Vikram Report 4
Vikram Report 4
The air brake was, for many years, used in place of the air brake as the standard, fail-
safe, train brake used by railways. Pneumatic braking systems use compressed air as the force
used to push blocks on to wheels. The air brake system is controlled through a brake pipe
connecting a brake valve in the driver's cab with braking equipment on every vehicle. A air is
created in the pipe by an ejector or exhauster. The ejector removes atmospheric pressure from
the brake pipe to create the air using steam on a steam locomotive, or an exhausted, using
electric power on other types of train. With no air the brake is fully applied. The air in the
brake pipe is created and maintained by a motor-driven exhauster. The exhauster has two
speeds, high speed and low speed. The high speed is switched in to create a air and thus
release the brakes. Slow speed is used to keep the air at the required level to maintain brake
release. Air against small leaks in the brake pipe is maintained by it.
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TABLE OF CONTENTS
ii
4 DESIGN OF EQUIPMENT AND DRAWING 22
4.1 Components and Specification 22
4.1.1 Drilling 22
4.1.2 Shaping 23
4.1.3 Cam arrangement 23
4.1.4 Bevel Gear 24
4.1.5 Hydraulic bottle jack 24
4.1.6 Vice 25
4.1.7 Bearing 25
4.1.8 Drilling tool 26
4.2 Drawing for fabrication of multi machine 28
using single motor
5 WORKING PRINCIPLE 29
6 MERITS AND DEMERITS 30
7 APPLICATIONS 31
7.1 List of Materials 31
7.1.1 Choice of materials 31
7.2 Properties 31
7.2.1 Cast ability 33
7.2.2 Weld ability 33
7.3 Manufacturing case 33
7.3.1 Quality required 33
7.3.2 Availability of material 34
7.3.3 Space consideration 34
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8 COST ESTIMATION 35
9 CONCLUSION 36
9.1 Conclusion 36
9.2 Future work 36
BIBLIOGRAPHY 37
PHOTOGRAPHY 39
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LIST OF FIGURES
NO NO
3 BALL BEARINGS 13
4 ROLLER BEARINGS 14
8 BEVEAL GEAR 18
10 NOMENCLATURE OF DRILL 27
11 MACHINE LAYOUT 28
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CHAPTER-1
INTRODUCTION
Usually driven by the vehicle engine, the air compressor is the source of energy for the air Brake
system; for the air brake system the air compressor builds the air pressure.
By the engine coolant system cools the air compressor is typically cooled and lubricated by the engine oil
supply.
(Certain models have self-lubricated and/or air-cooled versions available.) Note: Air compressor shafts
can rotate neither direction, at atmospheric pressure, the vehicle's compressor draws in filtered air from the
outside (or already at an increased pressure, from the engine turbocharger where permitted), and compresses
it. The brake system needs a supply of compressed air between a preset maximum and minimum. The
governor (along with a synchrony valve for the air compressor) monitors the air pressure in the supply
reservoir and controls when the compressor needs to pump air into the air system (also known as the "air build
cycle" - the compressors "running loaded") and when the compressor should simply turnover without building
pressure ("running unloaded). When the air pressure becomes greater than that of the preset "cut-out", the
governor controls. The unloaded mechanism of the air dryer to purge. As the service reservoir air pressure
drops to the "cut-in" setting of the governor, the governor returns the compressor back to building air and the
air dryer to air drying mode. As the atmospheric air is compressed, all the water vapor originally in the air is
carried along into the air system, as well as a small amount of the compressor lubricating oil as vapor.
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CHAPTER-2
LITERATURE SURVEY
2
CHAPTER-3
DESCRIPTION OF EQUIPMENTS
Driver controls the brake using this. It has the following positions: "Release",
"Running", "Lap" and "Brake On"."Neutral" or "Shut Down" positions are also available
which locks the valve out of use. He "Release" position connects the exhauster to the brake
pipe and switches the exhauster to full speed. This raises the air in the brake pipe as quickly as
possible to get a release. The exhauster keeps running but at its slow speed in the "Running"
position. This ensures that the air is maintained against any small leaks or losses in the brake
pipe, connections and hoses."Lap" is used to shut off the connection between the exhauster
and the brake pipe to close off the connection to atmosphere after a brake application has been
made."Brake On" closes off the connection to the exhauster and opens the brake pipe to
atmosphere.
3.2 Exhauster
A two-speed rotary machine fitted to a train to evacuate the atmospheric pressure from
the brake pipe, reservoirs and break cylinders to affect a brake release.
