ABSTRACT

This thesis deal with design, development and fabrication of MULTIPURPOSE

MECHANICAL MACHINE. This machine is designed for the purpose of
MULTI-OPERATIONs i.e. DRILLING, CUTTING, SHAPING and
GRINDING. This machine perform multipurpose operation at same time with
required speed & this machine is automatic which is controlled or operated by
motor which is run with the help of current. This machine is based on the
mechanism of whit worths return. This model of the multi OPERATIONAL
machine is may be used in industries and domestic OPERATION which can
perform mechanical operation like drilling, cutting &shaping of a thin metallic
as well as wooden model or body.

PROBLEM DEFINITION

To design and development of MULTI PURPOSE MECHANICAL

MACHINE, a structured which is designed for the purpose of MULTI-
OPERATIONs i.e. DRILLING, CUTTING & SHAPING.1.2 Problem
Identification This machine perform multipurpose operation at same time with
required speed & this machine is automatic which is controlled or operated by
motor which is run with the help of current. This machine is based on the
mechanism of whit worths return. This model of the multi OPERATIONAL
machine is may be used in industries and domestic OPERATION which can
perform mechanical operation like drilling, cutting & shaping of a thin metallic
as well as wooden model or body.

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INTRODUCTION

Multi-purpose machine can be defined as an instrument which is used to drill

holes grinding and cutting. Multi-purpose machine plays an important role in
mechanical workshops. The purpose of this project work is to get hold of
complete information pertaining to drilling machines. A Multi-purpose machine
comes in many shapes and sizes, from small hand-held power drills to bench
mounted and finally floor-mounted models. Today the Industrial growth is
purely depends up on latest machines; therefore the subject of Multi-purpose
machines is extended too widely, because today wide varieties of these
machines are designed for various applications. The most advanced version-
these machine is CNC (Computer Numeric Control); it is used for drilling the
PCB’s (Printed circuit boars). CNC Drilling is commonly implemented for mass
production.
Simple machines like hand held portable multi-purpose machines, power feed
drilling, cutting, grinding etc. are quite common; we can find these machines
everywhere. Often these machines are used for drilling a through hole over the
job; these machines cannot be used for number of machining operations for
specific applications. Human force is required to drill the hole, cutting and
grinding. drilling depth cannot be estimated properly, job may spoil due to
human errors, and different size holes cannot be drilled without changing the
drill bit. Consumes lot of time for doing repeated multiple jobs, these all are the
drawbacks. To overcome all theseproblems, this automated Multi-
purpose machine is designed which is aimed to drill the holesautomatically over
a job according to the drilling depth, cutting and grinding data programmed
through a key board. The main concept of this machine is to drill the holes over
particular jobs repeatedly at different depths, sequence is maintained. As the
machine contains drill motor, the movement is controlled accurately.

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It is multipurpose machine and applicable to all kinds of complex, difficult and high quality products also
easy to operate. With the help of this machine we can do mainly three major machining processes which
are classified as Cutting, Drilling and Shaping. The main advantage of this machine is that we can do all
above process in step by step manner by without changing the place of motor.
We can perform more than one work with using only one motor of power 0.5 HP. Easily moved from one
location to another are very useful. Very useful for small and light job It covered to small area. Suitable for
processing Metal, Aluminium, Wood and other light materials Excellent advantage of various functions,
small occupation and economization.

THEORY
Definition of a mechanism is a simplified model, usually in the form of a line
diagram, which is used to reproduce exactly the motion occurring in a machine.
The purpose if this reproduction is to enable the nature of the motion to be
investigated without the encumbrance of the various solid bodies which forms
the machine elements.

Component of machine

1) FRAME

2) BEVEL GEAR

3) WHITWORTH MECHANISM

4) MOTOR

5) PULLEY

6) BEARING (BALL & SLIDING BEARING)

7) ROCKER ARM

8) HACKSAW BLADE

9) TOOL POST
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10) DRILLING CHUCK

11) DRILL TOOL

12) SINGLE CUTTING TOOL

13) TABLE

14) NUT & BOLT

15) OTHER COMPONETS

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 REAR VIEW

OPERATION OF MACHINE
Operation performs by machine:-

1. DRILLING

2. SHAPING

3. CUTTING

4. GRINDING.

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1. DRILLING -Drilling is the operation of producing circular hole in the work-
piece by using a rotating cutter called DRILL.

 It is the simplest and accurate machine used in production shop.

