pro matter

PROJECT REPORT 2015 MOTORIZED MULTI PURPOSE MACHINE

CHAPTER 1

INTRODUCTION

The various machining process in manufacturing industries are carried out by

separate machining machine. It need more space requirement and time with high

expenses. But the fabrication of multi operation machine, which contains three

operations in a single machine. The operations are namely drilling, slotting and

shaping. It is a new concept specially meant to reduce the work time and save the

cost. Instead of using a slotting machine we are using the special arrangements for

slotting operation in the drilling machine same for the shaping operation also, so we

can save the investment cost of exceed slotting and shaping machine in the industries.

The machine operates through drilling machine with the bevel gear and cam

mechanism arrangements. Hence exactly we can carry out three operations in this

machine, namely drilling, slotting and shaping. It is a simple in construction and easy

to operate. Driller, Bevel gear, Drill bit, Chuck, Cam mechanism, bearings, slotting

tool, Hacksaw and guide are the main parts used in this machine.

The various machining process in manufacturing industries are carried out by

separate machining machine. It need more space requirement and time with high

expenses. But the fabrication of multi operation machine, which contains three

operations in a single machine. The operations are namely drilling, slotting and

shaping. It is a new concept specially meant to reduce the work time and save the

cost. Instead of using a slotting machine we are using the special arrangements for

slotting operation in the drilling machine same for the shaping operation also, so we

can save the investment cost of exceed slotting and shaping machine in the industries.

The machine operates through drilling machine with the bevel gear and cam

mechanism arrangements. Hence exactly we can carry out three operations in this

machine, namely drilling, slotting and shaping. It is a simple in construction and easy

to operate. Driller, Bevel gear, Drill bit, Chuck, Cam mechanism, bearings, slotting

tool, Hacksaw and guide are the main parts used in this machine.

In this project we are fabricate the multi operating machine using for the

different application. These projects we are using motor and gear arrangement to

DEPARTMENT OF MECHANICAL 1 ISSAT

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operate the machine are any multiple type various machining process variable

operation. Some needs of automation are described below.

1.1 NEED FOR AUTOMATION

Automation can be achieved through computers, hydraulics, pneumatics,

robotics, etc., of these sources, pneumatics form an attractive medium for low cost

automation.The main advantages of all pneumatic systems are economy and

simplicity. Automation plays an important role in mass production.

Nowadays almost all the manufacturing process is being atomized in order to

deliver the products at a faster rate. The manufacturing operation is being atomized

for the following reasons.

To reduce man power

To reduce the work load

To reduce the production time

To reduce the fatigue of workers


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CHAPTER 2

LITERATURE REVIEW

R.Maguteeswaran1, M.Dineshkumar, R.Dineshkumar, K.Karthi, R.Sabariselvan.

“Fabrication of multi process machine”. International journal of research in

Aeronautical and mechanical engineering.

The multi process machine is used to do the multi operations like Drilling,

Cutting, Slotting at a time and which is used to save the time and space requirement

of an industry. The main concept of machine is to do the operations like slotting and

shaping by the use of drilling operation using cam arrangement. Here the bevel gear

arrangement is used for carrying out the operations. Bevel gear is used to perpendicu-

lar (90) power transmission. One of the bevel gear is connected with the motor and

another one with the drill chuck hence when the motor is rotated the drill chuck also

rotates. The motor pulley shaft is connected to a cam arrangement on the other side.

Cam arrangement converts rotary motion into reciprocating motion and the recipro-

cating motion is used for the slotting and shaping operation. The slotting toll and

shaping tool are guided by a horizontal guide bush. The up down table is mounted on

a hydraulic bottle jack piston rod hence when the bottle jack handle is pumped the ta-

ble height can be adjusted according to the requirement when the after the process is

completed the pressure should be released through pressure relief valve to make the

table come down. A vice is mounted on the table to hold the work piece.

M. Anil Prakash, Nalla Japhia Sudarsan, K. Pavan Kumar and K.Ch.Sekhar.

“Advanced shaper”,International Monthly Refereed Journal of Research In

Management & Technology. Vol II july 13

A shaping machine (usually called shaper) is mainly used for producing flat

surfaces, which may be horizontal, vertical or inclined. Sometimes irregular or curved

surfaces are also produced by shapers. In existing shaping machines the stroke length

can be varied depends upon the changing the distance between centre of the bull gear

and pivot pin. It means the pivot pin will move away or towards the centre of the bull

gear.


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In advanced shaping machine the vertical slots are provide on one side of the

shaping machine. The slots can be used to move vertically (either upwards or

downwards) the bull gear position. It makes us easy to change the bull gear position.

It means centre of the bull gear position can be moved away or towards the pivot pin.

When the bull gear is move downwards or towards the pivot pin, stroke length can be

increased or vice versa. In advanced shaping machine the stroke length can be varied

in two types, one is to change the distance between centre of the bull gear and crank

pin and another is to change the vertical distance between centre of the bull gear and

pivot pin. So in an advanced shaping machine, without changing the diameter of the

bull gear and height of shaping machine, we can increase the stroke length greatly.

D.V.Sabariananda1, V.Siddhartha1, B.Sushil Krishnana1, T.Mohanraj. “Design and

Fabrication of Automated Hacksaw Machine”. Second National Conference on

Trends in Automotive Parts Systems and Applications (TAPSA-2014). Volume 3,

Special Issue 2, April 2014.

