DESIGN AND FABRICATION OF LOW COST SURFACE GRINDING MACHINE SUBMITED BY K.NAGA BHUPATHI 14FF5A0306 A.NAVEEN 13FF1A0301 G.SAI KUMAR VARMA 13FF1A0317 P.DILEEP KUMAR 13FF1A0332 R.NARESH 14FF5A0308

ABSTRACT The main aim of this project is manufacture and fabricate the low cost surface grinding machine by using the scrap material and we will design that low cost surface grinding machine by using the CATIA software for design reference and we had taken part dimensions as our manufacturing process and producing the low cost surface grinding machine. Finally we will done the project success fully with low cost for comparing the standard surface grinding machine.

INTRODUCTION Grinding is a manufacturing process in this process good surface finish and dimensional accuracy are complementary, and can be obtained by grinding. It is a process of removing metal in small quantities of using an abrasive wheel, called grinding wheel. It is regarded as a finishing process for obtaining desired surface finish, accuracy in size and geometrical configuration of the product. The grinding machine consists of a bed with a fixture to guide and hold the work piece, and a power-driven grinding wheel spinning at the required speed. The speed is determined by the wheel’s diameter and manufacturer’s rating. The grinding head can travel across a fixed work piece, or the work piece can be moved while the grind head stays in a fixed position.

TYPES OF GRINDING MACHINES Belt grinder Bench grinder Cylindrical grinder Surface grinder Tool cutter grinder Jig grinder Gear grinder

SURFACE GRINDING MACHINE Surface grinding is used to produce a smooth finish on flat surfaces. It is a widely used abrasive machining process in which a spinning wheel covered in rough particles (grinding wheel) cuts chips of metallic or non-metallic substance from a work piece, making a face of it flat or smooth.

TYPES OF SURFACE GRINDING MACHINES HORIZONTAL SURFACE GRINDING MACHINE

2. VERTICL SURFACE GRINDING MACHINE

PROCESS OF SURFCE GRINDING MACHINE Surface grinding is the most common of the grinding operations. It is a finishing process that uses a rotating abrasive wheel to smooth the flat surface of metallic or non-metallic materials to give them a more refined look or to attain a desired surface for a functional purpose.

GRINDING WHEELS Grinding wheel is widely used in grinding machines. These wheels are expendable wheels composing of an abrasive compound. These grinding wheels are formed out of an aluminium disc or solid steel by way of attaching the particles to the exterior surface. In general, this grinding wheel is normally prepared using the mould of hard-pressed coarse particles matrix that are allied together to make a firm circular shape. Based on the planned use of the wheel, various profiles and cross sections are also obtainable.

Abrasive grain: CHARECTERSTICS: There are five characteristics of a cutting wheel: material, grain size, wheel grade, grain spacing, and bond type. They are indicated by codes on the wheel's label. Abrasive grain: The abrasive aggregate is selected according to the hardness of the material being cut. Aluminum oxide(A) Silicon carbides (S) Ceramic (C) Diamond (D) Cubic boron nitride (CBN) Grinding wheels with diamond or CBN grains are called super abrasives. Grinding wheels with aluminum oxide (corundum), silicon carbide, or ceramic grains are called conventional abrasives.

GRINDING WHEEL SPECIFICATIONS: Diameter of grinding wheel 200 mm. Thickness of grinding wheel 20 mm. Bore diameter of grinding wheel 31.5 mm. Maximum speed of grinding wheel 3150 RPM.

Grain size: Coarse Medium Fine Very fine From 8 (coarsest) to 1200 (finest), determines the average physical size of the abrasive grains in the wheel. A larger grain will cut freely, allowing fast cutting but poor surface finish. Ultra-fine grain sizes are for precision finish work. Coarse Medium Fine Very fine 8 10 12 14 16 20 24 30 36 46 54 60 70 80 100 120 150 180 220 240 280 320 400 500 600

Wheel Grade: Soft Medium Hard The term grade as applied to a grinding wheel refers to the tenacity with which the bond holds the abrasive grains in place, and does not refer to the hardness of the abrasive. A wheel from which the grains are released rapidly during the grinding operation is called soft grade, whereas wheel that retains the grains more securely is called hard grade. Soft Medium Hard A B C D E F G H I J K L M N O P Q R S T U V W X Z

Temperature of Decomposition in oxygen Abrasive material properties and uses : Abrasive material Year of discovery Hard ness (K noop) Temperature of Decomposition in oxygen Properties and Uses Silicon carbide Aluminium oxide 1891 1893 2200-2800 1600-2100 1500-2000 1700-2400 Used for brass, bronze, aluminum stainless steel and cast iron. Softer and tougher than SiC, used on steel, malleability cast iron, tough bronze.

Grinding wheel properties : The properties of grinding wheels determine the productivity of the grinding process and the achievable grinding quality. Type of abrasive grain material. The size of the grit. The bond material. The properties of abrasive and bond. Porosity.

MANUFACTURING OF LOW COST SURFACE GRINDING MACHINE FRAME : First of all, the frame is constructed. We are taking the MS angular rods and then cutting as per the our dimensions and bends in required places bending machine and hammer. Then the angular rods are to be welded.