3
3.5 Air Reservoir:
A air reservoir is provided on, or connected to the upper side of the piston to ensure there
is always a source of air available to operate the brake.
4
3.1.1 Basic Working Principle Of An Driver’s Brake Valve.
Driver controls the brake using this. It has the following positions: "Release",
"Running", "Lap" and "Brake On"."Neutral" or "Shut Down" positions are also available
which locks the valve out of use. He "Release" position connects the exhauster to the brake
pipe and switches the exhauster to full speed. This raises the air in the brake pipe as quickly as
possible to get a release. The exhauster keeps running but at its slow speed in the "Running"
position. This ensures that the air is maintained against any small leaks or losses in the brake
pipe, connections and hoses."Lap" is used to shut off the connection between the exhauster
and the brake pipe to close off the connection to atmosphere after a brake application has been
made."Brake On" closes off the connection to the exhauster and opens the brake pipe to
atmosphere.
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CHAPTER-4
4.CONSTRUCTION
4.3AIR DRYER
Air Dryer is used Before the Compressor to remove the Moisture from the Air,
before entering into the Compressor. Because Moisture damages the Compressor Blades.
6
It is control by the Brake Pedal. When Driver press the brake pedal, Brake Valve
Opens, Therefore Air flows from the Storage Tank to Brake Chamber.
When Driver release the brake pedal, Brake Valve Closes, Therefore Air Stops to flows
from the Storage Tank to Brake Chamber.
The Diaphragm is connected to the push rod & Push Rod is connected to the
Lever & Lever is connected to the cam.
When Driver release the brake pedal, Return spring is keeps the diaphragm in
original position.
One end of the both shoes hinged & other ends are connected to the Cam. Hence when
cam rotates, the brake shoes expands inside the brake drum.
On the outer surface of the brake shoes has friction lining. Therefore when brake shoes
expands, Due to friction between shoes & brake drum, Wheel stops.
4.9 SHOES
he shoes are connected with the return spring. Therefore When driver release the
clutch pedal, Shoes are comes to original position due to spring.
CHAPTER-5
DESIGN OF EQUIPMENT AND DRAWING
7
the requirements of complete operation of the machine.
1. motor
2. hack saw
3. scotch yoke
4. base
5. hydraulic bottle jack
6. bevel gear
7. cam arrangement
8. vice
9. bearing
10.drilling tool
4.1 Drilling
A drill is a tool fitted with a cutting tool attachment, usually a drill bit used for
drilling holes in various materials or fastening various materials together with the use
of fasteners. The attachment is gripped by a chuck at one end of the drill and rotated
while pressed against the target material. The tip of the cutting tool does the work of
cutting into the target material. Drills are commonly used in woodworking,
metalworking and construction. Specially designed drills are also used in medicine,
space missions and other applications. Drills are available with a wide variety of
performance characteristics, such as power and capacity.
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4.2 Shaping
Shaper operates by moving a hardened cutting tool backwards and forwards
across the workpiece. On the return stroke of the ram the tool is lifted clear of the
workpiece, reducing the cutting action to one direction only. The workpiece mounts
on a rigid, box shaped table in front of the machine. The height of the table can be
adjusted to suit this workpiece, and the table can transverse sideways underneath the
reciprocating tool which is mounted on the ram, the table motion is usually under the
control of an automatic feed mechanism which acts on the feed screw. The ram slides
back and forth above the work, at the front end of the ram is a vertical tool slide that
may be adjusted to either side of the vertical plane. This tool slide holds the clapper
box and tool post from where the tool can be positioned to cut the straight, flat
surface on the top of the workpiece. The tool slide permits feeding the tool
downwards to put on a cut it or may be set away from the vertical plane, as required.
The ram is adjustable for stroke and due to the geometry of the linkage, it moves
faster on the return stroke than on the forward, cutting stroke. This action is via a
slotted link or whit worth link.
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4.6 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 from rubbing against the sides of the hole, most of the land is cut away,
leaving 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 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.
4.7 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. 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
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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.
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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 a narrow ridge called the margin that follows the edge of the side of
the flute that forms the cutting edge
.
Fig.10 Nomenclature of drill
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4.2 DRAWING FOR FABRICATION OF MULTI MACHINING
Fig.11Machine layout
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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 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
Easy To Implement
Low cost
Low maintenance
Easy to operate
Reduces time and increases production rate
Multi operations are performed at one time.
Our machine is used in return stroke mechanism also.
All operations are performed in single motor.
