HI-TECH POLYTECHNIC

AURANGABAD

Project Report On

“PAPER CUTTING & RE-WOUNDING

MACHINE”

SUBMITTED BY

DEPARTMENT OF MECHANICAL ENGINEERING

HI- TECH POLYTECHNIC COLLEGE,

AURANGABAD.

2008-2009
 Hi-Tech PolyTechnic
AurAngAbAd

Certificate

This is to certified that Mr. ----------------------------------------------

has successfully completed his project on “Paper Cutting And Wounding

Machine” during academic year 2008-2009 with all respect.

Project Guide H.O.D.

Prof. A. P. Golhar Prof. G. S. Dhage

Principal
Prof. A. V. Waware

Department Of Mechanical Engineering

Hi- Tech Polytechnic College,
Aurangabad.
 Declaration

This project report has been completed, edited, written and complied
by me and is submitted to Hi-Tech Polytechnic Collage, Aurangabad. In
partial fulfillment of the Diploma in mechanical engineering, As per the
syllabus of course, I declare that no part(s) or any content(s) of the project
has been used anywhere by anybody from the purpose of degree or
diploma course in any institution or university level of learning. Hence
every thing is original and conclusion drawn is my own view.

Dept. Of Mechanical Engineering

Hi-Tech Polytechnic, Aurangabad.
 Acknowledgement

I am very glad to represent project report on “PAPER CUTTING

AND WOUNDING MACHINE”. I have tried my level best to focus upon
each and every parameter. In concern with this topic the detail, necessary
figure, definition, tabular analysis has been enumerated in very easy,
simple, compact and lucid manner.

I have been able to achieve this task by the dynamic guidance of

honorable ------------------------------ sir; I have no wards to express my
gratitude towards his kind and outstanding treatment while clarifying my
confusion. Because of his reference to the Sun-Shine engineering works,
we able to fabricate our idea as a machine.

I also extend my sincere thanks to our esteemed H.O.D. -----------------

--------- whose guidance and constant inspiration where a great use in
working of this project.

I am also grateful to our honorable Principal PROF. ------------------

for providing numerous facilities and guidance due to which this difficult
task turned in a convenient task.

Also I am grateful to -----------------------------------------------------------

for helping us in our project with his experience in designing SPM. Also
thanks to them who directly or indirectly co-operated and contributed me
during work.

Last but not least, I am very thankful to my project partners without

whose kind cooperation it was difficult and impossible to go through the
leaps and bounds while preparing this project.
 Paper Cutting And Re-wounding Machine 2009

Index
Chapter I 8-10.
INTRODUCTION
1. Definition of project
2. Procedure for design of machine elements
3. Background of project

Chapter II 11-12.
CHARACTERISTICS OF MATERIAL AND WELDING PROCESS
1. Plain carbon steels
2. Strength of welded joints
3. Advantages of welded joints compared with other joints
4. Stress reliving of welded joints

Chapter III 13-28.

STRUCTURE FABRICATING PROCESS
SELECTION OF MATERIAL FOR ROLLS
1. Design of hollow shaft
2. Calculation for dimensions of welded solid shaft journal
3. Steps in machining of roll
ROLL FOR CUTTER MOUNTING
1. Steps In Machining Of Grooved Bush And End Plates
2. Cutter clamping modification

Chapter IV 29-34.
MOTOR MOUNTING ADJUSTMENT
1. Driving mechanism
BRAKE ADJUSTMENT
WORKING OF MACHINE
1. Advantages And Disadvantages
2. Specifications of machine

Chapter V 35-38.
MATERIAL REQUIREMENTS 6
 Paper Cutting And Re-wounding Machine 2009

TROUBLE SHOOTING
1. Belt drive troubles and their remedies
2. Defects and their prevention in lathe operation

Chapter VI 39-43.
TECHNICAL DATA

Chapter VII 44.

FUTURE MODIFICATIONS

Chapter VIII 45.

CONCLUSION

Chapter IX 46.
BIBLIOGRAPHY

7
Introduction
 Paper Cutting And Re-wounding Machine 2009

Definition Of Project

A project is a group of unique, inter-related activities that are planned and

executed in a certain sequence to create a unique product or service, within a specific
time frame, budget and the clients specifications. Some of the characteristics of the task
that qualify to be projects are:
1) Unique Activities
2) Attainment of a specific goal
3) Sequence of activities
4) Specified time
5) Interrelated activities

The success of the project is depend on the ability to strike a balance between the
following interrelated variables or constraints, that are:
1) Scope of product
2) Quality of product
3) Cost(design cost, material cost, Service cost & Transportation charges)
4) Time (lead time, manufacturing time)
5) Resources

According to this Chart given below the Project characteristics will come to know
that in small projects level of risk is very little and small projects are also less complex.

Project class
Project characteristics
Class I Class II Class III Class IV
Time span 18 months or Between 9 to 18 Between 3 to 3 months or
more months 9 months less
Level of risk High Medium Low Very low

Level of complexity High Medium Low Very low

Technology Breakthrough Contemporary Best Practical

Probability of problems 100% (certain) 50% (likely) 10% (low) No risk

Procedure For Design Of Machine Elements:

The design of machine element is the most important step in the complete
procedure of machine design. In order to ensure the basic requirement of machine
elements, calculation are carried out to find out the dimensions of the machine element.
These calculation form an integral part of the designing of machine elements. The basic
procedure of the design of element is as follows:
8
 Paper Cutting And Re-wounding Machine 2009

Specify Function of Element

Determine Forces Acting On Element

Select Suitable Material For Element

Determine Failure Mode Of

Determine Geometric Dimensions Of Element

Modify Dimensions For Assembly and Manufacturing

Prepare Working Drawing of Element

Background Of Project

At the time of deciding the subject of the project, there was a auction of one paper
mill named ‘Maharudra Paper mill Pvt. Ltd.’ And unfortunately we saw that add and as it
is near to our college we go there to see how was the setup of any paper mill. That time
first we saw the paper re-winding machine And wanting someone to explain working. So
by some reference We got the address of Mr. V.D. Zirmire, The chairmen of ‘Sun-Shine
Engineering Works’. We discussed with him and convinced him to guide us to Modify
the machine. So he says yes to not only guide us but also to give us free machining
charges. It look like dream come true that we got the help of such experienced person and
our Sir also.

