planned. People can make mistakes since the conventional milling machine is manually operated. To address this problem, the SPM will be interfaced with the PLC, which will handle the entire procedure. The design and development of a discrete special purpose machine component is the aim of this project.
KeyWords: Connecting rod, Face Milling, Spindle, Fixture Unit,PLCCoding
1.INTRODUCTION
Inordertoincreaseproductivity,SpecialPurposeMachines (SPM) are essential in the manufacturing sector. The majorityoftheoperationsarecarriedoutdifferentlyforthe smallandbigendsoftheconnectingrod.Previousresearch has considered two different methods for two different purposes.Anattemptismadetoconsolidateactivitiesinthis dissertation work in order to increase productivity. This particularequipmentisdesignedtosimultaneouslyboretwo workpieces.Timewillbesaved,andproductionwillriseas well.Becausethespindleshaftinthismachineisacrucial component,astaticandmodalanalysisofthespindleshaft willbeperformedtodeterminethedistributionofstress.
TheAutomaticandSpecialPurposeMachines(SPM)are madetoruncontinuouslyfor24hoursadaywiththeleast amountofsupervision.Generallyspeaking,specialpurpose machinesareproduct-specificandmustbedevelopedand designed to meet each unique requirement. Using Change ToolingConcept,itmayoccasionallybepossibletocaterto jobswithsimilar features butdifferentdimensions. These Special PurposeMachines(SPM)are eithercam-operated, employhydraulicandpneumaticelementsasactuators,or combine all three. Positional sensors and transducers are
frequently employed in conjunction with a dedicated programmablelogiccontrollertoprovidecommandstothe acting elements occasionally. Actuating elements include variousspecialmotors,suchasservoandsteppermotors. Afteralloftheseefforts,averyhighlevelofproductivitywas achieved. Three to ten times as much productivity is achievable. Strict quality control must be applied to the automaticmachine'sinputinordertoreapthebenefitsof thesehighlyspecializedmachines.
2 FIXTURE UNIT
A. Component side resting pad
ItiscomposedofO.H.N.S.(OilHardeningNon-ShrinkingDie steel),whichismostlyutilizedforheavilystressedmachine partswithhighstrengthandcoretoughnessthataremeant tobecemented.Particularcareistakenwhilechoosingthe materialbecauseonesideoftheconnectingrodwillrelyonit.
B. Component Resting Piece
The primary purpose of the component resting piece is to provideappropriatesupportfortheconnectingrodduring thefacemillingprocess.ThematerialusedtomakeitisWPS (Die steel 1.2080/D3), which has good hardenability, resistance to plastic deformation, wear resistance, and compressivestrength.
FigNo.1CADmodelofFixtureUnit
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 05 | May 2024 www.irjet.net p-ISSN: 2395-0072
C. Hydraulic Cylinder MTG. Bracket (Top)
Thehydrauliccylindersthatareplacedatopthefixtureunit areheldinplacebyabracket.Thebracket'sjobistosupport thehydrauliccylinderproperly,guideitintherightdirection, and hold it there so that it can hold the connecting rod securelyenoughtosupportthefacemillingoperation.
D. Hydraulic Cylinder MTG.Bracket for Bracket (Bottom)
The complete fixture unit rests on the Hydraulic Cylinder MTG.BracketforBracket,whichresemblesabottomCplate. Itisoneofthemostsignificantandimportantcomponentsof thefixtureunitandhasavitaljobtoplay.Itiscomposedof Cast Iron FG-260, which is reasonably priced and has an excellent tensile strength. Cast iron is the recommended material for the Hydraulic Cylinder MTG Bracket since it undergoesanumberofmachiningoperations.
E. Hydraulic Cylinder MTG. Bush
Itisalsoacrucialcomponentofthefixtureunit,servingthe dualpurposeofsupportingtheconnectingrodandproviding inputtothePLCviaasensorinstalledalongthebush.Ithasa cylinder-shapedpartandabushthatareattachedtothefront ofthedevicealongwiththesensor.CastironFG-260,whichis reasonablypricedandhasstrongtensilestrength,makesup theHydraulicCylinderMTGBush.
3. POWER CALCULATIONS
A spindle in machine tools is the machine's rotating axis, whichfrequentlyhasashaftatitscenter.Althoughthename "spindle"referstotheshaftitself,inshopfloorpracticeitis commonlyusedmetonymicallytorefertothefullrotaryunit, includingthebearingsthataremountedtotheshaftaswell astheshaftitself.Usually,thelargestspindleisthemainone. Agroupoffour,six,orevenmoremainspindlescanbefound in some machine tools that are designed for high volume massmanufacturing.
CuttingSpeed(V)=(3.14*D*N)/1000 =3.14*125*750/1000 =294.5
MetalRemovalRate(Q)=b*t*Sm/1000 =80*1*350/1000 =28
PoweratSpindle(N)=UQ =69**1.57*1.21*28 =5Kw.
PowerofMotor=6Kw.
A. Design of Belt and Pulley
Becausethemotorispositionedabovethespindlehousing, there is less space between the spindle and motor shafts,
making the V belt and V pulley a better choice for power transmission. Spindle shaft radial load is applied by belt tensionduringpowertransmission.Thus,whiledesigninga shaft,thebendingmomentcausedbybeltstrainshouldbe takenintoaccount.Thefollowingformulaisusedtofindthe beltandpulleyvaluesthatcorrespond:
Sr.No. Properties Values
B. Calculation of Bending Moment
Thedrivenpulleyextends86millimetersbeyondtheclosest bearing center. The graphic below displays the shaft and bendingmomentdiagramconfiguration.