Welding : Welding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the work pieces and adding a filler material to form a pool of molten material (the weld pool) that cools to become a strong joint, with pressure sometimes used in conjunction with heat, or by itself, to produce the weld.  

Mechanical properties : Strength Hard ness Tough ness Malleability Ductility Elasticity Plasticity Durability Brittle ness

Properties of cast iron and mild steel : Type of metal Properties 1 . Cast iron 2 . Mild steel Brittle ness, hard ness, fusibility, and non malleability. Which means that is can not be stretched. Its has a crystalline structure. Mild steel is tough ness, ductility and malleability. It has good strength but poor corrosion resistance. It is mainly used as an all-purpose engineering material.

LOW COST SURAFCE GRINDING MACHINE SURFACE GRINDING MACHINE COMPARING THE LOW COST SURFACE GRINDING MACHINE & SURFACE GRINDING MACHINE LOW COST SURAFCE GRINDING MACHINE SURFACE GRINDING MACHINE This is having less weight. Low power consumption. Accuracy is good. High efficiency. This is occupies less space. This is easily to move one place to another place. This machine cost is low. The construction of this machine is very simple. This is having more weight. High power consumption. Accuracy is more. This is comparing to occupies more space . This is comparing to not easily to one place to another place. This machine cost is very high. The construction of this machine is very complicated.

SPECIFICATIONS OF LOW COST SURFACE GRINDING MACHINE PARTS FRAME HORIZONTAL FEED OF MILLING BED CROSS FEED OF MILLING BED ELEVATING SCREW MECHANICAL VICE HAND LEVER LENGTH 60.2 CM 100 CM 20.4 CM 50.4 CM 20.6 CM 20.2 CM WIDTH 40.2 CM 30.8 CM _ 10.7 CM 0.3 CM THICK NESS 4 MM 10.1 CM 20 CM 0.7 CM 2 MM BASE HEIGHT 130 CM DIAMETER

PARTS OF LOW COST SURFACE GRINDING MACHINE Frame Motor Horizontal feed of milling bed Cross feed of milling bed Elevating screw Mechanical vice Hand lever

LOW COST SURFACE GRINDING MACHINE

DESIGN IN CATIA V5 INTRODUCTION TO CATIA: Computer Graphics-Aided Three-Dimensional Interactive Application (CATIA) is the world’s leading computer-aided design (CAD)/computer-aided manufacturing (CAM)/computer-aided engineering (CAE) package. Developed by Desalt systems and marketed worldwide by IBM, CATIA delivers one of the best Product Lifecycle. CATIA started as an in-house development in 1977 by French aircraft manufacturer Avionics Marcel Desalt, at that time customer of the CAD/CAM CAD software to develop Dassault's Mirage fighter jet, and then was adopted in the aerospace, automotive, shipbuilding, and other industries.

PROCEDURE OF PARTS TO BE DESIGN Frame step 1:STRAT –Mechanical design- sketcher. In the sketcher we have done the sketcher part of frame. Step 2: In this frame we are using shell option, pad, and pocket option.

Electric motor Step 1: start-mechanical design-sketcher In the sketcher we have done the part of electric motor Step 2: In this sketcher part we are using pad, drafted fillet, multi solid, and mirror, circles, and holes options. Step 3: Then go to the surface design and then selecting the helical option and then select the slot option then click enter button and then form a screw thread.

Horizontal feed of milling bed Step 1:start-mechanical design-sketcher In this sketcher we have to done the part of horizontal feed of milling bed Step 2: In this sketcher part we are using pad, pockets and mirror, circles, rib, and holes options. Step 3: Then go to the surface design and then selecting the helical option and then select the slot option then click enter button and then form a screw thread.

Cross feed of milling bed Step 1:start-mechanical design-sketcher In this sketcher we have to done the part of cross feed of milling bed Step 2: In this sketcher part we are using pad, pockets and mirror, circles tools in the sketch based features. Step 3: For the screw spindle go to the surface design and then select the helix option and create the height of the screw spindle then go to the part design select the slot option then click enters button and then form a screw thread.

Step 2: And later we will just creates the hexagonal nut. Elevating screw Step 1: For the elevating screw ,we will just create the helical gear by using multi section commands. Step 2: And later we will just creates the hexagonal nut.

Mechanical vice Step 1:bench vice is used for the work piece holding purpose. Step 2: by using pad, pocket, helix and the slots options we just created the mechanical bench vice.

Hand lever Step 1: lever is used to move the horizontal and cross feed of milling beds. Step 2: in this we used the draft options and the pad options.

ASSEMBLY OF LOW COST SURFACE GRINDING MACHINE

DRAFTING OF LOW COST SURFACE GRINDING MACHINE

CONCLUSION The low cost surface grinding machine featuring high accuracy and high rigidity pursued hand in hand with the technological capability of a machine tool manufacture. The joint development of a grinding wheel with a leading tool manufacture has enabled the use of an optimum grinding wheel that has a wide application scope and that matches the user needs.

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