The conventional paper re-winding machine was 9-10 feet in length, 5 feet in
width and almost 6 feet in height. It also facilitate complex mechanisms. Thus after
9
 Paper Cutting And Re-wounding Machine 2009

discussing with Golhar sir and Mr. Chirmule we decided to give some minor
modifications to the machine.

The floor space acquired by the machine is too large thus we decided to cut the
length of machine up to 6 feet and also height up to 4.5 feet and put the width as it is
because it is the size of standard paper. (But as our project is a demo project we decided
to take the width 3 feet.)

Then they have also used the complex mechanism for mounting the roll which is
to be re-winded. So we decide to use the Self aligning bearing with extended inner ring
for easy mounting and un-mounting.

Then we see there a cutter and roll adjustment for cutting paper Which add
extremely high wt. to machine and decided to give some new design which is also
discussed .

Then as they are using the motor mounting outside the structure it consumes
much more floor space and also create difficulties in operating the break. So we are
Giving the motor mounting adjustment within the structure itself. Above and other
modifications are explained in sequence with the structure fabricating process in the
report.

10
Characteristics of materials and welding
process
 Paper Cutting And Re-wounding Machine 2009

Plain Carbon Steels:

Depending upon the percentage of carbon. plain carbon steels are classified into
following three groups:
a) Low carbon steel
b) Medium carbon steel
c) High carbon steel

Low carbon steel: they contain less than 0.3% carbon. It is popular as ‘mild
steels’. Low carbon steels are soft and very ductile. They can be machined and welded
easily. however, due to low carbon content, they are unresponsive to heat treatment. So
we are using M.S.

Strength Of Welded Joints:

Welded joints are classified into following two categories:

a) Where strength of weld is more than the strength of parts joined together.
b) Where strength of weld is less than strength of parts joined together.

In first category the failure occur in the parts joined together by weld while in
second one it will occur in the weld deposit. Strength of weld deposit is more than the
strength of connected parts under the following conditions:
a) The components are mead up of mild steel with less than 0.3% of carbon.
b) The welding electrode contain 0.15% carbon.
c) Electrode are coated resulting in shielded wilding.

During the welding process coating on the electrode gives off an inert gas which
acts as a shield, protecting the arc from the surrounding atmosphere. Coating also forms
the slag on the molten metal and protects it during cooling process. When components
are mead up of material such as high carbon steel or alloy steel the weld deposits is
weaken than the strength of connected components.

Welded Joints Offer Following Advantages Compared With Other Joints:

a) Riveted joints required additional cover plates, gusset plates, straps, clip angles
and a large number of rivets that increase weight.

b) due to elimination of these components cost of welded assembly is lower than that
of riveted assembly.

c) Welded structures are lighter than corresponding iron casting by 50% and steel
casting by 30%.

d) Welded structure has smooth and pleasant appearance, the projection of rivet head
adversely affects the appearance of riveted structure. 11
 Paper Cutting And Re-wounding Machine 2009

e) Strength of welded joint is high, very often the strength of weld is more than the
strength of the plates that are joined together.

f) machine components of certain shape such as circular steel pipe find difficult in
riveting, However they can be easily welded.

Stress Reliving Of Welded Joints:

Welded joints are subjected to residual stresses due to non-uniform heating of

parts being joined. There is always possibility that localized thermal stresses may result
from uneven heating and cooling during fusion and subsequent cooling. This is also
results in distortion. The magnitude of residual stresses cannot be predicted with any
degree of certainty. This is the major disadvantage of welded joints. Following two
methods can reduces the residual stresses.

a) Preheating of the weld area to retarded cooling of the metal in the vicinity of the
joint.

b) Stress reliving of weld area by using proper heat treatment such as normalizing
and annealing in temperature range of 550O C to 675O C.

One of the method of stress reliving is ‘hand peening’. It consist of hammering the weld
along the length with peen of hammer while joint is hot. It reduce residual stress and
induced residual compressive stress on surface. This improves fatigue strength of joint.

12
Manufacturing process
 Paper Cutting And Re-wounding Machine 2009

Structure Fabricating Process:

For structure fabrication we are using the c-channel of size 75 X 40 mm. The
approximate wt. of it per meter is 6.8 kg. Steps in fabrication of structure are given
below:

Step One: First cut the c-channel in pieces of length 71” (i.e. 6 feet – two pieces)
and in 36” ( i.e. 3 feet – three pieces). Then Put the two lengths of
6 feet parallel to each other at a distance of 3 feet from each other.
Then put the lengths of 3 feet on either end of two parallel lengths
and weld them as shown below. The two diagonals Must be same.

Step Two: Then cut four pieces of c-channel of length 24” (i.e. 2 feet) and weld two
of them on one end of rectangular structure vertically using engineers
block. Then weld remaining two pieces vertically at a distance of 30”
from previous pieces.

Step Three: Then brought the two pieces of flat of size 75 X 12 X 760 mm and weld
them on the top of four columns as shown.

Step Four: Then cut another two pieces of length 48” (i.e. 4 feet) and weld them
vertically at a distance of 16” from previously welded columns.
Afterwards weld the previously cut piece of 36” on top and in between
the upper ends of these columns.

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 Paper Cutting And Re-wounding Machine 2009

Step Five: Then cut two pieces of c-channel of length 15”. and four pieces of 4”
length. Then at a distance of 4.5” from nearest end weld them to form a
frame as shown below.