The objective of this work is to automate the conventional power hacksaw ma-

chine in order to achieve high productivity of work-pieces than the power hacksaw

machine using Microcontroller. The automated machine acquires two inputs from the

user namely the number of pieces to be cut and the length of each piece that is re-

quired to be cut. The inputs are given by the user with the help of a keypad and an

LCD display, which will help the user to verify the data given by him. The operator

need not measure the length of the work-piece that is to be cut and to load and unload

the work-piece from the chuck each time after a piece has been cut. After acquiring

the two inputs from the user, the machine automatically feeds the given length of

work-piece in to a chuck and starts to cut till the given number of work-pieces has

been cut. The machine feeds the work-piece with the help of a conveyor, which is

driven by a DC motor and an IR sensor ensures that the feeding stops when the speci-

fied length has been reached. A pneumatic cylinder is used for holding the work-piece

when cutting operation is done. An AC motor is used to bring about the reciprocating

motion required for cutting the work-pieces. There is a self-weight attached with the

reciprocating mechanism to provide the necessary downward force required for pene-

tration of hacksaw blade in to the work-piece. When a single piece has been cut, a

limit switch will get triggered by the self-weight mechanism, which is sensed by the


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microcontroller to start the cyclic operation again provided if the specified number of

work-pieces has not been cut.

Gautam Jodh , Piyush Sirsat , Nagnath Kakde , Sandeep Lutade. “Design of low Cost

CNC Drilling Machine”. International Journal of Engineering Research and General

Science Volume 2, Issue 2, Feb-Mar 2014.

A drilling machine is a device for making holes in components. The manuall

operated type of drilling machine creates problems such as low accuracy, high setup

time, low productivity, etc. A CNC machine overcomes all these problems but the

main disadvantage of a CNC drilling machine is the high initial cost and requirement

of skilled labour for operating the machine. Hence, there arises a need for a low cost

CNC machine which can not only drill holes with high accuracy and low machining

time but also have low initial cost. The need for skilled operator is eliminated by pro-

viding a software with a more user friendly graphical user interface.

The observations about operator utilization, a rather controversial and complex

subject. If you would like to comment, please e-mail me and explain how your own

experiences compare with what I say. I’ll relate the responses I get in an upcoming

column. Columns From: 1/1/2008 Modern Machine Shop, Mike Lynch

Many companies use one operator to run more than one CNC machine.

Indeed, I’d bet the majority of companies in the United States use at least some of

their operators in this manner.

Several factors contribute to the wisdom of having one operator run two or

more CNC machines. Some of the most important considerations include lot sizes;

cycle times; setup times; machine costs versus operator costs; urgency of getting jobs

done; and even availability of skilled operators in your area

In many cases, I disagree with the decision to use one operator to run multiple

machines—at least from a cost standpoint. I’ve been in many companies in which

using operators in this fashion actually costs more than having a separate operator run

each machine.

I suspect that at least part of the reason some companies have one operator

running multiple machines are that management just can’t stand to see someone idle.


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While this may be an important concern, a hasty decision to have one operator run

multiple machines often results in much lower overall machine output. Again, this

may cost more than having a separate operator run each machine.

My discussions will be limited to comparing costs from having a separate

operator for each machine, as opposed to one operator for two machines. This means,

of course, that you must know your costs. The only costs in this equation are machine

cost and operator cost.

2.1 MACHINE COST

For this purpose, machine cost is the hourly rate a company pays to use the

machine (not the cost your company charges for the machine’s use). At the very least,

it is the monthly payment a company makes (loan/lease) divided by the number of

hours per month the machine is in use.

There is usually much more involved with determining machine cost than just

the monthly payment. Cost of upkeep, which includes preventive maintenance,

lubricants, coolant and even crash repair, should be included in your machine-cost

calculation. Some companies also include the cost of floor space the machine

requires.

Note that I’m not including tooling of any kind in the machine cost. We need

only the amount of money your company must pay per hour for the machine’s use.

(By the way, if no one in your company can tell you the cost of each machine, find

out why.) Machine cost should be an important factor in determining the amount of

profit your company makes for each job you do or the product you sell.

For accounting purposes, some companies apply a blanket rate to the machines

they own. For these companies, every machine the company owns—be it a $5,000

knee mill or a $200,000 CNC machine—has the same cost per hour. This may be

good for approximating purposes, but it won’t be accurate enough for making wise

decisions related to operator utilization.

2.2 OPERATOR COST

Again, we’re looking for a cost per hour. This cost will, of course, include the

operator’s wages. But like machine cost, there is more involved with determining


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operator cost. All benefits the operator receives (insurance, employment taxes and

retirement-fund contributions) are among the costs you must consider.

It is not unusual for the total of all benefits to equal or exceed the operator’s

hourly wage. For our examples, we’ll simply double the operator’s hourly wage for

the operator cost.

2.3 QUICK COMPARISON

The more the operator’s cost, the more advantageous it will be to have one

operator run two or more machines. The more each machine’s cost, the less

advantageous it will be to have one operator run two or more machines.

In many companies I’ve visited, a manager can point out every penny that

goes into what an operator costs (again, wages plus benefits). One company I visited

even includes the cost of the parking space the operator uses to park his or her car.

However, when it comes to machine costs, they are not nearly so knowledgeable and

diligent. Again, having an accurate value for both operator and machine cost is of

paramount importance to making wise operator-utilization decisions. Inflated operator

costs and/or devalued machine costs lead to poor operator-utilization decisions. It will

appear that using one operator for two or more machines is more cost-effective than it

really is.

Though I may be getting ahead of myself a bit, note that the maximum cost

benefit you can expect per hour is the cost of one operator. Think about it. When you

have one operator running two machines instead of a separate operator for each

machine, the most you can gain per hour is the hourly cost of one operator.

The VAS-T machines incorporate secondary operations with traditional thread

rolling and bending.

Machines are capable of performing the following operations:

Wire feeding and straightening by Videx’s reciprocating straightener.

Cutting to precise length, using a positive stop with a short cut sensor.


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Secondary Operations Including; Chamfer Cutting, Cross Drilling, End

Drilling, Flattening, Stamping, Marking, Grooving, or even Assembly

of pins, washers, or flux balls, etc.

Thread Rolling on a planetary system, using the “Controlled Start

Technique”.

Bending optional) using the “Slide Die Bender” adjustable throughout

the machine range.