 The work piece is held stationary i.e. Clamped in position and the drill
rotates to make a hole.

Types of drilling

 Portable drilling
 Bench drilling
 Radial drilling
 Pillar drilling
 Gang drilling
 Multiple drilling

Portable drilling :-

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Bench drilling
 These are light duty machines used in small workshops.
 Also called Sensitive drilling because of its accurate and well
balanced spindle.
 Holes of diameter 1 mm to 15 mm.

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Radial drilling
 These are heavy duty and versatile drilling used to
perform drilling operate on large and heavy work
piece.

 Holes up to 7.5 cm.

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Drilling operation
 Reaming
 Boring
 Counter boring
 Counter sinking
 Spot facing
 Tapping

Reaming

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 It is a process of smoothing the surface of drilled holes
with a tool.
 Tool is called as reamer.
 Initially a hole is drilled slightly smaller in size.
 Drill is replaced by reamer.
 Speed is reduced to half that of the drilling.

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Boring
 It is process carried on a drilling to increase the size
of an already drilled hole.
 Initially a hole is drilled to the nearest size and using
a boring tool the size of the hole is increased.

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Counter boring
 This process involves increasing the size of a hole at
only one end.
 Cutting tool will have a small cylindrical portion
called pilot.
 Cutting speed = two-thirds of the drilling speed for
the same hole.

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Counter sinking
 This is an operation of making the end of a hole into a
conical shape.
Cutting speed = half of the cutting speed of drilling for
same hole

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Spot facing
 It is a finishing operation to produce flat round
surface usually around a drilled hole, for proper
seating of bolt head or nut.
It is done using a special spot facing tool

Drill bit
Drill bits are cutting tools used to create cylindrical holes. Bits are held in a tool
called a drill, which rotates them and provides torque and axial force to create
the hole. Specialized bits are also available for non-cylindrical-shaped holes.

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This article describes the types of drill bits in terms of the design of the cutter.
The other end of the drill bit, the shank, is described in the drill bit shank article.
Drill bits come in standard sizes, described in the drill bit sizes article. A
comprehensive drill and tap size chart lists metric and imperial sized drills
alongside the required screw tap sizes. The term drill can refer to a drilling
machine, or can refer to a drill bit for use in a drilling machine. In this article,
for clarity, drill bit or bit is used throughout to refer to a bit for use in a drilling
machine, and drill refers always to a drilling machine.

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TWIST DRIL

The twist drill bit is the type produced in largest quantity today. It drills holes in
metal, plastic, and wood. The twist drill bit was invented by Steven A. Morse
of East Bridgewater, Massachusetts in 1861. He received U.S. Patent 38,119for
his invention on April 7,1863. The original method of manufacture was to cut
two grooves in opposite sides of a round bar, then to twist the bar to produce the
helical flutes. This gave the tool its
name. Nowadays, the drill bit is usually made by rotating the bar while moving i
t past a grinding wheel to cut the flutes in the same manner as cutting helical

gears. Tools recognizable as twist drill bits are currently produced in diameters
covering a range from 0.05 mm (0.002") to100 mm (4"). Lengths up to about
1000 mm (39") are available for use in powered hand tools.

The geometry and sharpening of the cutting edges is crucial to the

performanceofthe bit. Users often throw away small bits that become blunt, and
replace them with new bits, because they are inexpensive and sharpening them
well is difficult. For larger bits, special grinding jigs are available. A special
tool grinder is available for sharpening or reshaping cutting surfaces on twist
drills to optimize the drill for a particular material. Manufacturers can produce
special versions of the twist drill bit, varying the geometry and the materials
used, to suit particular machinery and particular materials to be cut. Twist drill
bits are available in the widest choice of tooling materials. However, even for
industrial users, most holes are still drilled with a conventional bit of high speed
steel. The most common twist drill (the one sold in general hardware stores) has
a point angle of 118 degrees.

This is a suitable angle for a wide array of tasks, and will not cause the
uninitiated operator undue stress by wandering or digging in. A more aggressive

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(sharper) angle, such as 90 degrees, is suited for very soft plastics and other
materials. The bit will generally be self-starting and cut very quickly. A
shallower angle, such as 150 degrees, is suited for drilling steels and other
tougher materials. This style bit requires a starter hole, but will not bind or
suffer premature wear when a proper feed rate is used. Drills with no point
angle are used in situations where a blind, flat-bottomed hole is required. These
drills are very sensitive to changes in lip angle, and even a slight change can
result in an inappropriately fast cutting drill bit that will suffer premature wear.
The twist drill does most of the cutting with the tip of the bit. There are flutes to
carry the chips up from the cutting edges to the top of the hole where they are
cast off.· Some of the parts of a drill bit are diagramed below as viewed from
the cutting tip of the drill.