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 Paper Cutting And Re-wounding Machine 2009

Selection Of Material For Roll’s:

It is observed that torsional shear stress as well as bending stresses are zero at the
shaft centre (r = 0, y = 0) and negligibly small in the vicinity of shaft centre, where radius
is small. As the radius increases the resisting stresses due to external bending and
torsional moments increases. Therefore outer fibers are more effective in resisting the
applied moments.

In hollow shaft the material at centre is removed and spread at large radius.
Therefore hollow shafts are stronger than solid shafts having same weight. Compared
with solid shaft, hollow shaft offer following advantages:

a) The stiffness of hollow shaft is more than that of solid shaft with same weight.

b) The strength of hollow shaft is more than that of solid shaft with same weight.

c) Natural frequency of hollow shaft is higher than that of solid shaft with same
weight.

Design Of Hollow Shaft:

Design of hollow shaft consist of determining the correct inner and outer
diameters from strength and rigidity consideration. Such shafts are subjected to axial
tensile force, bending moment, torsional moment or combination of these loads. For
hollow shaft we are using low carbon steels because strength of weld is higher in case of
low and medium carbon steels. Material of shaft is plain carbon steel 40C8 (Syt = 380
N/mm2

38 mm

do = 89 mm

120 mm 750 mm 120 mm

Roll A, B, C & D are the combination of hollow pipe and solid shaft journal. We
are using this type of roll because of the reasons listed above. Roll A, C &D has to bear
load of 3000 N on them, which we suppose acts centrally for calculation purpose.

Permissible shear stress is given by:

15
 Paper Cutting And Re-wounding Machine 2009

S sy 0.5 S yt
max = = F
( f s) (3)

0.5(380)
= F
(3)

max = 63.33 N/mm2

As we are going to wound paper of weight 300 kg on roll, Assume that load of 3000N is
acting centrally on shaft.

Bending moment Mb = 3000 x 375

= 1.125 x 106 N-mm

60 x P 60 x (746)
Torsional moment Mt = F= F
2n 2x (541.35)

= 13159.27 N-mm

Shafts can be designed on the basis of ( i ) Max. shear stress theory and ( ii ) Max.
principle stress theory. But, we are not going to use Max. principle stress theory.
Because, experimental investigations suggest that this theory gives good predictions for
brittle materials. Shafts are made of ductile materials like steel and therefore this is not
applicable for shaft design. Instead of this theory we use Max. shear stress theory because
it is more logical to apply this theory to ductile material. During calculations it is also
recommended that bending and torsional moments to be multiplied by Shock factor ( Kb
) and fatigue factor ( Kt ), to account for shock’s and fatigue in operating conditions.

Now, di
C= F
do
Where, di = Inner diameter of hollow shaft

do = Outer diameter of hollow shaft

C = Ratio of inner diameter to outer diameter of hollow shaft

Let’s assume that ratio of inner diameter to outer diameter i.e. C = 0.90

When shaft is subjected to bending moment, bending stresses are given by:

16
 Paper Cutting And Re-wounding Machine 2009

Mb y
b = F 9(a)
I

For hollow circular cross section

( do4 – di4 ) ( do4 – C4 d4 )

I= F= F
64 64

do4 (1 – C4 ) (b)
I= F
64

And, do
y= F (c)
2

Substituting eqn. (b) & (c) in eqn. (a)

32 Mb
b = F [I]
do3 4
(1 – C )

When shaft is subjected to pure torsional moment, torsional shear stress is given by:

Mt r
 F (d)
J

For hollow circular cross section

 (do4 – di4)  (do4 – C4 do4)

J= F = F
32 32

do4 (1 – C4 )
J= F (e)
32
do
And, r= F (f )
2
Substituting eqn. (e) & (f ) in eqn. (d)

17
 Paper Cutting And Re-wounding Machine 2009

16 Mt
 F [ II ]
do3 4
(1 – C )

There are two conditions for calculating principle stress i.e. x

i) Shaft subjected to combination of axial forces, bending and torsional moments.

x = t + b

ii) Shaft is subjected to a combination of bending and torsional moments only, without
axial force.
x = b

Substituting eqn. [ I ] & [ II ] in following fundamental eqn.

design = x 
( F)2 + ( )2
2

= b 
( F)2 + ( )2 as x = b
2

= 16 Mb 16 Mt
2
{ } +{ }2
do3 (1 – C 4 ) do3 (1 – C 4 )

16
= } ( ( Mb )2 + ( Mt )2
do3 (1 – C4 )

Also, allowable shear stress for shaft material is:

Ssy 0.5 ( Syt ) 0.5 (380)

max = F = F= F = 63.33 N/mm2
fs fs 3

we are considering combined shock & fatigue factor for bending = Kb = 1 and combined
shock & fatigue factor for torsion= Kt = 1.2

18
 Paper Cutting And Re-wounding Machine 2009

16
design = } ( Kb x Mb )2 + ( Kt x Mt )2
do3 (1 – C4 )

From the design point of view & requirement we are going to take value of outer
diameter do = 89mm. Substituting these values in above eqn.

16
design = } (1 x 1.125 x 106)2 + ( 1.2 x 13159.27)2
3 4
(89) ( 1 – 0.90 )

 design = 23.63 N/mm2

So the induced shear stress in design is much more less than allowable shear stress in
shaft material, and design is safe.

Calculation For Dimensions Of Welded Solid Shaft Journal :

The roll has 3000 N load on it, so there will be reaction of 1500 N on both the
side shafts. By the design point of view length of shaft must not be less than 100mm. And
diameter we are taking is 38mm because of having that size of pedestal bearing blocks.
So we have to find what should be the thickness & height of weld.