The VAS-T line is used for production of a wide range of parts such as B7

Studs, Weld Studs, Long blanks for long Headed Bolts, Bicycle Shafts with rounded

ends, Pre-pointed Bolts, Blanks for High Tensile Steel and Stainless Steel Threaded

Rods.

The chips from the turning process are separated and diverted into a bin

outside the machine. The machines are equipped with a Quick-Change System, which

allows effective manufacturing of short production batches, using less skilled

operators. The VAS-T line has the capacity to combine any number and any

combination of operations in one machine. Expected production rates are 30-60 PPM,

depending upon the type of secondary operations.


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CHAPTER 3

DESCRIPTION OF EQUIPMENTS

Different equipments are used in fabrication of multipurpose machine, and

they are described below

3.1 INDUCTION MOTOR (IM)

An induction motor (IM) is a type of alternating current motor where power is

supplied to the rotating device by means of electromagnetic induction. It is also called

asynchronous motor.

An electric motor converts electrical power to mechanical power in its rotor

(rotating part). There are several ways to supply power to the rotor. In a DC motor

this power is supplied to the armature directly from a DC source, while in an

induction motor this power is induced in the rotating device.


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Fig.3.1 Motor


An induction motor is sometimes called a rotating transformer because the

stator (stationary part) is essentially the primary side of the transformer and the rotor

(rotating part) is the secondary side. Induction motors are widely used, especially

polyphase induction motors, which are frequently used in industrial drives.

Induction motors are now the preferred choice for industrial motors due to

their rugged construction, absence of brushes (which are required in most DC motors)

and thanks to modern power electronics the ability to control the speed of the motor.

3.2 PRINCIPLE OF OPERATION AND COMPARISON TO SYNCHRONOUS

MOTORS

The basic difference between an induction motor and a synchronous AC motor

is that in the latter a current is supplied onto the rotor. This then creates a magnetic

field which, through magnetic interaction, links to the rotating magnetic field in the

stator which in turn causes the rotor to turn. It is called synchronous because at steady

state the speed of the rotor is the same as the speed of the rotating magnetic field in

the stator.

By way of contrast, the induction motor does not have any direct supply onto

the rotor; instead, a secondary current is induced in the rotor. To achieve this, stator

windings are arranged around the rotor so that when energized with a polyphase

supply they create a rotating magnetic field pattern which sweeps past the rotor. This

changing magnetic field pattern induces current in the rotor conductors. These

currents interact with the rotating magnetic field created by the stator and in effect

cause a rotational motion on the rotor.

However, for these currents to be induced, the speed of the physical rotor and

the speed of the rotating magnetic field in the stator must be different, or else the

magnetic field will not be moving relative to the rotor conductors and no currents will

be induced. If by some chance this happens, the rotor typically slows slightly until a

current is re-induced and then the rotor continues as before. This difference between

the speed of the rotor and speed of the rotating magnetic field in the stator is called

slip. It is unit less and is the ratio between the relative speed of the magnetic field as


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seen by the rotor (the slip speed) to the speed of the rotating stator field. Due to this

an induction motor is sometimes referred to as an asynchronous machine.

3.3 CONSTRUCTION

The stator consists of wound 'poles' that carry the supply current to induce a

magnetic field that penetrates the rotor. In a very simple motor, there would be a

single projecting piece of the stator (a salient pole) for each pole, with windings

around it; in fact, to optimize the distribution of the magnetic field, the windings are

distributed in many slots located around the stator, but the magnetic field still has the

same number of north-south alternations. The number of 'poles' can vary between

motor types but the poles are always in pairs (i.e. 2, 4, 6, etc.).

Induction motors are most commonly built to run on single-phase or three-

phase power, but two-phase motors also exist. In theory, two-phase and more than

three phase induction motors are possible; many single-phase motors having two

windings and requiring a capacitor can actually be viewed as two-phase motors, since

the capacitor generates a second power phase 90 degrees from the single-phase supply

and feeds it to a separate motor winding. Single-phase power is more widely available

in residential buildings, but cannot produce a rotating field in the motor (the field

merely oscillates back and forth), so single-phase induction motors must incorporate

some kind of starting mechanism to produce a rotating field. They would, using the

simplified analogy of salient poles, have one salient pole per pole number; a four-pole

motor would have four salient poles. Three-phase motors have three salient poles per

pole number, so a four-pole motor would have twelve salient poles. This allows the

motor to produce a rotating field, allowing the motor to start with no extra equipment

and run more efficiently than a similar single-phase motor.


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3.4 TYPES OF ROTOR

There are different types of rotor are avalabile for the opereations called slip

ring rotor, solid core rotor

3.4.1 Squirrel-Cage Rotor

The most common rotor is a squirrel-cage rotor. It is made up of bars of either

solid copper (most common) or aluminum that span the length of the rotor, and are

connected through a ring at each end. The rotor bars in squirrel-cage induction motors

are not straight, but have some skew to reduce noise and harmonics.

3.4.2 Slip Ring Rotor

A slip ring rotor replaces the bars of the squirrel-cage rotor with windings that

are connected to slip rings. When these slip rings are shorted, the rotor behaves

similarly to a squirrel-cage rotor; they can also be connected to resistors to produce a

high-resistance rotor circuit, which can be beneficial in starting

3.4.3 Solid Core Rotor

A rotor can be made from solid mild steel. The induced current causes the

rotation.

3.5 DRILLING MACHINE

Drilling is a machine process by which a hole is produced or enlarged by a

drill. Drill is a revolving tool. It is usually the most effective and economic method of

producing hole in solid materials. The hole is produced either by giving movement to

the rotating drill or moving the work axially against the rotating drill. Drilling

machine is more suitable than lathe and vertical milling machine. Drilling machine

can also be used for boring, reaming, tapping and spot facing. It is specific type of end

cutting tool called drill. It is used for drilling holes. It carries the cutting edge at the

flat end or at the end of flute.


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Fig.3.2 Drill Bit Nomenclature

Drilling tool is a cylindrical end-cutting tool used to originate or enlarge circular holes

in solid material.

