final year project

1. THE NATIONAL INSTITUTE OF ENGINEERING
DEPARTMENT OF INDUSTRIAL AND PRODUCTION
ENGINEERING
Presented by
ADARSH V
GAGAN PONNAPPA M G
RAKESH J M
YATHISH B
Under the guidance:
Dr H N Divakar
Associate professor

2. PROBEM DEFINITION
Weakening of a material is the progressive and
localised structural damage that occurs when a
material is subjected to cyclic loading. If the loads are
above a certain threshold, microscopic cracks will
begin, eventually crack will reach a critical size, the
crack will propagate suddenly, and the structure will
fracture
To calculate the fatigue strength of the materials,
high cycle fatigue machines are available.

3. PROBEM DEFINITION
 High cycle fatigue strength (about 104
to 108
cycles) can
be calculated by the machine, such as load-controlled
servo-hydraulic test rig is commonly used in these
tests, with frequencies of around 20–50 Hz. Other sorts
of machines—like resonant magnetic machines—can
also be used, to achieve frequencies up to 250 Hz.

4.  The current fatigue testing machines are universal in
nature. These machines are designed to test all the
factors responsible for fatigue in a component. These
machines are capable of testing fatigue strength for
different types of components and materials. Hence
these machines are extremely large, very expensive
and require highly skilled labour to operate.
 Ex: Servo hydraulic test system
PROBEM DEFINITION

5. PROBEM DEFINITION
Servo hydraulic test system

6.  The prototype that is being designed is for a
specific specimen, mainly sheet metals. This
machine can be used to determine the minimum
requirements for a component to pass a fatigue
test.
 This prototype is less expensive and easy to
operate and are more useful in small scale
industries which do not require high end
specifications.
PROBEM DEFINITION

7. OBJECTIVE

8. OBJECTIVE

9. SPECIMENS USED
Aluminium Sheet Metal
Aluminium is also a popular metal used in sheet metal
due to its flexibility wide range of options, cost
effectiveness, and other properties
Common applications include electronic chassis,
tanks, and pressure vessels. It is used in modern aircraft
structure.

10. SPECIMENS USED
Brass Sheet Metal
Brass can also withstand very high temperatures, and
has excellent conductivity, making them ideal materials
for conveying hot water in a residential or commercial
space.
Moreover, brass is surprisingly flexible and highly
moldable compared to other metals.

11. SPECIMENS USED
Copper Sheet Metal
Copper alloys become stronger and more ductile as
temperature goes down.
 They also retain excellent impact resistance to 20 K.

12. METHODOLOGY
Metal cutting
Metal cutting processes work by causing fracture of
the material that is processed. Usually, the portion
that is fractured away is in small sized pieces, called
chips. Common cutting processes include sawing,
shaping (or planning).

13. METHODOLOGY
Welding
Joining process is done with the help of welding
(SMAW). SMAW is briefly explained below:
In the shielded metal arc welding process (SMAW)
the 'stick' electrode is covered with an extruded
coating of flux.

14. METHODOLOGY
Drilling
Drilling is a cutting process that uses a drill bit to
cut or enlarge a hole of circular cross-section in solid
materials.
Common drill bit materials include hardened steel
(High Speed Steel, Titanium Nitride coated steel); for
cutting harder materials, drills with hard inserts, e.g.
carbide or CBN inserts, are used.

15. METHODOLOGY
Assembly
An assembly line is a manufacturing process (most of
the time called a progressive assembly) in which
parts (usually interchangeable parts) are added as
the semi-finished assembly moves from work station
to work station where the parts are added in
sequence until the final assembly is produced.

16. STEPPED PULLEY CIRCULAR PLATE BEARING RING
MILD STEEL ANGLE BAR LINEAR BEARING BLOCK V-TYPE BELT
COMPONENTS USED

17. DESIGN
Factors considered in Design
 Safety
 Reliability
 Low cost
 Durability
 Ease of Use
 Maintenance

18. Components Diagram
CAD Design
Design of Shaft Design of Hammer Shaft

19. Design of Frame Design of crank
Components Diagram

20. Design of Moving HingeDesign of motor Pulley
Components Diagram

21. Universal Joint Design of Disc and Connecting Rod
Components Diagram

22. ELECTRIC
Components Diagram
2D Model

23. 3D Model FABRICATED MACHINE
DESIGN

24. DIMENSIONS OF PLATFORM
LENGTH OF PLATFORM: 0.6 m
WIDTH OF PLATFORM: 0.61 m
THICKNESS OF PLATFORM MATERIAL:
0.025 m
HEIGHT OF PLATFORM : 0.69m
PLATFORM
Dimensions of Components

25. DIMENSIONS OF BOARD ON
WHICH HAMMER SHAFT
TRACK IS MOUNTED,
WIDTH: 0.6m
HEIGHT: 0.07m
THICKNESS: 0.035m
BOARD
Dimensions of Components

26. DIMENSIONS OF HAMMER
SHAFT
LENGTH: 0 .22m
DIAMETER OF SHAFT: 0.30m
LENGTH OF CONNECTING
ROD: 0.17m
DIAMETER OF HAMMER BALL:
0.30m
HAMMER
SHAFT
Dimensions of Components

27. DIMENSIONS OF SHAFT
LENGTH OF SHAFT: 0.27m
DIAMETER: 0.3m
SHAFT
Dimensions of Components

28. MOTOR SPECIFICATIONS,
AKASH SINGLE PHASE AC
MOTOR,
POWER: 1.5 HP
VOLTS: 220 V
CURRENT: 9.9 A
SPEED: 1475 RPM
DIMENSIONS OF MOTOR
PLATFORM,
LENGTH OF TRACK: 0.205m
WIDTH OF TRACK: 0.22m
HEIGHT OF TRACK: 0.07m
MOTOR
Dimensions of Components