1500 N

38

100
mm
Bending moment Mb = 1500 x 100

= 150 x 103 N-mm

Torsional moment Mt = 19760.26 N-mm

Primary shear stress in weld is given by:

P P 1500 12.56
 F F  F ( ) N/mm2
A D t (38) t t

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 Paper Cutting And Re-wounding Machine 2009

Consider the elemental section of area A. It is located at an angle  & subtends an angle
d Y

y = t sin
X
X

Y

 (Ixx ) = (A ) ( y2 )

= ( r dt ) ( r sin 2 )

= t r3 sin2 .d

Moment of inertia of annular fillet weld is obtained by integrating above Eqn


Ixx = 2 t r3 sin2  d
0

= 2t r3 sin2  d
0

 cos 2
3
= 2t r [ ] d
0 2

= 2t r3 ( )
2

Or, Ixx = t r3

By symmetry, Iyy = t r3
For given welded joint,
Ixx = t ) (19)3

Bending stress is given by: 20

 Paper Cutting And Re-wounding Machine 2009

Mb y (1500 x 100) (19)

b = F= F
3
I t ) (19)

132.26
=( ) N/mm2 9(a)
t

Max. shear stress in weld is given by:

max = b
( )2 + ( )
2

132.26 12.56
= ( )2 + ( )2
2t t

67.31
=( ) N/mm2 9(b)
t

Since we are assuming permissible shear stress in weld is 25N/mm2. from eqn ( b ) we
get:

67.31
25 = ( )
t

t = 2.69 mm

 t 2.69
h = ( ) =( ) = 3.80 mm
0.707 0.707

But we are taking the value of ( t ) = 4mm & ( h ) = 5.5mm

So by giving this size of weld,

1) The primary shear stress in weld will be:

P P 1500
 F F  F  3.14N/mm2
A D t (38) (4)
2) Max. shear stress in weld will be:
21
 Paper Cutting And Re-wounding Machine 2009

max = b
( )2 + ( )
2

132.26 12.56
2
= ( ) + ( )2
2(4) (4)

= 16.82 N/mm2

Steps In Machining The Roll:

Roll is mead up of hollow pipe, solid circular plates & solid shaft journal. So we
have to manufacture each part as per required size and then assemble it as a roll. Steps in
this task are

Step one: First brought the hollow pipe of required dimensions i.e. of required
outer, inner diameters and length. If not available then cut it on hacksaw
machine

750

Step two: Then brought two circular plates of 10 mm thickness, face them from
both sides by holding them on lathe machine. and turn out to the
diameter as equal to inner diameter of hollow pipe so they can fit into
pipe for welding purpose.

Step three: Take solid bar of M.S. of 50 mm diameter cut it to length 110 mm. Hold
this bar on lathe chuck and turn it out up to the diameter 38 mm so that it
can be fit in pedestal self-aligning bearing block.

Step four: Now, weld the turned solid bar to each of two solid circular plates
axially by using engineers square. for minimizing the residual stresses
induced in shaft and plates, perform ‘hand pining’ operation before it get
cool.

22
 Paper Cutting And Re-wounding Machine 2009

Grove for
welding the
bars at centre

Step five: Now, weld these plates in the bore of hollow pipe and do the same hand
pining operation in welded area.

Step six: The roll is completed, but because of welding different parts it need to
be turned again using lathe machine. Hold the journal on one side in
chuck and turn the other journal as well as hollow pipe part of roll. do
the same operation by holding other journal in chuck so the roll will
rotate along its axis accurately.
120

750

120

Steps In Machining Of Grooved Bush And End Plates:

(A) Steps in machining of grooved bush

23
 Paper Cutting And Re-wounding Machine 2009

Step One: First take the round bar of 100 mm diameter. Then cut it using
Hacksaw or bend saw machine at thickness 22 mm. Take the piece of
bar 55X20 and weld it at the centre of that plate as possible.

5 3 3 5
Grooved bush

89
75

50 36

Step Two: Then hold that piece on lathe machine using three jaw self
centering chuck. And face it from one side. Then turn it out to diameter
89 mm (as this is the diameter of core pipe).

Step Three: Then turn out the step of diameter 75 mm up to the thickness 5 mm. so
that it will fit in the bore of core pipe.

Step Four: Then fix the drill of 14 mm on the tail stock and drilled out the through
bore in the plate. Then by using boring bar make through bore in the
plate of dia. 36 mm..

Step Five: Then take the parting tool and fix it on the tool post. Then make the
groove on periphery of 89 mm diameter area at the distance of 3 mm
from its edge
.
Step Six: Then take out the job and again fix it by taking the un-machined side to
front for machining. perform the operations above turn out the step of
diameter 75 mm up to thickness 5 mm. then turn out the welded piece to
dia. 50 mm.

Step Seven: By using drill machine make the through holes of dia. 10 mm on two
sides of welded piece. And then using tap of 10 make the taping
operation.

(B) Steps in machining of end plates:

Step One: First take the round bar of 100 mm diameter. Then cut it using
Hacksaw or bend saw machine at thickness 15 mm. Take the piece of
bar 55X25 and weld it at the centre of that plate as possible.
24
 Paper Cutting And Re-wounding Machine 2009

Step Two: Then hold that piece on lathe machine using three jaw self
centering chuck. And face it from one side. Then turn it out to
diameter 89 mm.( for endplates of rewinding roll turn out this step to 89
mm dia. )

Step Three: Then turn out the step of diameter 75 mm up to the thickness 5 mm. so
that it will fit in the bore of core pipe. And make the step of 89 mm dia.
of thickness 8 mm.

Step Four: Then fix the drill of 20 mm on the tail stock and drilled out the through
bore in the plate. Then by using boring bar make through bore in the
plate of dia. 36 mm.( for end plates of rewinding roll instead of 36 mm
drill use the 28 mm drill)

Step Five: Then take out the job and again fix it by taking the un-machined side to
front for machining. Then turn out the welded piece to dia. 50 mm.

5 8 22

89R

75R
28R 50R

End Plate

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 Paper Cutting And Re-wounding Machine 2009

Cutter Clamping Modification:

In conventional machine they are using bar of 30-36 mm diameter an fix it on the
column and then by suitable bolting mount cutter on it as shown in photo (8).But using
solid M.S. bar of 30-36 mm dia. will increase wt by 5.13 kg.-7.8 kg.
Thus we decided to give new clamping for cutter on the structure itself. So from
all possibilities discussed, we make the c-clamp with the two bolts to clamp and one
extended piece of flat for mounting of cutter.