Size is compact therefore it requires less space.
Time saving.
Less man power is required.
Low manufacturing and maintenance cost.
DEMERIT
Uneven forces act on the wok piece
Only small components can be machined
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CHAPTER-7
APPLICATIONS
1. Used in small scale industries to reduce machine cost.
3. Multipurpose machine
7. used in machine.
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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, elastic 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.
7.2.2 Weldability
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For both activities, competent personnel and accredited testing
laboratories are available at SLV Duisburg. With regard to the weld execution and
the test programme, we are oriented to your stipulations, depending on whether you
must fulfil a special customer specification or work according to recognised
standards.
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7.4.4 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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CHAPTER-8
COST ESTIMATION
1. EQUIPMENTS COST:
Material cost(mild steel) 3500
BELT & PULLEY 1500
AC MOTOR 1500
Bearings 700
HYDRAULIC JACK 1800
WORM GEAR 600
2. OVERHEAD CHARGES:
The overhead charges are arrived by “manufacturing cost”
Manufacturing Cost = Material Cost + Labor Cost
= 3500+2500
= 6000
Overhead Charges =20%of the manufacturing cost
3. TOTAL COST:
Total cost = Material Cost +Labor Cost +Overhead Charges
=3500+2500+1400
Total cost for this project =74
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CHAPTER-9
CONCLUSION
9.1 Conclusion
The project carried out by us made an impressing task in the field of small-
scale industries and automobile maintenance shops. It is very useful for the workers
work in the lath and small-scale industries.
This project will reduce the cost involved in the concern. Project has been
designed to perform the entire requirement task at the shortest time available. All
production-based sectors desire low production costs and a high work rate, which can
only be achieved by utilizing multi-function operating machines that consume less
power, time, and labour. Because this equipment allows you to work at multiple
centers, you can cut down on your time to a significant extent. In a given industry, a
significant amount of the investment is spent on machinery installation, which is
quite expensive. The machine is very handy for small businesses. Workers'
movements can be reduced to a minimum. A single machine may do a large number
of processes. The amount of energy used is lowered. The amount of floor space
required is lowered. Manufacturing costs are also lowered.
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BIBLIOGRAPHY
[1] S.Mithun, S.Mariappa, Suresh Gayakwad " Modeling and simulation of pneumatic brake
system used in heavy commercial vehicle" (2014) e-ISSN: 2278-1684,p-ISSN:
International Journal Of Mechanical Engineering and Robotics Research ISSN 2278 - 0149 Vol. 3,
No. 4, October, 2014© 2014 I|MERR.
[3] Ayman A. Aly, El-Shafei Zeidan, Ahmed Hamed, Farhan Salem An Antilock-Braking Systems
(ABS) Control: A Technical Review Received April 23, 2011; revised May 18,
[5] Robert D. Hoover, Jr., MD, MPH, FACP "Pneumatic Compression Devices "February 2009
"VIVA Institute of Technology, Virar, Maharashtra International Journal of Emerging Research &
Development ISSN: 2454-132X Impact factor: 4.295
(Volume 4, Issue 3)
23
[9]. Jyothi, Surendra Guptha, Vikash (2018) “Design and Fabrication of Multi Purpose Machine”,
International Conference on Recent Innovations in Science, Vol. 4, Issue1.
[10]. Krishnappa R, Venkatesh G, Shrima M, Gowtham T (2017) “Design and Fabrication of
Motorized Multi Purpose Machine”, International Journal Recent Trends in Engineering and
Research.Vol.3, Issue- 2.
[11]. Manish kale, Mahajan (2015) “Design and Fabrication of Special Purpose Machine for
Drilling and Riveting Operation”, International Journal of Advanced Research and Innovative Ideas
in Education, Vol.2, Issue-2.
[12]. Perumal.S, Manikandan.T, Mubarak .S(2017) “Designand Synthesis of Multi Purpose Hand
Driller Machine for Various Process”,International Journal of Science and Technology , Vol.4,
Issue-1.
[13]. Prathyusha, Mounica, Kalyani, Venkata (2016) “Multi Purpose Operating Machine”,
International Journal and Magazine of Engineering Technology Management Machine, Vol.3,
Issue-5.
[14]. Praveen Karanam, Kartthick.A.V, Akshay S Bhat, Swaroop .H.P, Ganesh (2018)
“Development and Fabrication of Multipurpose Machine”, International Journal of Mechanical and
Production Engineering Vol.6, Issue-4.
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PHOTOGRAPHY
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