Top view of drill bit

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 Side view of a drill bit

Typical parameters for drill bits are,

1. Material is High Speed Steel2.

2. Standard Point Angle is 118°

Harder materials have higher point angles; soft materials have lower point
angles. The helix results in a positive cutting rake. Drill bits are typically
ground (by hand) until they are the desired shape. When done grinding, the lips
should be the same length and at the same angle, otherwise and oversized hole
may be produced. Drill sizes are typically measured across the drill points with
a micrometer.

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Hacksaw Blade

A hacksaw is a fine-tooth hand saw with a blade held under tension in a frame,
used for cutting materials such as metal or plastics. Hand-held hacksaws consist
of a metal arch with a handle, usually a pistol grip, with pins for attaching a
narrow disposable blade. A screw or other mechanism is used to put the thin
blade under tension. 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. On the push stroke, the arch will flex slightly, decreasing the tension on
the blade, often resulting in an increased tendency of the blade to buckle and
crack. Cutting on the pull stroke increases the blade tension and will result in
greater control of the cut and longer blade life

A hacksaw is a fine-tooth saw with a blade under tension in a frame, used for
cutting materials Such as metal. Hand-held hacksaws consist of a metal frame
with a handle, and pins for attaching a narrow disposable blade. A screw
or other mechanism is used to put the thin blade under tension. A power
hacksaw (or electric hacksaw) is a type of hacksaw that is powered
by electric motor. Most power hacksaws are stationary machines but
some portable models do exist. Stationary models usually have a mechanism to
lift up the saw blade on the return stroke and some have a coolant pump to
prevent the saw blade from overheating.

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Components of drilling machine
1. Spindle - The spindle holds the drill or cutting tools and revolves in a fixed
position in a sleeve.

2. Sleeve - The sleeve or quill assembly does not revolve but may slide in its
bearing in a direction parallel to its axis. When the sleeve carrying the spindle
with a cutting tool is lowered, the cutting tool is fed into the work: and when it’s
moved upward, the cutting tool is withdrawn from the work. Feed pressure
applied to the sleeve by hand or power causes the revolving drill to cut its way
into the work a fraction of an mm per revolution.

3. Column - The column is cylindrical in shape and built rugged and solid. The
column supports the head and the sleeve or quill assembly.

4. Head - The head of the drilling machine is composed of the sleeve, a spindle,
an electric motor and feed mechanism. The head is bolted to the column.

5. Worktable - The worktable is supported on an arm mounted to the column.

The worktable can be adjusted vertically to accommodate different heights of
work or it can be swung completely out of the way. It may be tilted up to 90
degree in either direction, to allow long pieces to be end or angle drilled.

6. Base - The base of the drilling machine supports the entire machine and when
bolted to the floor, provides for vibration-free operation and best machining
accuracy. The top of the base is similar to the worktable and may be equipped
with t- slot for mounting work too large for thetable.

7. Hand Feed - The hand- feed drilling machines are the simplest and most
common type of drilling machines in use today. These are light duty machine
that are operated by the operator, using a feed handled, so that the operator is
able to “feel” the action of the cutting tool as it cuts through the work piece.
These drilling machines can be bench or floor mounted.

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8. Power feed - The power feed drilling machine are usually larger and heavier
than the hand feed ones they are equipped with the ability to feed the cutting
tool in to the work automatically duty work or the work that uses large drills
that require power feed larger work pieces are usually clamped directly to the
table or base using t –bolts and clamps by a small work places are held in a vice.
A depth –stop mechanism is located on the head, near the spindle, to aid in
drilling to a precise depth.

INTRODUCTION TO GRINDING PROCESS

• It is the only economical method of cutting hard material like hardened
steel.

• It produces very smooth surface, suitable for bearing surface.

• Surface pressure is minimum in grinding. It is suitable for light work,

which will spring away from the cutting tool in the other machining
processes.

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 Types of grinding operation
1. Ruff or precision Grinding

a) Snagging

b) Off-hand

2. Precision Grinding

a) Surface grinding

b) Cylindrical grinding

c) Center less grinding

d) Form and profile grinding

e) Plunge cut grinding

Grinding Process
Grinding is an abrasive machining process that uses a grinding wheel as
the cutting tool.