Step One: First take the flat of 25 X 10 and cut it by bend saw in size of 90 mm, 65
mm, 60 mm and 40 mm.

Step Two: Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of
40 mm in length and weld it on the 65 mm side of clamp.

Step Three: Then using drill machine make the three through holes of 10.7 mm at the
points shown below in complete assembly of cutter. Afterwards take the
tap of size ½” and perform the tapping operation.

Roll For Cutter Mounting:

In above way four rolls can be machined. In conventional machine either:

(1) Grooved rolls are used which are made up of 6-7 mm thick pipe having
diameter of about 100-120 mm. Various equidistance grooves are made on periphery of
that roll but it increase the weight tremendously. or
(2) A solid bar of 30-40 mm is used on which the aluminium bushes of diameter
60-70 mm and thickness of about 25-50 mm are used. the cutter is then fixed between
any two consecutive bushes for cutting purpose. but it also increase the weight.

For weight loss, making operation easy, eliminate excess machining and give
freedom of cutting paper of any size we are design a bush having only one groove of 3
mm thickness and 5 mm depth on the periphery of bush. And on either side of bush there
are the steps of 5 mm thickness and having diameter equal to inner diameter of core pipe.
26
 Paper Cutting And Re-wounding Machine 2009

The core pipes are used to rewind paper. These are also made up of paper but are much
tuff to sustain higher weight.

When paper being cut it is preferred that it must not be loosen between grooved
bush and end plate so firstly we think of using wooden blocks between end plates and
grooved bush. But there is one problem that if you want to change the size of paper being
cut, you have to change the distance between endplates and grooved bush and also size of
wooden block accordingly. and it will take much time to machine the block so we decide
to use core pipe. It is simple to use core pipe than any other option. Because one can
adjust the bushes and cut the core pipe of required size within few minutes.

When using our new adjustment firstly we have to measure size of paper and
adjust the end plates, then decide the size of rolls have to be cut and adjust the grooved
accordingly. Then measure the distance between grooved bush and each end plate and cut
core pipe accordingly. then fix the one piece of core pipe between one end plate and one
side of grooved bush, then fix second piece of core pipe between second end plate and
other side of grooved bush. The bush and end plates have nuts to fix them with bar thus
they will not move. Then take the roll and with the help of pillow block, bolted it on the
column. But one precaution has to be taken that the cutter shaft must be parallel to the
roll at bottom on which paper is to be rolled.

For the re-winding roll also we are going to use same type of arrangement, only
the difference is instead of using grooved bush in middle of end plates we are using an
inner bush. This inner bush is bolted at middle and support one end of each core pipe.

27
 Paper Cutting And Re-wounding Machine 2009

Then adjust the c-clamp connected with cutter as shown in fig. (a) and fix it with
the help of nut bolts. then press the cutter and put it in the groove of bush as shown in fig.
(b) then because of spring tension cutter remain pushed towards the edge of groove.

The complete cutter assembly is shown below.

28
 Paper Cutting And Re-wounding Machine 2009

Motor Mounting Adjustment

In conventional machine the motor is mounted outside the structure of machine. It

will not only increase the floor area occupied by machine but also create difficulties in
operating the block brake. Because of the operator cannot get to break quickly they have
to be given the additional feature i.e. steering like car to operate the break from distant.

To tackle these disadvantages we decided to give motor mounting arrangement

within structure itself. First we take piece of angle of 45 X 45 and of length 30 cm. and
weld it at the proper location, where the motor is to be mounted. Then we take two flats
of size 25 X 10 X 40 mm and drilled out two holes on them to fix the lower end of motor
mounting plate.

Then for adjusting the tension in belt we weld two flats with one through hole on
each to the neighboring column. And then by suitable bolting tie upper end of motor
mounting plate to column. The complete assembly is shown below.

Thus by using motor mounting plate one can move motor horizontally and also
tight or loose the belt to adjust tension in belt with the help of nut-bolt given at the upper
side of motor mounting plate.
29
 Paper Cutting And Re-wounding Machine 2009

Driving Mechanism:

As our project as a demo and also designed for small weight we use the 1 Hp A.C.
motor. It is having the 1440 rpm speed. We use two pulleys of 50 mm dia. One on the
motor shaft and another is on the shaft of roll.

Now the numbers of belts required for given application is decided by following
equation:

( transmitted power in kW) X ( Fa)

No. of belts = )
( kW rating of single V-belt) X (Fc) X ( Fd)

P X Fa
= ) (A).
Pr X Fc X Fd
Where,
P = drive power to be transmitted (kW)
Fa = Correction factor for industrial service ( table 4)
Pr = Power rating for single V-belt (table 5)
Fc = Correction factor for belt length (table 6)
Fd = Correction factor for arc of contact ( table 7)

In this application we required a power of 0.746 kW for approximately 10 hours

per day. From table 4 the correction factor according to service (Fa) is :

Design power = Fa ( transmitted power)

= 1.1 ( 0.746)
P = 0 kW (B).

Plot a point with coordinates kW and 1440 rpm speed in table 3 It is
observed that the point is located in the region of A-section belt. Therefore for this
application the cross-section of belt is A.
30
 Paper Cutting And Re-wounding Machine 2009

As we are using pulleys on both, the driver and driven shaft speed ratio is 2.66.

d = 75 mm D = 200 mm

From table 2 the preferred pitch length for A-section belts is 1100 and 1250 and
1430 . But from the design point of view we take the pitch length of belt is 1250 mm.
Substituting this value of pitch length in following equation.