Usually, drills are rotated by a drilling machine and fed into stationary work,

but on other types of machines a stationary drill may be fed into rotating work or drill

and work may rotate in opposite directions. To form the two cutting edges and to

permit the admission of a coolant and the ejection of chips, two longitudinal or helical

grooves or flutes are provided. The point, or tip, of a drill is usually conical in shape,

and it has cutting edges where the flutes end. The angle formed by the tapering sides

of the point determines how large a chip is taken off with each rotation of the drill.

The degree of twist of the helical flutes also affects the drill’s cutting and chip-

removal properties. For general-purpose twist drills the helix angle is about 32°. The

angle formed by the two sides of the tapering point is 118° for standard drills, while

for drilling tough metals, a flatter point with a 135° angle is recommended.

The peripheral portion of the drill body not cut away by the flutes is called the

land, and to reduce friction and prevent the land from rubbing against the sides of the

hole, most of the land is cut away, leaving a narrow ridge called the margin that

follows the edge of the side of the flute that forms the cutting edge. The fluted part, or

body, of a drill is either hardened high-carbon steel or high-speed steel; other drills


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have inserts of cemented carbide to form cutting edges or are made from sintered-

carbide rods. The shanks of twist drills are either straight or tapered and when not

integral with the body are made from low-carbon steel and welded to the body.

Straight-shank drills must be gripped in a chuck; tapered shanks fit with a sticking

taper in matching holes in the machine and are driven partly by the taper and partly by

a tang that fits in a slot in the machine. For enlarging cored, punched, or drilled holes,

core drills are particularly suited. These have three or four flutes, and because the

cutting edges do not extend to the centre of the drill, they cannot originate holes in

solid materials. Cutting is accomplished by a chamfered edge at the end of each flute.

3.6 BELT AND PULLEY

Belt and pulley mechanism is provided for transmitting drive from the motor

to drill spindle and cam arrangement.

3.6.1 Pulley

A pulley is a wheel with a groove along its edge, also called a sheave, for

holding a rope or cable. Pulleys are usually used in sets designed to reduce the amount

of force needed to lift a load. The same amount of work is necessary for the load to

reach the same height as it would without the pulleys. The magnitude of the force is

reduced, but it must act through a longer distance. The effort needed to pull a load up

is roughly the weight of the load divided by the number of wheels. The more wheels

there are, the less efficient a system is, because of more friction between the rope and

the wheels.

The pulleys and lines are weightless, and that there is no energy loss due to

friction. It is also assumed that the lines do not stretch. With this assumption, it

follows that, in equilibrium, the total force on the pulley must be zero. This means

that the force on the axle of the pulley is shared equally by the two lines looping

through the pulley. The lines are not parallel, the tensions in each line are still equal,

but now the vector sum of all forces is zero.

A second basic equation for the pulley follows from the conservation of

energy the product of the weight lifted times the distance it is moved is equal to the

product of the lifting force times the distance the lifting line is moved. The weight


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lifted divided by the lifting force is defined as the advantage of the pulley system. It is

important to notice that the amount of work done in an ideal pulley is always the

same. The work is given by the effort times the distance moved. The pulley simply

allows trading effort for distance.

3.6.2 Belt

Belts are used to mechanically link two or more rotating items. They may be

used as a source of motion, to transmit power at up to 98% efficiency between two

points, or to track relative movement.

Fig. 3.3 Pulley and Belt

As a source of motion, a conveyor belt is one application where the belt is

adapted to continually carry a load between two points. A belt may also be looped

between two points so that the direction of rotation is reversed at the other point.

Power transmission is achieved by specially designed belts and pulleys. The demands

on a belt drive transmission system.

Belts normally transmit power only on the tension side of the loop. Designs

for continuously variable transmissions exist that use belts that are a series of solid

metal blocks, linked together as in a chain, transmitting power on the compression

side of the loop.

3.7 CAM

A cam is a projecting part of a rotating wheel or shaft that strikes a lever at

one or more points on its circular path. The cam can be a simple tooth, as is used to

deliver pulses of power to a steam hammer, for example, or an eccentric disc or other


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http://en.wikipedia.org/wiki/Continuously_variable_transmission

http://en.wikipedia.org/wiki/Conveyor_belt

http://en.wikipedia.org/wiki/Transmission_(mechanics)

http://en.wikipedia.org/wiki/Pulley

http://en.wikipedia.org/wiki/Work


shape that produces a smooth reciprocating (back and forth) motion in the follower

which is a lever making contact with the cam.

The reason the cam acts as a lever is because the hole is not directly in the

centre, therefore moving the cam rather than just spinning. On the other hand, some

cams are made with a hole exactly in the centre and their sides act as cams to move

the levers touching them to move up and down or to go back and forth.

3.8 HYDRAULIC BOTTLE JACK

Bottle jacks are hydraulic jacks that are placed in a horizontal position. These

jacks push against a lever, which lifts the main lift arm. Bottle jacks have a longer

handle than most hydraulic jacks, however, and it is possible to get more lift per

stroke with the increased leverage they provide when compared to regular models of

jacks. Bottle jacks are versatile because their horizontal position makes it possible to

place them in tight spots and provides good leverage. Recently bottle jacks have

proven useful in search and rescue missions following earthquake damage. As a

result, bottle jacks are standard equipment in firehouses and for search and rescue

teams. They are also used for lifting, spreading, bending, pushing, pressing, or

straightening requirements. The base and cylinders of bottle jacks are electrically

welded for strength, and all models are capable of working in upright, angled, or

horizontal positions.

Fig. 3.4 Hydraulic Jack


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3.8.1 Characteristics and Properties for Hydraulic Oils

Low temperature sensitivity of viscosity;

Thermal and chemical stability;

Low compressibility;

Good lubrication (anti-wear and anti-stick properties, low coefficient of friction);

Hydrolitic stability (ability to retain properties in the high humidity environment);

Low pour point (the lowest temperature, at which the oil may flow);

Water emulsifying ability;

Filterability;

Rust and oxidation protection properties;

Low flash point(the lowest temperature, at which the oil vapors are ignitable);

Resistance to cavitation;

Low foaming;

Compatibility with sealant materials.

