1. Design & fabrication of lapping machinefor fatigue test sample
A Project Seminar on
Design & fabrication of lapping machinefor fatigue test sample

2. Project team Amrit Kumar (1JS08ME008) Nilesh Meher (1JS08ME033)
Chethan P (1JS07ME001)
Under the Guidance of:
Prof. Sankarlingegoud N

3. introduction
Lapping is a process in which two surfaces are rubbed together with an abrasive between them.
This can take two forms.
The first type  (grinding), involves rubbing a brittle surface against another brittle surface with an abrasive in between them.
This produces microscopic conchoidal fractures as the abrasive rolls about between the two surfaces and removes material from both.

4. introduction
The other form involves a softer material  for the lap, which is "charged" with abrasive.
The lap is then used to cut a harder material—the work piece.
The abrasive embeds within the softer material which holds it and permits it to score across and cut the harder material
Taken to a finer limit, this will produce a polished surface
We are using this form of lapping

5. Problem definition
Component gives wrong interpretation on fatigue test because of surface having irregularities such as tool mark or rough finish
So lapping is accomplished to give a smoother finish in order of 30UM.
Lapping Machine available in the market cost around 1.64Lac to 4.5Lac which is costly for lab dealing with fatigue test

6. Design of individual part
Female Block
Material Used = Mild Steel (EN8)

7. Male Block
Material Used = Mild Steel (EN8)

8. Cam Plate
Material Used = Mild Steel (EN8)
Hole is drilled for lift

9. Fixture
Material Used = Mild Steel (EN8)
Made from 6mm sheet metal plate

10. CALCULATION

11. Machine

12. Components and specification
Machine Stand
Length =
Width =
Height =
Material = Stainless Steel
Fixture
Thickness = 6mm
Material = Mild steel EN 8

13. Gear Box 3Litre Wet Grinder Motor Single Phase motor Power = 1HP
Volt = 200/220V
Speed = 1440rpm
Gear Box
3Litre Wet Grinder

14. Pulley
Diameter = 14inch
Material = Zirconia Steel
Drill Chuck
5mm-20mm
Comes with 4MT Arbor with chuck key

15. Pulley
Diameter = 7inch
Material = Zirconia Steel
Pulley
Diameter = 4 inch
Double Pulley
Material = Zirconia Steel

16. Bearing Connected to shaft
Bearing with housing
Inner dia = 20 mm
Outer dia = 40 mm
Housing dia = 50 mm
Bearing Connected to shaft

17. A32 A64 Belt Material = polyester cord Neoprene Jacketed
Cross section shape = trapezoidal
Shape = V Shape
Optimal speed range is 1000–7000 ft/min

19. Rectifier
Used in 2motor
DC Motor
3000rpm
12 volt

20. Transformer
24 volt output
Bush
Material = Silicon Carbide
Size = 50mm dia

21. Sanding Belt
Grade 60, 120,240 available
60 grade used
½ inch belt

22. TECHNICAL SPECIFICATIONS
Sl. no
Feature
Description 1
Total weight
40 kg 2
Maximum height
600 mm 3
Maximum width
500 mm 4
Maximum length
1500 mm 5
Working speed
15 rpm 6
Capacity
18 kg/hr 7
Geneva wheel
Diameter = 120 mm
Thickness = 6 mm 8
Geneva driver
Diameter = 140 mm 9
Electric Gear Motor
0.5 hp, 3 Phase,15 rpm 10
Shaft
Length= 900 mm
Diameter = 20 mm

23. COSTING DETAILS Input Materials(Direct Costs) SL. NO PART QUANTITY
PRICE IN RUPEES 1
Motor
6500 2
Big Sprocket 6
1200 3
Small Sprocket
240 4
Plummer Block 8
720 5
Shaft
500
Chain
700 7
Geneva
900
Total
10,760

24. Assembly Costs (Indirect Costs)
Sl . NO.
FABRICATION
PRICE IN RUPEES 1
Cups
400 2
Cutting, Drilling, Slot Cutting etc
200 3
Over Costs
500 4
Total
1100
TOTAL
11860

25. CONCLUSION
Simple in design
Economical
Less space requirements

26. SCOPE FOR FUTURE WORK
Speed can be decreased by using 3 phase motor

27. Bibliography BOOKS WEBSITES
R S Khurmi and J K Gupta, A Text of Machine Design, Eurasia Publishing House (P) Ltd, 13th Edition, 2000
Dr. K Lingaiah, Machine Design Data Handbook, Suma Publishers, 4th Edition, 2006
WEBSITES

28. THANK YOU