(D+d) ( D – d )2
L = 2C + +
2 4C

 ( 200 + 75 ) ( 200 – 75 )2
1250 = 2C + +
2 4C

Simplifying the above expression,

C2 – 409.01 C + 1953.125 =0

409.01 + (409.01)2 – 4 ( 1953.125)

 C= +
2

C = 404.17 mm

Therefore the correct centre distance is 404.17 mm And

 Fa = 1.1 (C).

From table 6 ( A-section and 1250 mm pitch length),

 Fc = 0.93 (D).

Therefore the Arc of contact on pulley is:

D–d
s = 180 – 2 sin -1 ( )
2C

200 - 75
= 180 – 2 sin -1 ( )
2 X 404.17
-1
= 180 – 2 sin (0.1546 ) 31
 Paper Cutting And Re-wounding Machine 2009

s = 162.200

Thus from table 7, Fd = 0.96 (E).

From table 5 ( 1440 rpm, 75 mm pulley, A- section ) ( speed ratio 2.66)

Pr = 0.91 + 0.17
= 1.08 kW (F).

Therefore the numbers of belts:

P X Fa
= )
Pr X Fc X Fd

(0.8206) (1.1)
= )
(1.08) (0.93) (0.96)

= 0.9361  or only one belt

This application Required only one belt to transmit power . The decision of taking no. of
belts is the first thing in any driving mechanism.

Brake Adjustment:

In conventional machine very complex design is used for break. They are used
double band brake and it is having a wheel which is connected to break with the help of
connecting rod for the ease in operation. But as we minimize the length of machine and
also facilitate the motor inside the structure itself it is easy to operator to get at the break
for adjusting pressure.

Thus we decided to use the single block brake. It is consist of the break drum of
dia. 110 mm which can be fixed on the journal of roll. Then quarter circular plate which
is hinged at one end is fixed with one hole on other end. Through this hole one nut of
32
 Paper Cutting And Re-wounding Machine 2009

suitable length is passed which fix with bolt welded at the bottom of plate. Thus when nut
is being fitted it moves down and press the break linear against the drum. The total Single
Block break assembly is shown below

Break linear

Hinged

Spring

Break drum

Working Of Machine

As we give number of modifications it is necessary to briefly explain working

procedure of machine. When the paper being manufactured in paper mill it is not of
standard size an also get torn out at the edges. And here is the need of re-winding
machine. The roll of paper manufactured is mounted on the roll (A). In our machine we
have given the self aligning bearing with inner extended ring for ease in mounting and
um-mounting.

Then paper is passed around roll (B) to ensure that paper remain straight and
tight. Then it passed through the cutter and grooved bush on top of machine, where it is
cut. Because of our modification to this cutter roll the wt. of machine is decreased.

Then the paper which is cut is come to the two rolls at bottom, one of these two
rolls powered by 1 Hp motor with 1440 rpm. This rotating roll make other roll to rotate
and not only wound the paper but also pull the paper to make the operation going.

33
Work plan and requirements
 Paper Cutting And Re-wounding Machine 2009

Specifications Of Machine

Length 6 feet ( 152.4” )

Width 0.914 feet ( 36” )

Height 4 feet ( 48” )

Consisting 4 Hollow rolls, One cutter roll

10 pillow blocks.
Motor 1 Hp, 3 phase, induction motor

34
 Paper Cutting And Re-wounding Machine 2009

Material Requirements

Sr. Description Qty. Rate Amount

No
1) Pipe 80 m Swastic 4 meter. Rs. 362 per meter. 1448.00

2) M.S. Bars

X 1500 7.245 kg. 398.47

 50 X 1300 20.03 kg. 1101.65

Rs. 55 per kg.
 36 X 1500 11.05 kg. 607.75

80 X 400 12.150 kg. 668.25

100 X 120 7.847 kg 431.58

3) M. S. Flat
12 X 75 X 760 (2 no.) 10.79 kg Rs. 57 per kg. 615.03
4) C-channel
75 X 40 (12.2 meter ) 82.96 kg Rs. 36.50 per kg. 3028.04
5) Pillow Blocks

No 206 i.e.  30 mm 2 no. Rs. 300 per block 600.00

No 208 i.e.  40 mm 4 no. Rs. 400 per block 1600.00

Self aligning with 4 no. Rs. 500 per block 2000.00

extended inner ring

6) Pulleys 3” 1 no. Rs. 150 per pully 150.00

Pulley 8” 1 no. Rs. 250 per pully 250.00
7) V- Belt of A-47 1 no. 100.00

8) Paper 50 kg Rs. 14.50 per kg. 725.00

9) Motor 1 Hp - - -

Total 13,723.77

35
Technical data
 Paper Cutting And Re-wounding Machine 2009

Belt Drive Troubles And Their Remedies :-

As the driving mechanism is hart of our machine Because it don’t have any other
Mechanism for operating and the pulling of paper is depend on the condition of driving
mechanism. We have given some problem may occur in belt drive and their remedies.
Sr. Trouble Problem cause Remedies
No.
1) Belt slip in a) Belt is over loaded i.e. Reduce load or change the
the drive. being used to transmit more belt to suit the requirements.
power than what it is designed
for.
b) The belt is too heavy for Replace the set of pulleys to
small pulley. suit the requirements.
c) The centre distance between Increase the centre distance
two pulleys is too short. between two pulleys if
d) Ratio of diameter of two possible.
pulleys is too large (it should Sprinkle the small amount
not exceeds 6:1 ) of powder of resin on to the
inside surface of belt or use
Jockey pulley.
2) Belt does not a) Alignment of pulleys is Check and correct.
run properly wrong.
and frequently b) Alignment of shafts is Check and correct.
goes off wrong.
pulley. c) One or both pulleys are Check the balance of each
unbalanced. pulley and rectify the defect.
d) Belt is over loaded. Check the load and belt
capacity and adjust the load
accordingly or change the
belt.
e) Belt is running at excessively Check and reduce the speed.
high speed. Check and correct.
f) Belt ends have not been cut
square for joining.
3) Belt wear Running belt rub against the Discourage the use of
badly at the flanges of pulley. flanged pulleys as far as
edges. possible.