29. DIMENSIONS OF MOTOR
PULLEY
DIAMETER OF MOTOR
PULLEY: 0.04m
WIDTH OF PULLEY: 0.02
MOTOR PULLEY
Dimensions of Components

30. DIMENSIONS OF PULLEY
DIAMETER OF PULLEY: 0.21m
WIDTH OF PULLEY: 0.02m
HEIGHT OF VERTICAL
COLOUMN: 0.7 m
PULLEY
Dimensions of Components

31. DIMENSIONS OF UPPER STEPPED
PULLEY
DIAMETER OF PULLEYS: 0.12m,
0.10m, 0.09m
WIDTH OF PULLEY: 0.02m
HEIGHT OF VERTICAL COLOUMN:
1.16m
UPPER STEPPED
PULLEY
Dimensions of Components

32. DIMENSIONS OF LOWER
STEPPED PULLEY
DIAMETER OF PULLEYS:
0.03m, 0.06m, 0.08m
WIDTH OF PULLEY: 0.02m
HEIGHT OF VERTICAL
COLOUMN: 0.69m
LOWER
STEPPED
PULLEY
Dimensions of Components

33. •Hemispherical
indentation tool
•Chisel indentation tool
•Ball indentation tool
•Point indentation tool
Indentation tools

34. CALCULATIONS

35. Speed Reduction Ratio
 It is the ratio of the product of diameter and
speed of the one shaft to the product of diameter and
speed of the another shaft which is to be connected
each other. Its value must be unity.
 To calculate the speed reduction ratio
diameter of each shaft/pulley and the speed of any
one shaft/pulley is required.
 i.e Speed Reduction Ratio is calculated by
N1D1=N2D2
SPEED CALCULATIONS

36. Specification of the pulleys
Position Diameter in meter Speed in rpm
Motor pulley 0.04 1475
Middle shaft pulley 0.21 280
Middle shaft stepped-
pulleys
0.03, 0.06, 0.09 280
Upper shaft stepped-
pulley
0.12, 0.10, 0.08 70, 168, 315
Crank 0.14 60, 120, 180
SPEED CALCULATIONS

37. CALCULATIONS

38. Using Load Cell
One can calculate the load acting by keeping the
load cell below the hammer when the hammer is in
working. Load cell measures the load acting on it
and gives the convenient values.
This method gives very accurate value.
This is less time consuming process.
The Load acting on the sheet metal in Low Cycle
Fatigue testing machine when it is working condition
is 12N
Load Acting on the Work Piece

39. SPECIMEN TEST
Dimension of the specimen
LENGTH OF SPECIMEN: 0.24 m
WIDTH OF SPECIMEN: 0.06 m
THICKNESS OF SPECIMEN: 0.001m
TESTING AND RESULT

40. TESTED SPECIMENS
TESTING AND RESULT
Original Specimen Sample specimen
work with 32,400 cycle
stroke

41. TESTING AND RESULT
TESTED SPECIMENS
sample specimen
work with 36,500
cycle strokes
sample specimen work
with 40,000 cycle
strokes

42. Graph of breaking point of GI for different strokes
X-axis represents different strokes
Y-axis represents Number of cycles
ANALYSIS

43. Graph of breaking point of MS for different strokes
X-axis represents different strokes
Y-axis represents Number of cycles
ANALYSIS
75000
67000

44. X-axis represents different strokes
Y-axis represents Number of cycles
Graph of breaking point of AL for different strokes
ANALYSIS
37000
34500

45. CONCLUSION

46. CONCLUSION

47.  cost estimated = Rs 19,000
 Present cost = Rs 16,000
COST ESTIMATION

48. Components Cost
(Rs)
Mild steel Angular 1500
Bearing Blocks 2000
Pulley Stepper 2000
Belt 1000
Motor 3000
Linear Bearing 800
Linear Bearing Block 300
Paint 600
Lathe Work 1000
Miscellaneous 800
Fabricating Cost 3000
ESTIMATED AMOUNT 16000
COST ESTIMATION

49. PROBLEMS FACED

50. ADVANTAGES

51. SCOPE OF FUTURE

52. WORK PHASE

53.  J. T. P. Yao and W. H. Munse, report SSC- 137, University of
Illinois, Urbana, Illinois under Department of the Navy.
 P. W. BEAVER, MULTIAXIAL FATIGUE AND FRACTURE.
 Vitaliy Kazymyrovych, Very High Cycle Fatigue of Engineering
Materials, Department of Materials Engineering, Karlstad
University SE-651 88, Sweden, Karlstad University Studies
2009:22, ISSN 1403-8099, ISBN 978-91-7063-246-4.
 M. Marini and A. B. Ismail, Torsional Deformation and Fatigue
Behavior Of 6061 Aluminum Alloy.
REFERENCE

54.  Gajendra Singh Rathore1, Upendra Kumar Joshi2,Issue 3,
Vol.2 (May 2013).
 M.L. Roessle 1, A. Fatemi , Strain-Controlled Fatigue
Properties of Steels and Some Simple Approximations,
Department of Mechanical, Industrial, and Manufacturing
Engineering, The University of Toledo, Toledo, Ohio 43606,
USA,Received 20 February 1999; received in revised form 5
August 1999; accepted 4 February 2000.
 Jun Zhang, M.S, Study on Fatigue Life and Fracture
Toughness of Sheet Metal after Laser Forming, Washington
State University,School of Mechanical and Materials
Engineering, December 2003.
REFERENCE

55. GUIDE
………...STUDENTS………