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Surface Grinding
Surface grinding uses a rotating abrasive wheel to remove material, creating a
flat surface.

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Cylindrical Grinding

Cylindrical grinding (also called center-type grinding)

is used to grind the cylindrical surfaces and shoulders of
the work piece.
1. External cylindrical grinding
2. Internal cylindrical grinding

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External cylindrical grinding

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Internal cylindrical grinding

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Center less grinding

Form and profile grinding

Form grinding is a specialized type of cylindrical grinding where the grinding

wheel has the exact shape of the final product. The grinding wheel does not
traverse the work piece

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Plunge cut grinding

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Infeed (Plunge) Grinding is used to grind workpieces which
have projections or shoulders, multiple diameters or other
irregular shapes which preclude the use of through feed
grinding.
For example :- Grinding of crank shaft.

Electrochemical grinding

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Electrochemical grinding
 The wheels and work piece are electrically conductive.

 Wheels used last for many grindings - typically 90% of the metal is
removed by electrolysis and 10% from the abrasive grinding wheel.

 Capable of producing smooth edges without the burrs caused by

mechanical grinding.

 Does not produce appreciable heat that would distort work piece.

Decomposes the work piece and deposits them into the electrolyte solution. The
most common electrolytes are sodium chloride and sodium nitrate at
concentrations of 2 lbs. per gallon

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SHAPING
The shaping is used to machine flat metal surfaces especially where a large
amount of metal has to be removed. Other machines the shaping machine is a
simple and yet extremely effective machine. It is used to remove material,
usually metals such as steel or aluminium, to produce a flat surface.

However, it can also be used to manufacture gears such as rack and pinion
systems and other complex shapes. Inside its shell/casing is a crank and slider
mechanism that pushes the cutting tool forward and returns it to its original
position. This motion is continuous.

A shaper is a type of machine tool that uses linear relative motion between the
work piece and a single-point cutting tool to machine a linear tool path. Its cut is
analogous to that of a lathe, except that it is (archetypal) linear instead of
helical. (Adding axes of motion can yield helical tool paths, as also done in
helical planning.) A shaper is analogous to a plane, but smaller, and with the
cutter riding a ram that moves above a stationary work piece, rather than the
entire work piece moving beneath the cutter. The ram is moved back and forth
typically by a crank inside the column; hydraulically actuated shapers also exist.

SHAPING PROCESS:-
Shaping is a material removal process in which a cutting tool takes mass and shapes a
stationary object to produce a sculpted or plane surface.
The shaping process is used to machine flat metal surfaces especially where a large amount
of metal has to be removed. Other machines such as milling machines are much more
expensive and are more suited to removing smaller amounts of metal, very accurately.
The reciprocating mechanism of shaping machine is done with the help of rotating disc. As
the disc rotates the top of the machine moves forwards and backwards, pushing a cutting tool.
The cutting tool removes the metal from work which is carefully bolted down.

Types

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Shapers are mainly classified as standard, draw-cut, horizontal, universal,
vertical, geared, crank, hydraulic, contour and travelling head. The horizontal
arrangement is the most common. Vertical shapers are generally fitted with a
rotary table to enable curved surfaces to be machined (same idea as in helical
planning). The vertical shaper is essentially the something as a slotter (slotting
machine), although technically a distinction can be made if one defines a true
vertical shaper as a machine whose slide can be moved from the vertical. A
slotter is fixed in the vertical plane.

Small shapers have been successfully made to operate by hand power. As size
increases, the mass of the machine and its power requirements increase, and it
becomes necessary to use a motor or other supply of mechanical power. This
motor drives a mechanical arrangement (using a pinion gear, bull gear, and
crank, or a chain over sprockets)or a hydraulic motor that supplies the necessary
movement via hydraulic cylinders.

OPERATION

A shaper operates by moving a hardened cutting tool backwards and forwards

across the work piece. On the return stroke of the ram the tool is lifted clear of
the work piece, reducing the cutting action to one direction only. The work
piece mounts on a rigid, box-shaped table in front of the machine. The height of
the table can be adjusted to suit this work piece, and the table can traverse
sideways underneath the reciprocating tool, which is mounted on the ram. Table
motion may be controlled manually, but is usually advanced by automatic feed
mechanism acting 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 along
the stroke axis. This tool-slide holds the clapper box and tool post, from which
the tool can be positioned to cut a straight, flat surface on the top of the work
piece. The tool-slide permits feeding the tool downwards to deepen a cut. This

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adjustability, coupled with the use of specialized cutters and tool holders, enable
the operator to cut internal and external gear tooth profiles, dovetails, and
keyways.