4) There is a loss a) Belt is too tight to put Adjust tension in belt.

of power. excessive strain on bearings and
belt. Adjust tension or take other
b) Excessive slip is there. measures to avoid slipping as
described in no.1 above.

36
 Paper Cutting And Re-wounding Machine 2009

Defects and their prevention in lathe operation

As our project was totally mechanical, we had to many problems during the
machining of different components of our machine. Thus we have also facilitate the
trouble shooting chart for different errors that may occur during operating the lathe
machine.

Operation Defects in work Possible cause Method of prevention

Certain portion of a) Stock size not uniform The job once made under
job remain un- and under size at these conditions cannot
machined. different places. be corrected as it will
b) Machining allowance become undersize on
is not sufficient. further machining.
c) The bar stock is not However after this defect
straight. is noted, the proper cause
d) Stock has not been set should be found out and
Cylindrical true. necessary correction
or plain e) Live and dead centers done accordingly.
turning are not properly aligned.
Dimensions of a) Tool setting is Correct the tool setting
work produced are in-accurate. and turn it a second time
incorrect. b) Measurement taken if it is oversized. If it is
during operation are under sized it can’t be
incorrect. helped.
The work produced Live and dead centers are Remove the
has tapered surface. not properly aligned. misalignment of centers.

The work produced a) Spindle runs out of It should be checked

hasn’t got a true centre due to uneven frequently and repaired.
circular cross wear of its bearings.
section.
Surface finish is a) Tool has been ground Locate the proper cause
very poor. poorly. and remove the
b) Tool overhang in the corresponding
tool post is too much. deficiency.
c) Tool angles are not
correct.
d) Tool is clamped
loosely.
e) work vibrates while
rotating due to either
improper holding or
worn out spindle
bearing.
37
 Paper Cutting And Re-wounding Machine 2009

Operation Defects in work Possible cause Method of prevention

Certain portion of a) Machining allowance Sufficient machining
the face remains is not sufficient. allowance should be
un-machined. provided.
b) Dimension of the Check the dimensions of
stock bar are incorrect. the bar stock
c) Work has not been set Set the work true.
concentric with the
spindle.
d) Tool has not been set Reset the tool properly.
at correct height.
The turned face is a) Tool overhangs too Reduce the overhang .
not square with the much.
Facing axis of the work. b) Tool loosely clamped Clamp the tool properly.
in tool post.
c) Cross feed of tool is Reduce the cross feed.
too much.
d) Ways of the cross Ways need
slide is inaccurate. reconditioning.
Surface finish is a) tool is not properly Clamp the tool properly.
very poor. clamped.
b) Job is not properly Hold the job tightly.
clamped.
c) Tool is not ground Take care in grinding.
properly.
d) Feed is too high. Reduce the tool feed.
e) Tool is overhang too Reduce the overhang.
much.
f) Tool has gone blunt. Regrind the tool.
g) Spindle runs out. Check the bearing and
get them made true.
Width of the Tool angles are incorrect Check the angle of tool
groove is larger or or a wrong tool is used. before using and select a
smaller than proper tool.
required.
Depth of groove is Cross feed has not been Control the feed
more or less than given properly. properly.
Grooving required.
and Groove is not Marking is not correct. Mark properly and check
parting off. located correctly before starting the
along the job operation.
length

38
 Paper Cutting And Re-wounding Machine 2009

Table 1 Dimensions of standard cross-section

Belt Pitch width Nominal top Nominal Recommended Permissible
Section in mm. width in mm. height in minimum minimum
mm. pitch dia. of pitch dia. of
pulley in mm. pulley in
mm.
Z 8.5 10 6 85 50
A 11 13 8 125 75
B 14 17 11 200 125
C 19 22 14 315 200
D 27 32 19 500 355
E 32 38 23 630 500

Table 2 Nominal pitch lengths for standard size of V-belts

Z A B C D E
405 630 930 1560 2740 4660
447 700 1000 1760 3130 5040
530 790 1100 1950 3330 5420
625 890 1210 2190 3730 6100
700 990 1370 2420 4080 6850
780 1100 1560 2720 4620 7650
920 1250 1690 2880 5400 9150
1080 1430 1760 3080 6100 12230
1330 1550 1950 3310 6840 13750
1420 1640 2180 3520 7620 15280
1540 1750 2300 4060 8410 16800

Table 3

39
 Paper Cutting And Re-wounding Machine 2009

Table 4 Correction factor according to service factor (Fa)

Service Type of driven machine Type of driving units

A.C. motor: normal torque, A.C. motor: high torque,

squirrel cage, synchronous, induction, single phase.
and split phase D.C. motor: series and
D.C. motor: shunt wound, compound wound, single
multi cylinder I.C. engine cylinder I.C. engine, multi
over 600 rpm. cylinder I.C. engine under
600 rpm.-line shaft.
Operational hours per day Operational hours per day
0-10 10-16 16-24 0-10 10-16 16-24

Light Blower, Exhauster, 1.0 1.1 1.2 1.1 1.2 1.3

duty Centrifugal pump,
Compressor and fan up to
7.5 kW
Medium Belt conveyor, fans over 1.1 1.2 1.3 1.2 1.3 1.4
duty 7.5 kW, Generator, Press,
Heavy Bucket elevator, Hammer 1.2 1.3 1.4 1.4 1.5 1.6
duty mill, Piston pump, Saw
mill.
Extra- Crusher, Mill, Hoist 1.3 1.4 1.5 1.5 1.6 1.8
heavy
duty
Table 5

40
 Paper Cutting And Re-wounding Machine 2009

Table 6 Correction factor for belt pitch length (Fc)