3.8.2 Types of Hydraulic Fluids

Optimal properties of hydraulic oils are achieved by a combination of a base

oil and additives (anti-wear additives, detergents, Anti-oxidants, anti-foaming agents,

Corrosion inhibitors etc.).

1. Mineral hydraulic oil (petroleum base).

Mineral based oils are the most common and low cost hydraulic fluids. They

possess most of the characteristics important for hydraulic oils. The disadvantages of


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mineral (petroleum) based oils are their low fire resistance (low flash point), toxicity

and very low biodegradability.

2. Phosphate ester based synthetic hydraulic fluids.

Phosphate esters are produced by the reaction of phosphoric acid with

aromatic alcohols. Phosphate esters based hydraulic fluids possess excellent fire

resistance; however they are not compatible with paints, adhesives, some polymers

and sealant materials. They are also toxic.

3. Polyol ester based synthetic hydraulic fluids.

Polyol esters are produced by the reaction of long-chain fatty acids and

synthesized alcohols. Polyol ester based hydraulic fluids are fire resistant and possess

very good lubrication properties. They are environmentally friendly but their use is

limited by high cost.

4. Water glycol synthetic hydraulic fluids.

Water glycol based fluids contain 35-60% of water in form of solution (not

emulsion) and additives (anti-foam, anti-freeze, rust and corrosion inhibitors, anti-

wear etc.). Water glycol based hydraulic fluids possess excellent fire resistance, they

are non-toxic and biodegradable. However their temperature range is relatively low:

32°F - 120°F (0°C - 49°C). Water evaporation causes deterioration of the hydraulic

fluids properties.

5. Vegetable hydraulic oils.

Vegetable hydraulic oils are produced mainly from Canola oil. Their chemical

structure is similar to that of polyol esters. Vegetable hydraulic oils possess very good

lubrication properties and high viscosity index (low temperature sensitivity of

viscosity). They are non-toxic and biodegradable. The main disadvantage of vegetable

hydraulic oils is their relatively low oxidation resistance.

3.8.3 Viscosity of Hydraulic Oils


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Viscosity of a hydraulic fluid depends on its composition and the temperature.

Low viscosity limit is determined by the lubrication properties of the oil and its

resistance to cavitation. Upper viscosity value is limited by the ability of the oil to be

pumped.

Common viscosity of hydraulic oils is in the range 16 - 100 centistokes.

Optimum viscosity value is 16 - 36 centistokes.

3.8.4 Safety Instructions

1. Park the vehicle or load to be lifted on a flat firm surface and place wedges under

the wheels to stop movement.

2. Position de jack on a solid, even and horizontal surface, never use the jack on a

slope.

3. The jack should be positioned so as to avoid the user from having to operate it

under the vehicle. Every vehicle lifted by a jack should always have a secondary

safety support such as mechanical stands.

4. It is imperative that all possible precautions are taken to avoid unexpected

movement of the load when it is being lifted.

5. The load to be lifted should never exceed the rated capacity of the jack.

6. Never operate the jack beyond its maximum stroke.

7. If these basic rules are not followed, injury to the user, the jack or the load being

lifted may result.

8. As an additional safety feature the jack is equipped with a valve to prevent the unit

from being overloaded. This unit is factory set and must no be tampered with.

3.8.5 Use and Operation

1. Before operating the jack you must purge its hydraulic circuit in order to eliminate

any possible air in the system. To purge the system open the release valve, turning it

anti-clockwise. Then with the aid of the lever operate the pump several times.


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2. Close the release valve with the lever in a clockwise direction until it is fully

closed. The jack is now ready for use.

3. To lower the jack, turn the release valve very slowly in an anti-clockwise direction.

4. Always keep the jack in vertical position, with the ram, extension screw and pump

retracted after use.

5. If you require operating the jack in a horizontal manner the pump should be located

on the lower side of the jack.

3.8.6 Maintenance

1. Lubricate all moving parts at regular intervals.

2. Always keep the jack clean and protected from aggressive conditions.

3. If you have to replace the oil, the correct volume is indicated in the parts list. Make

sure the piston is fully retracted.

Important: An excess of oil will render the jack inoperative.

4. Use only hydraulic oil, type HL or HM, with an ISO grade cinematic viscosity of

30 c St at 40º C or an Engler viscosity of 3 at 50º C.

Very important: Never use brake fluid.

5. When ordering spare parts, please make note of the part number as shown in the

exploded view drawing provided. A repair kit is available containing all the common

spare parts

3.8.7 Repair

Both maintenance and repair of this jack shall be carried out by qualified persons

who on base of their education and experience have enough knowledge in jacks and

associated equipment.

3.9 BEVEL GEAR


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Two important concepts in gearing are pitch surface and pitch angle. The pitch

surface of a gear is the imaginary toothless surface that you would have by averaging

out the peaks and valleys of the individual teeth. The pitch surface of an ordinary gear

is the shape of a cylinder. The pitch angle of a gear is the angle between the face of

the pitch surface and the axis. The most familiar kinds of bevel gears have pitch an-

gles of less than 90 degrees and therefore are cone-shaped. This type of bevel gear is

called external because the gear teeth point outward. The pitch surfaces of meshed ex-

ternal bevel gears are coaxial with the gear shafts; the apexes of the two surfaces are

at the point of intersection of the shaft axes. Bevel gears that have pitch angles of

greater than ninety degrees have teeth that point inward and are called inter-nal bevel gears.

