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FINAL PROJECT PRESENTATION (3rd YEAR) - Copy
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- 2. 1/ The rollersare positioned in a pyramid configuration 2/ The top roller is vertically adjustable 3/ Two bottom feed rollers rotate in the same direction Feed rollers Top feed roller Material being rolled
- 3. Original conceptsketch for pyramid type slip rolls
- 5. Four phases ofmanufacture 1/ Cutting of all materials to specified dimensions 2/ Machining all components to specified dimensions 3/ Fabrication and Welding 4/ Assembly
- 9. Testing criteria 1/ Testingof a range of different materials 2/ Testing of a range of different thicknesses of materials 3/ Theoretical testing of machine using the formulae for simple bending theory 4/ Practical testing of machine using a range different materials in various thicknesses 5/ Establishing whether the theoretical testing is validated by the practical testing 6/ Record and tabulate practical testing results
- 10. Mild steel b =0.5m / d = 0.003m / y = 0.0015m / Yield (σ) = 210mPa I = 𝒃𝒙𝒅 𝟑 𝟏𝟐 𝒔𝒐 𝑰 = (𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟑) 𝟑 𝟏𝟐 𝒔𝒐 𝑰 = 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐 𝒎 𝟒 𝝈 𝒀 = 𝑴 𝑰 so M = 𝝈 𝒀 𝒙 𝑰 𝒔𝒐 𝑴 = 𝟐𝟏𝟎 𝒙 𝟏𝟎 𝟔 𝑵𝒎 𝟎.𝟎𝟎𝟏𝟓 𝒎 𝒙 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐 𝒎 𝟒 Therefore M = 157.5 Nm M = 𝑭 𝟐 𝒙 𝟎. 𝟎𝟒𝒎 so M = 0.02F so F = 𝑴 𝟎.𝟎𝟐 so F = 𝟏𝟓𝟕.𝟓 𝑵𝒎 𝟎.𝟎𝟐 𝒎 Therefore F = 7875 N
- 11. TABLE OF RESULTSFOR THE TESTING OF THE FUNCTIONAL LIMITS OF PYRAMID TYPE SLIP ROLLS TESTS MATERIAL b (m) d (m) Y (m) FEED ROLLER CENTRES (m) POINT OF MAXIMUM BENDING (m) S.M.O.A I (m^4) YIELD STRENGTH σ (Pa) MAXIMUM BENDING MOMENT (Nm) FORCE (N) STATUS TEST 1 STEEL 0.5 0.001 0.0005 0.08 0.04 4.16667E-11 2.10E+08 17.5 875 PASS TEST 2 STEEL 0.5 0.002 0.001 0.08 0.04 3.33333E-10 2.10E+08 70 3500 PASS TEST 3 STEEL 0.5 0.003 0.0015 0.08 0.04 1.125E-09 2.10E+08 157.5 7875 PASS TEST 4 STEEL 0.2 0.004 0.002 0.08 0.04 1.06667E-09 2.10E+08 112 5600 PASS TEST 5 ALUMINIUM 0.15 0.002 0.001 0.08 0.04 1E-10 1.25E+08 12.5 625 PASS TEST 6 ALUMINIUM 0.1 0.002 0.001 0.08 0.04 6.66667E-11 1.25E+08 8.33E+00 416.667 PASS TEST 7 COPPER 0.1 0.006 0.003 0.08 0.04 1.8E-09 2.68E+08 160.8 8040 PASS (AT LIMITS)
- 13. MANUFACTURING PLAN FORPYRAMID TYPE THREE ROLL SLIP ROLLS COMPONENT MANUFACTURING PROCESSES TIME TAKEN (Hours) WEEK STATUS RHS BASE FRAME CUTTING, DRILLING, WELDING 2 14 Completed THREADED INSERTS FOR RHS FRAME CUTTING, DRILLING, TAPPING, WELDING 2 14 Completed IDLE END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 15 Completed GEAR END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 16 Completed TOP ROLLER CUTTING, TURNING, 4 16 Completed BOTTOM FRONT FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed BOTTOM BACK FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed GEAR KEYS FOR BOTTOM FEED ROLLERS CUTTING, MILLING, FILING 4 17 Completed INTERMEDIATE GEAR SHAFT CUTTING, TURNING, MILLING 2 18 Completed INTERMEDIATE GEAR SHAFT KEY CUTTING, MILLING, FILING 1 18 Completed BRASS TOP ROLLER GUIDES CUTTING, DRILLING, FILING, MILLING 6 18 Completed BOTTOM LOCKING BLOCKS CUTTING, DRILLING, COUNTERSINKING 4 18 Completed TOP LOCKING BLOCKS CUTTING, DRILLING, COUNTERBORING 4 18 Completed THREADED ROUND SCREWJACK GUIDE CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed SCREWJACK TURNING HANDLES CUTTING, WELDING 2 19 Completed SCREWJACK TURNING HANDLE BODIES CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed RETAINING RING FOR BRASS GUIDES CUTTING, DRILLING, WELDING 2 19 Completed THREADED ROD CUTTING 1 19 Completed CRANKING HANDLE CUTTING, DRILLING, WELDING 2 19 Completed CRANKING HANDLE BOSS CUTTING, DRILLING, FILING,WELDING 2 19 Completed PRESSING BEARINGS HYDRAULIC PRESSING 1 19 Completed ASSEMBLY ASSEMBLING OF COMPONENTS AND TORQUEING OF BOLTS 4 20 Completed TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 21 Completed TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 22 Completed
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