Cross-section Belt pitch length in mm.
factor Z A B C D E
0.80 630
0.81 930
0.82 700 1560 2740
0.83 1000
0.84 790 1760
0.85 1100
0.86 405 890 3130
0.87 1210 1950 3330
0.88 990
0.89
0.90 475 1100 1370 2190 3730 4660
0.91 2340
0.92 530 1560 2490 4080 5040
0.93 1250
0.94 2720 4620 5420
0.95 625 1760 2800
0.96 1430 3080 6100

Table 7 Correction factor for arc of contact (Fd)

D–d Arc of contact on Correction factor
) smaller pulley (in
C degrees)
0.00 180 1.00
0.05 177 0.99
0.10 174 0.99
0.15 171 0.98
0.20 169 0.97
0.25 166 0.97
0.30 163 0.96
0.35 160 0.95
0.40 157 0.94
0.45 154 0.93
0.50 151 0.93

41
 Paper Cutting And Re-wounding Machine 2009

M.S. FLAT M.S. FLAT

Size in mm Wt. in kg. per meter Size in mm Wt. in kg. per meter
12 X 3 0.28 50 X 3 1.2
16 X 3 0.38 50 X 5 2.0
16 X 5 0.63 50 X 6 2.4
20 X 3 0.47 50 X 10 3.9
20 X 5 0.63 50 X 12 4.7
20 X 6 0.94 50 X 16 6.3
25 X 6 1.02 50 X 20 7.8
25 X 10111111 2.001111111111111 65 X 6 3.1
25 X 12 2.4 65 X 8 4.1
30 X 5 0.700 65 X 10 5.1
30 X 6 0.900 65 X 12 6.1
30 X 10 2.4 65 X 16 8.2
30 X 12 2.8 65 X 20 10.2
35 X 6 1.6 65 X 25 12.8
35 X 10 2.8 65 X 32 16.3
35 X 12 3.3 70 X 25 13.8
35 X 16 4.4 75 X 6 3.5
40 X 3 0.900 75 X 8 4.7
40 X 5 1.6 75 X 10 5.9
40 X 6 1.9 75 X 121111111111 7.111111111111111
40 X 10 3.1 75 X 16 9.4
40 X 12 3.8 75 X 20 11.8
40 X 16 5.0 75 X 25 14.7
45 X 6 2.1 75 X 32 18.8
45 X 10 3.5 80 X 25 20.1

M.S. CHANNEL
Size in mm. Wt. in kg. per meter.
75 X 40111111111111111111 6.81111111
100 X 50 9.2
125 X 65 12.8
150 X 75 16.4
175 X 75 17.6
200 X 75 21.5
225 X 80 26.0
250 X 80 30.4
300 X 90 33.1

42
 Paper Cutting And Re-wounding Machine 2009

MILD STEEL BRIGHT BAS

Size in Wt. in kg. Size in mm. Wt. in kg. Size in mm. Wt. in kg.
mm. per foot. per foot. per foot.
3 0.017 16 0.486 32111111111 1.94611111
4 0.030 17 0.549 35 2.328
5 0.048 18 0.616 36111111111 2.46211111
6 0.063 19 0.685 40 3.040
7 0.093 20 0.760 45 3.848
8 0.122 21 0.850 50 4.750
9 0.154 22 0.920 55111111111 5.74811111
10 0.190 24 1.094 60 6.840
11 0.230 25 1.188 70 9.310
12 0.274 26 1.300 75 10.688
13 0.321 27 1.385 80 12.160
14 0.373 28111111111 1.490111111 90 15.390
15 0.428 30 1.710 10011111111 19.0001111

43
Future modifications and advantages
 Paper Cutting And Re-wounding Machine 2009

Future Modifications

In the Paper Re-winding machine there must be some weight on the roll that is
being wounded after cutting. Because during demo we found that the paper is wounded
loosely. Actually we suppose that because of self weight of paper it will going to wind
tightly, But that stage comes after 50 kg of paper is wounded, before that the paper get
wounded loosely. So in our future modification we want give one hinged roll which can
add some weight on winding roll. As the complete idea is not clear, and also because of
money problem we have only given the sketch of it.

we also thinking to facilitate some weight counting and length counting gadgets.
Because when the winding and cutting operation is going on there is no way to find that
how much paper had been wound and how much is remained.

Advantages

1) It is more compact as compared with conventional one.

2) Operation is simple Because of eliminating complex mechanisms.
3) Saving of floor space as motor is adjusted inside the structure.
4) New cutter clamping assembly given by us will eliminate the biggest
disadvantage of machine i.e. high weight.
Disadvantages

5) The main problem that we caught during demo that paper get winded loosely, but
for that we have given one suggestion in topic future modification.
44
Experiences and conclusions
 Paper Cutting And Re-wounding Machine 2009

Experiences And Conclusion:

During this wonderful project I have came across many difficulties but I have
tackled them successfully. During this I have gained knowledge about various machines
used in industries, The ideas and tricks that are used in industry.

The project facilitate much more improved functions related with weight loss,
simplifying operation, and other aspects. And more ever it will not add cost but we try to
minimize the cost also. Even then we want to say that there is much space to
improvement in the machine. The experience will be very useful for our future.

Actually Mr. ------------------- said to us that “ It is not important that how much
you improved machine, but that on your level you can manage to imagine and dare to
express your ideas with your little knowledge.” And after this small experience of
industry we have to say that it is the key thing in industry. So we are happy that we get
the experience of practical world beyond text book.

During completing this projects we came to know the various problems occurring
in any process. And if you want to success you have to manage each and every part of
any task or project. Now we are more confident that we can also do something new and
are interested to start our new carrier in mechanical engineering.

45
Bibliography
 Paper Cutting And Re-wounding Machine 2009

Bibliography

1) Forbes Marshall- Engineering Data Book

2) Workshop Technology- B. S. Raghuwanshi

(Vol. I & II)

3) Production Management- ICFAI University

4) Elements of machine design- V. B. Bhandari

5) Strength of materials- R. K. Bansal

46
Future modification1.bmp
Future modification2.bmp
Future modification3.bmp
Future modification4.bmp
Future modification5.bmp