Fig. 3.5 Bevel Gear

3.10 BEARING

A bearing is a device to permit constrained relative motion between two parts,

typically rotation or linear movement. Bearings may be classified broadly according

to the motions they allow and according to their principle of operation. Low friction

bearings are often important for efficiency, to reduce wear and to facilitate high

speeds. Essentially, a bearing can reduce friction by virtue of its shape, by its material,

or by introducing and containing a fluid between surfaces.


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By shape, gains advantage usually by using spheres or rollers. By material,

exploits the nature of the bearing material used. Sliding bearings, usually called

bushes bushings journal bearings sleeve bearings rifle bearings or plain bearings.

Rolling-element bearings such as ball bearings and roller bearings. Jewel bearings, in

which the load is carried by rolling the axle slightly off-center. fluid bearings, in

which the load is carried by a gas or liquid magnetic bearings, in which the load is

carried by a magnetic field. Flexure bearings, in which the motion is supported by a

load element which bends. Bearings vary greatly over the forces and speeds that they

can support. Forces can be radial, axial (thrust bearings) or moments perpendicular to

the main axis. Bearings very typically involve some degree of relative movement

between surfaces, and different types have limits as to the maximum relative surface

speeds they can handle, and this can be specified as a speed in ft/s or m/s.

The moving parts there is considerable overlap between capabilities, but plain

bearings can generally handle the lowest speeds while rolling element bearings are

faster, hydrostatic bearings faster still, followed by gas bearings and finally magnetic

bearings which have no known upper speed limit.

A linear-motion bearing or linear slide is a bearing designed to provide free

motion in one dimension. There are many different types of linear motion bearings

and this family of products is generally broken down into two sub-categories: rolling-

element and plane.

Motorized linear slides such as machine slides, XY tables, roller tables and

some dovetail slides are bearings moved by drive mechanisms. Not all linear slides

are motorized and non-motorized dovetail slides, ball bearing slides and roller slides

provide low-friction linear movement for equipment powered by inertia or by hand.

All linear slides provide linear motion based on bearings, whether they are ball

bearings, dovetail bearings or linear roller bearings. XY Tables, linear stages,

machine slides and other advanced slides use linear motion bearings to provide

movement along both X and Y multiple axis.

There are many types of bearings, each used for different purposes either

singularly or in combinations. These include ball bearings, roller bearings, ball thrust

bearings, roller thrust bearings and tapered roller thrust bearings.


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http://en.wikipedia.org/wiki/X-Y_Table

http://en.wikipedia.org/wiki/Roller_bearing

http://en.wikipedia.org/wiki/Ball_bearing

http://en.wikipedia.org/wiki/Ball_bearing

http://en.wikipedia.org/wiki/Bearing_(mechanical)


3.10.1 Ball bearings

Fig. 3.6 Ball Bearing

Ball bearings, as shown to the left, are the most common type by far. They are

found in everything from skate boards to washing machines to PC hard drives. These

bearings are capable of taking both radial and thrust loads, and are usually found in

applications where the load is light to medium and is constant in nature (ie not shock

loading). The bearing shown here has the outer ring cut away revealing the balls and

ball retainer.

3.10.2 Roller bearings

Fig. 3.7 Roller Bearing

Roller bearings like the one shown to the left are normally used in heavy duty

applications such as conveyer belt rollers, where they must hold heavy radial loads. In

these bearings the roller is a cylinder, so the contact between the inner and outer race

is not a point (like the ball bearing above) but a line. This spreads the load out over a

larger area, allowing the roller bearing to handle much greater loads than a ball

bearing. However, this type of bearing cannot handle thrust loads to any significant

degree. A variation of this bearing design is called the needle bearing. The needle

roller bearing uses cylindrical rollers like those above but with a very small diameter.


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This allows the bearing to fit into tight places such as gear boxes that rotate at higher

speeds.

3.10.3 Thrust ball bearings

Fig.3.8 Thrust Bearing

Ball thrust bearings like the one shown to the left are mostly used for low-

speed non precision applications. They cannot take much radial load and are usually

found in lazy susan turntables and low precision farm equipment.

3.10.4 Roller thrust bearing

Fig.3.9 Roller Thrust Bearing

Roller thrust bearings like the one illustrated to the left can support very large

thrust loads. They are often found in gearsets like car transmissions between gear

sprockets, and between the housing and the rotating shafts. The helical gears used in

most transmissions have angled teeth; this can causes a high thrust load that must be

supported by this type of bearing.

3.10.5 Taper roller bearing


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Fig. 3.10 Taper Roller Bearing

Tapered roller bearings are designed to support large radial and large thrust

loads. These loads can take the form of constant loads or shock loads. Tapered roller

bearings are used in many car hubs, where they are usually mounted in pairs facing

opposite directions. This gives them the ability to take thrust loads in both directions.

The cutaway taper roller on the left shows the specially designed tapered rollers and

demonstrates their angular mounting which gives their dual load ability.

The above bearing types are some of the most common. There are thousands

of other designs, some standard and some specific applications but all perform the

same basic function. Essentially further types of bearings usually take all or some of

the characteristics of the above bearings and blend them into one design. Through the

use of careful material selection and applying the correct degree of machining

precision, a successful bearing solution can usually be found.

3.11 VICE

It is a device consisting of two parallel jaws for holding a work piece; one of

the jaws is fixed and the other movable by a screw, a lever, or a cam. When used for

holding a work piece during hand operations, such as filing, hammering, or sawing,

the vise may be permanently bolted to a bench. In vises designed to hold metallic

work pieces, the active faces of the jaws are hardened steel plates, often removable,

with serrations that grip the work piece; to prevent damage to soft parts, the

permanent jaws can be covered with temporary jaws made from sheet copper or

leather. Pipe vises have double V-shaped jaws that grip in four places instead of only

two. Woodworking vises have smooth jaws, often of wood, and rely on friction alone

rather than on serrations.

For holding work pieces on the tables of machine tools, vises with smooth

hardened-steel jaws and flat bases are used. These machine vises are portable but may


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be clamped to the machine table when in use; means may also be provided for

swiveling the active part of the vise so that the work piece can be held in a variety of

positions relative to the base. For holding parts that cannot be clamped with flat jaws,

special jaws can be provided.