The total upward force acting at the pulley's center line is thusgivenby,andthebendingmomentontheshaftcaused by the belt tension is calculated below. Regarding a single belt, = 282.05N
TwoVbeltsareusedsototalforce = *2 =
C. Calculation of Torsional Moment
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 05 | May 2024 www.irjet.net p-ISSN: 2395-0072
D. Design of Shaft on Strength Basis
Torsional,bending,andaxialloadsarealltakenintoaccount whendesigningthespindleshaft.Incaseswheretheshaft experiences axial load in addition to torsion and bending load,itisnecessarytoaddtheaxialloadstresstothebending stress. Since the shaft is composed of ductile material, the maximumshearstresshypothesisisusedinthisdesign.
Kb=Combinedshockandfatiguefactorappliedtobending moment
Kt=Combinedshockandfatiguefactorappliedtotorsional moment
di=Innerdiameterofshaft
do=Outerdiameterofshaft
C=Ratioofinsidediametertooutsidediameter
=Maximumpermissibleshearstress
F.S.=Factorofsafety
ShaftismadeupofSAE8620materialhavingultimatetensile strength is 660 N/mm2 and yield tensile strength is 385 N/mm2 = 64.16N/mm2
Pulley is keyed on the shaft hence, = 0.75 × 64.16 = 48.12N/mm2
Forverticalplane
Forhorizontalplane
Bearinglifecalculation = 2700 million rev.
Dynamicloadcarryingcapacity
C = = 1741.98 N and = 19547.93 N.
Assume = 0.6
TheASMEcodeshaftdesignstatesthatinordertoaccount forshockandfatigueintheshaftduringworkingconditions, thebendingandtorsionalmomentsshouldbemultipliedby factorsKbandKt,respectively.Therefore,thegreatestshear stress( )is,
Consideringavailablediameterofadapterwhichfitsinto innerdiameterofspindle,selectionofdo=30mm,di=18 mm,d1=Shaftdiameterwherepulleyfits=55mm.
E. BearingSelection
The pulley exerts radial load, whereas the lack of an operational gear system results in no axial stress being exerted.Theseradialsaretransmittedthroughthespindleon a bearing. Therefore, choosing a bearing that can support radialloadisappropriate.Forthisreason,asinglerowdeep groove ball bearing is chosen. The following forces are consideredwhilechoosingabearing
So,61810and61812singlerowdeepgrooveballbearingis selected.
Machiningtimecalculations
Machiningtime ( ) =
Where,L=Feedlengthinmm,A=O=Approachdistance =Feedrate(mm/minute) = = 9 sec.
Sliderapidmovement=9seconds.
ConnectingrodMounting=5seconds
Totalcycletimeis25seconds
4. RESULT
The Shaft's finite element analysis is completed in the following stages: preparation, processing, and postprocessing.SolidWorks2015isusedtogenerateathreedimensional model of the spindle, and ANSYS Workbench 18.2isusedforanalysis.–
International Research Journal of Engineering and Technology (IRJET) e-ISSN: 2395-0056
Volume: 11 Issue: 05 | May 2024 www.irjet.net p-ISSN: 2395-0072
The ANSYS program is used to assess the spindle. Static analysistakesintoaccountastructure'sresponsetostable loadingwhileignoringinertiaanddampingeffects,suchas thosebroughtonbytime-varyingstresses[13].Time-varying loads can be roughly comparable to static loads in static analysis, although stable inertia loads like gravity and rotationalvelocitycanalsobeincluded.Byapplyingdifferent forcestobuildingsorcomponents,thevonMisesstressescan befoundviastatic analysis.ANSYSimportsthespindle3D modelfromSolidWorks2015.Standardbearingsarechosen andinstalledatpredeterminedlocationsonthespindle.They musthavethenecessaryinnerandouterdiametersaswellas thedynamicandstaticloadcarryingcapacitydeterminedby the calculated calculation. The shaft is made of SAE 8620 material. The ductile solid material yields, according to distortionenergytheory,whenthevonMisesstressisgreater thanthematerial'syieldvalue.SincethevonMisesstressis lowerthantheyieldstrength,thespindle'sdesignissafer.
5. CONCLUSION
The designand study of spindles for specific purposesare beingdoneincurrentresearch.Facemilling,whichisusedto facemilltheconnectingrod,wasdone.Thespindlematerial's yieldtensilestrengthismorethanthevonMisesstressvalue thatwasproduced.Withonly25secondsneededforasingle task,productionhasincreasedandcycletimehasdecreased.
6. REFERENCES
1) Broke Jaya, “Design and manufacturing of spindle of universal milling head” International journal on applied science and Engineering technology volume8 , February 2017.
2)Shaileshpachbhai,LaukikRaut,“DesignandDevelopment ofHydraulicFixtureforMachiningHydraulicLifthousing”, InternationaljournalpfmechanicalengineeringandRobotics Research,ISSN2278-0149,VOL.3.NO.3,JULY2016.
3)KumarB,MohanRam,“DesignandFabricationof Lathe FixtureforBreakDrumMachining”,Internationaljournalof scientific and research publication, Volume 4, Issue 7, July 2015.
4) Hamad M Abouhenidi, “Jig and Fixutre”, International journal of scientific and Engineering Research, Volume 5, Issue2,February2017.
5) “Central Machine Tool Institute (CMTI), Bangalore CataloguePageno638-652.
6) “Simplifiedtimeestimation bookletforbasic machining operations”byK.C.PolgarandG.W.Wentworth.June2000.
7) “Machine tool spindle design” by Jamie Hoyt Rochester InstituteofTechnology.May2000.
8) “Design of Machine Elements” by V.B.Bhandari, third edition,McgrawHillEducation(India)privatelimited.
FigNo.2Analysisoftheshaft
PLCProgramming
FigNo.3LadderLogic