The ram is adjustable for stroke and, due to the geometry of the linkage, it
moves faster on the return (non-cutting) stroke than on the forward, cutting
stroke. This action is via a slotted link or Whitworth link

3. CUTTING - A hacksaw is a fine-tooth saw with a blade held under tension

in a frame, used for cutting materials such as metal or plastics. Hand-held
hacksaws consist of a metal arch with a handle, usually a pistol grip, with pins
for attaching a narrow disposable blade. A screw or other mechanism is used to
put the thin blade under tension. 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. On the push stroke, the arch will flex slightly, decreasing the tension
on the blade. Blades are available in standardized lengths, usually 10 or 12
inches for a standard hand hacksaw. "Junior" hacksaws are half this size.
Powered hacksaws may use large blades in a range of sizes, or small machines
may use the same hand blades.

CUTTING OPERATION
Cutting is the separation of a physical object, or a portion of a physical object, into two
portions, through the application of an acutely directed force.
Selecting the correct blade for the material to be cut is important when setting up a hacksaw.
High Speed Steel (HSS) blades are used for tough, resistant materials whilst High Carbon
Steel blades are for general cutting. Selecting the correct number of teeth per inch (25mm) is

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also important. The general rule is that at least three teeth should extend across the surface of
the material to be cut.

Types of cutting operation

• Following are the types of cutting operations performed in sheet metal
working.

• Shearing

• Blanking

• Punching

• Cut off

• Parting

• Slotting

• Perforating

• Notching

• Trimming

• Shaving

Fine blanking

Shearing
• It is a sheet metal cutting operation along a straight line between two
cutting edges.

• It is typically used to cut large sheets into smaller sections for subsequent
press working operations.

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• It is performed on a machine called a power shear or squaring shear

• Shearing operation:

• (a) side view of the shearing operation.

• (b) front view of power shears equipped with inclined upper cutting
blade.

• Symbol v indicates motion.

Blanking

• It involves cutting of sheet metals along a single step to separate the piece
from the surrounding stock.

• The part that is cut out is the desired product in the operation and is called
the blank.

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 Punching

• Punching is similar to blanking except that the piece that is cut out is
scrap called the slug.

• The remaining stock is the desired product

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 Cut off

• It is a shearing operation in which blanks are Separated from a sheet

metal strip by cutting the opposite side of the part in sequence.

• With each cut, new part is produced.

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 Parting

• Parting involve cutting a sheet metal strip by a punch with two cutting
edges that match the opposite sides of the blank.

• Parting is less efficient Than cut off in the sense that it results in some
wasted materials.

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 Slotting

• Slotting is a punching operation that cuts out an elongated or rectangular

hole.

Perforating

• Perforating involves the simultaneous punching of a pattern of holes in a

sheet metal.

• The hole pattern is usually for decorated purposes, or to alloy passage of

light, gas or fluid.

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Specification of hacksaw Size of hacksaw blade:-

Thickness;-1.27-2.54 mm

Width;-25.40-50.80mm

Length 304.80-609.60mm

We can perform various operations like cutting, drilling or shaping individually

by introducing coupling

ADVANTAGES
1. Low manufacturing
2. Less man power is required
3. Time saving
4. Size is compact therefore it requires less space
5. All operation is performed by only one motor
6. The return stroke of shaper machine is utilized as cutting operation
7. Our machine is used Return stroke (whit worth) mechanism

8. Multi operations are performed at one time

The work piece is held stationary i.e. clamped in position and the drill rotates to
make a hole. It is the simplest and accurate machine used in production shop.
The most common drill used is the twist drill.

Drilling Machine - The drilling operation can also be accomplished in lathe, in

which the drill is held in tail stock and the work is held by the chuck. The
machine used for drilling is called drilling machine.

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FUTURE IMPLIMENTATION
We can change the speed of motor by regulator.

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

drilling tool. We can perform Grinding operation by introducing a grinding tool
at the main shaft between them.

CONCLUSION
After completing the major project on “MUILTI PURPOSE MECHANICAL
MACHINE” we are much happy and would like to thank our professor, guides
and the lectures of the concerned department who have guided us. While
making this project we have been able to learn a lot and understand the various
aspects of “MULTI PURPOSE MECHANICAL MACHINE” we can use our
knowledge, which we get during our study.

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