For holding parts that cannot be clamped with flat jaws, special jaws can be provided.

Fig. 3.11 Vice

3.12 HACK SAW

A hacksaw is a fine-toothed saw, originally and principally for cutting metal.

They can also cut various other materials, such as plastic and wood; for

example, plumbers and electricians often cut plastic pipe and plastic conduit with

them. There are hand saw versions and powered versions (power hacksaws). Most

hacksaws are hand saws with a C-shaped frame that holds a blade under tension. Such

hacksaws have a handle, usually a pistol grip, with pins for attaching a narrow

disposable blade. The frames may also be adjustable to accommodate blades of


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http://en.wikipedia.org/wiki/Pistol_grip

http://en.wikipedia.org/wiki/Tension_(physics)

http://en.wikipedia.org/wiki/Blade

http://en.wikipedia.org/wiki/Hand_saw

http://en.wikipedia.org/wiki/Electrical_conduit

http://en.wikipedia.org/wiki/Plastic_pipework

http://en.wikipedia.org/wiki/Electrician

http://en.wikipedia.org/wiki/Plumber

http://en.wikipedia.org/wiki/Metal

http://en.wikipedia.org/wiki/Saw


different sizes. A screw or other mechanism is used to put the thin blade under

tension. Panel hacksaws forgo the frame and instead have a sheet metal body; they

can cut into a sheet metal panel further than a frame would allow. These saws are no

longer commonly available, but hacksaw blade holders enable standard hacksaw

blades to be used similarly to a keyhole saw or pad saw. Power tools including

nibblers, jigsaws, and angle grinders fitted with metal-cutting blades and discs are

now used for longer cuts in sheet metals.

On hacksaws, as with most frame saws, the blade can be mounted with the

teeth facing toward or away from the handle, resulting in cutting action on either the

push or pull stroke. In normal use, cutting vertically downwards with work held in a

bench vice, hacksaw blades should be set to be facing forwards. Some frame saws,

including Fret Saws and Piercing Saws, have their blades set to be facing the handle

because they are used to cut by being pulled down against a horizontal surface.

3.13 CUTTING TOOL

In the context of machining, a cutting tool (or cutter) is any tool that is used to

remove material from the work piece by means of shear deformation. Cutting may be

accomplished by single-point or multipoint tools. Single-point tools are used in

turning, shaping, planning and similar operations, and remove material by means of

one cutting edge. Milling and drilling tools are often multipoint tools. Grinding tools

are also multipoint tools. Each grain of abrasive functions as a microscopic single-

point cutting edge (although of high negative rake angle), and shears a tiny chip.

Cutting tools must be made of a material harder than the material which is to

be cut, and the tool must be able to withstand the heat generated in the metal-cutting

process. Also, the tool must have a specific geometry, with clearance angles designed

so that the cutting edge can contact the work piece without the rest of the tool

dragging on the work piece surface. The angle of the cutting face is also important, as

is the flute width, number of flutes or teeth, and margin size. In order to have a long

working life, all of the above must be optimized, plus the speeds and feeds at which

the tool is run.


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http://en.wikipedia.org/wiki/Speeds_and_feeds

http://en.wikipedia.org/wiki/Hardness

http://en.wikipedia.org/wiki/Rake_angle

http://en.wikipedia.org/wiki/Machining

http://en.wikipedia.org/wiki/Sheet_metal


CHAPTER 4

DESIGN AND DRAWING

The mechanical multipurpose machine is consists of the following

components to full fill the requirements of complete operation of the machine.

4.1 MACHINE COMPONENTS

1. Motor

2. Bevel gear

3. Cam

4. Belt and pulley

5. Hydraulic bottle jack

6. Bevel gear

7. Clamping vice

8. Bearing block

9. Driller


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4.2 DRAWING FOR MOTORIZED MULTI PURPOSE MACHINE

(DRILLING, SLOTTING AND CUTTING)

Fig. 4.1 Motorized Multipurpose Machine

Item Description Quantity Meterial

1 Motor 1

2 Hacksaw frame 1 M.S

3 Pulley 1 C.I

4 Drill chuck 1 M.S

5 Column 1 M.S

6 Slotting tool 1 M.S

7 Belt 1 Nylon

8 Bearing 5 S.S

9 Bevel gear 1 S.S


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FABRICATED MOTORIZED MULTIPURPOSE MACHINE

Fig.4.2 Fabricated MMPM


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4.3 CALCULATIONS

1. Drilling Speed

Np = Ng x (Tg/Tp) rpm (1)

Where, Np = Speed of drill spindle in rpm

Ng = Speed of gear=120rpm

Tg = No. of gear teeth=17

Tp = No. of pinion teeth=13

Hence,Np = 120x(17/13)=156rpm

2. Slotting Velocity

V = L xN x(1+K)/1000 m/min (2)

Where, L = Stroke Length=80mm

N = No. of Cutting stroke/ min=145

K = return stroke time/ cutting stroke time=1

Hence, V = 80x145x(1+1)/1000=23.2m/min

3. Cutting Speed of Hack saw

Ns = Da/Db x Nm rpm (3)

Where, Ns = wheel speed in rpm


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Nm= speed of motor in rpm=1400rpm

Da = dia of small pulley in mm=30mm

Db = dia of large pulley in mm =290mm

Hence,Ns = (30/290)x1400=145rpm


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CHAPTER 5

WORKING PRINCIPLE

Here the bevel gear arrangement is used for carrying out the operations. Bevel

gear is used to perpendicular (900) power transmission. One of the bevel gear is

connected with the motor and another one with the drill chuck hence when the motor

is rotated the drill chuck also rotates. The motor pulley shaft is connected to a cam

arrangement on the other side. Cam arrangement converts rotary motion into

reciprocating motion and the reciprocating motion is used for the slotting and cutting

operation. The slotting tool and cutting tool are guided by a horizontal guide bush.

The up down table is mounted on a hydraulic bottle jack piston rod hence when the

bottle jack handle is pumped the table height can be adjusted according to the

requirement when the after the process is completed the pressure should be released

through pressure relief valve to make the table come down. A vice is mounted on the

table to hold the work piece.


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CHAPTER 6

MERITS & DEMERIT

6.1 MERITS

Easy To Implement

Low cost

Low maintenance

Easy to operate

Reduces time and increases production rate

Multi operations are performed at one time

All Operations performed by only one motor

Time Saving

Less Man power is required

6.2 DEMERIT

Uneven forces acts on the wok piece

Only small components can be machined


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CHAPTER 7

APPLICATION

Used in small scale industries to reduce machine cost.

In such places where frequent change in operation are required.


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CHAPTER 8

LIST OF MATERIALS

The various factors which determine the choice of material are discussed

below.

8.1 PROPERTIES

The material selected must possess the necessary properties for the proposed

application. The various requirements to be satisfied

Can be weight, surface finish, rigidity, ability to withstand environmental attack from

chemicals, service life, reliability etc.

The following four types of principle properties of materials decisively affect

their selection

a. Physical

b. Mechanical

c. From manufacturing point of view

d. Chemical

The various physical properties concerned are melting point, thermal

Conductivity, specific heat, coefficient of thermal expansion, specific gravity,

electrical conductivity, magnetic purposes etc.The various Mechanical properties

Concerned are strength in tensile,

Compressive shear, bending, torsional and buckling load, fatigue resistance,

impact resistance, eleastic limit, endurance limit, and modulus of elasticity, hardness,

wear resistance and sliding properties.

The various properties concerned from the manufacturing point of view are,

Cast ability

Weld ability

Surface properties

Shrinkage

Deep drawing etc.


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8.2 MANUFACTURING CASE

Sometimes the demand for lowest possible manufacturing cost or surface qualities

obtainable by the application of suitable coating substances may demand the use of

special materials.

8.3 QUALITY REQUIRED

This generally affects the manufacturing process and ultimately the material.

For example, it would never be desirable to go casting of a less number of

components which can be fabricated much more economically by welding or hand

forging the steel.

8.4 AVAILABILITY OF MATERIAL

Some materials may be scarce or in short supply, it then becomes obligatory

for the designer to use some other material which though may not be a perfect

substitute for the material designed. The delivery of materials and the delivery date of

product should also be kept in mind.

8.5 SPACE CONSIDERATION

Sometimes high strength materials have to be selected because the forces involved are

high and space limitations are there.

8.6 COST

As in any other problem, in selection of material the cost of material plays an

important part and should not be ignored.

Sometimes factors like scrap utilization, appearance, and non-maintenance of

the designed part are involved in the selection of proper materials


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Table 8.1 Cost of Particulars

Sl.No. Particulars Total QuantityCost Rs./-

Per UnitTotal Cost

1 Motor-1440 rpm 1 2250 2250

2 Pulley-290mm 1 450 450

3 Pulley-30mm 1 150 150

4 v-Belt 1 200 200

5 Ball bearing 5 100 500

5 Bevel Gear Set 1 850 850

6 Hydraulic Jack 1 1100 1100

7 Drill Chuck-3/8” 1 600 600

8 Vice 1 650 650

9 Hack Saw Frame 1 100 100

10 Material Cost 5350 5350

11 Labour Cost 4250 4250

12 Transport 500 500

13 Paint & Painting Items 350 350


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CHAPTER 9

COST ESTIMATION

1. LABOUR COST

Lathe, drilling, welding, drilling, power hacksaw, gas cutting cost

2. OVERGHEAD CHARGES

The overhead charges are arrived by” manufacturing cost”

Manufacturing Cost =Material Cost + Labor Cost

=5350+4250

=9600/-

Overhead Charges =20%of the manufacturing

=4850x20/100

=1070/-

3. TOTAL COST

Total cost = Material Cost +Labor Cost +Overhead Charges

=5350+4250+1070

=10670

Total cost for this project =10670/-


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CHAPTER 10

FUTURE IMPLEMENTATION

We can perform various operations like Cutting,Drilling,or Slotting individually

by introducing coupling (engagement and disengagement) between them

We can perform Grinding Operation by introducing a grinding tool at the

Machining Shaft

We can perform boring operation by introducing a boring tool by replacing

drilling tool.

We can change the speed of Motor by Regulator.


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CHAPTER 11

CONCLUSION

This project is made with pre planning, that it provides flexibility in operation.

This innovation has made the more desirable and economical. The project “Motorized

Multi Purpose Machine (Drilling, Slotting and Cutting)” is designed with the hope

that it is very much economical and helps full to power transmitter to the driving unit

with variable speed. This project helped us to know the periodic steps in completing a

project work. Thus we have completed the project successfully.


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REFERANCE

[1] R Maguteeswaran1,M Dineshkumar,R Dineshkumar,K Karthi.“Fabrication of

multi process machine”. International journal of research in Aeronautical and

mechanical engineering.Vol 2 issue 2. PP 105-111

[2] 2013, M. Anil Prakash, Nalla Japhia Sudarsan, K. Pavan Kumar and

K.Ch.Sekhar. “Advanced shaper”,International Monthly Refereed Journal of

Research In Management & Technology. Vol II

[3] 2014, D.V.Sabariananda1, V.Siddhartha1, B.Sushil Krishnana1, T.Mohanraj.

“Design and Fabrication of Automated Hacksaw Machine”. Second National

Conference on Trends in Automotive Parts Systems and Applications

(TAPSA-2014). Volume 3, Special Issue 2.

[4] 2014 Gautam Jodh , Piyush Sirsat , Nagnath Kakde , Sandeep Lutade. “Design

of low Cost CNC Drilling Machine”. International Journal of Engineering Re-

search and General Science Volume 2, Issue 2, Feb-Mar 14.


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