automation in burnishing

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Proceedings of the National conference on Advances in Engineering, Technology and Applied Sciences SPANDAN-13.

AUTOMATION IN OUTER DIAMETER

BURNISHING MACHINE

Mangesh S. Raimal, Gopal P. Badarkhe, Ashay G. Kohad

B.E. 8th Sem.

Mechanical, Y.C.C.E., Nagpur

[email protected]

AbstractIn todays world of automation every industry wantsto make the machine tool or equipment automatic so as to

increase productivity; as automation reduces cycle time and

increases accuracy & efficiency. The company where we areapproaching to do automation has a burnishing machine where

round bars have been feed manually into the machine. Company

wants to make machine labour free by doing automation into it;

for doing so we virtually made mechanisms to feed bars

automatically and proposed these solutions to the company and

they have accepted it.

In first solution the mechanism has a conveyor belt with

grooves. Hopper is placed above the belt and one rod will occupy

space in groove and move forward to the burnishing chuck and it

will pushed inside with the help of plunger.

In second solution bars will slide and then it will be picked upby the clamps on the pulley then that clamp will come in front of

chuck & bar will be pushed inside with the help of plunger.

INTRODUCTION

Excel controlinkages pvt. Ltd. (situated at MIDC, Hingna,

Nagpur) is one of the leading manufacturer of control linkages

and automobile equipments. Different types of machines are

used in the company. One of them is mini centre less OD

burnishing machine which is used for super finishing

operation. Presently it is manually operated due to which

production rate is low. As company required more production

rate, we have given solution about automation in burnishing

machine.

Roller burnishing is a cold working process, which

produces a fine surface finish by the planetary rotation of

hardened rolls over turned parts. It improves surface structure

of turned part. Mini centre less OD burnishing machines are

suitable for small pins/shafts from 2 to 20 mm OD. In

company different jobs are burnished having diameters 4.7,

6.35, 7.8 and 9.5mm.

So we have virtually design portable, simple and flexible

bar feeding mechanisms and proposed these solutions to the

manager of company and they have accepted. This mechanism

consists of simple pulleys, clamps, belt, motor, plunger andsensors. This mechanism is simple in sense that it gets easily

detached from the actual machine, Also adjustment is

provided for varying length and diameters of bars.

Fig.1 Burnishing Machine

PROJECTOBJECTIVE

1. Automation in Mini Centre less OD BurnishingMachine to increase the production rate.

2. To provide a feeding mechanism of bars havingdifferent diameters and length.

3. To assist comfort for workers.
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METHODOLOGY

1. Project selection:-We have decided to work on the industrial

project as there is much scope to generate feasible

system and to assist our self to a level that it develops

our confidence and to generate some innovation.

2.

Problem identification:-We have searched for the problem faced by the

worker and different machines. After that we have

decided to automate the burnishing machine in sense

to design feeding mechanism of bars.

3. Study of machine:-We were visited the company weekly to study

the actual construction and working of machine and

taken all the dimensions and specifications to

generate the cad model.

4. Software used:-To generate cad model we have select CATIA &

PRO-E. We virtually design the CAD model and

proposed these models to the manager of companyand they have accepted these solutions.

FIRST SOLUTION

Jobs will be placed in hopper, from which they will

occupy place in grooves on belt. Then Belt will move ahead.

When sensor near pallet sense the job it will stop the motor as

the motor is stepper motor and at the same time actuate

plunger, which will push the job into the machine. Machine

automatically burnishes the job. When job returns back, again

sensor will sense the job and activate electromagnet which

will attract job and pull it out. At that point after some timelag belt will start moving. Again when sensor sense new job

same process will be repeated. At end burnish job will be

collected in pan. The adjustable plunger is provided for the

different length of bar & hopper is provided for different

diameters.

fig.2 View 1 Bar Feeding Mechanism

fig. 3 View 2 Bar Feeding Mechanism

SECOND SOLUTION

Set of Pins will be placed in hopper. Motor starts, then

one pin will be picking up by clamp. Then in next pulse motor

rotates and clamp will reach to the next position.(i.e. in front

of the pallet) Pin gets sensed by sensor. Considering some

time lag plunger will get activated and push the pin into the

burnishing machine pallet. Burnishing process will start.

Sensor will sense the returning pin and activate electromagnet

which will pull the rod from machine. Considering some time

lag, motor will start and clamp will rotate and release the pin

into the collecting pan. Again same process will be repeated.

Angle positions are

1. 0 to120Clamps are in close condition2. 120 to 360Clamps are in open condition

fig 4 View 1 Bar feeding mechanism


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Fig. 5 view 2 bar feeding mechanism

SCOPE

1. The project on which we are working is feedingmechanism of steel bars of varying length and

diameters; as these bars are of varying length and

diameters the feeding mechanism has a adjustable

plunger for length and hopper for position change forvarying diameters.

2. The feeding mechanism provided is totally detachableso that we can use it in another machine of same

purpose also.3. This mechanism is also use to convey material of

round shape and in length.4. By providing magnetic attachment we can use this

mechanism for separation of different material which

has got mixed

Conclusions

1. Due to automation in Burnishing Machine, productionrate increases.

2. Due to automation in Burnishing Machine, machinecan be operated without involvement of labour.

3. Due to automation in Burnishing Machine, efficiencyof material handling increases.

4. Due to automation in Burnishing Machine, we canremove bar from machine at exact time due to which

processing errors are reduced. This means that if bar is

not removed on time it may get damaged.

5. Due to automation in Burnishing Machine, overalllabour cost required is reduced.

ACKNOWLEDGMENT

Apart from our efforts, success of any project depends

largely on the encouragement and guidelines of many others.

We take this opportunity to express our gratitude to the people

who have been instrumental in the successful completion of

the project.

It is with deep sense of respect that, we would like to

show our greatest appreciation to our guide Prof S.S.Akant for

his valuable guidance, constant motivation, encouragement

and other useful suggestions during the course of our project.

We express our deep gratitude to Mr.Avinash Lanjewar

(senior manager) and complete crew of EXCEL CONTROL

LINKAGES Pvt Ltd. For their time to time guidance,

cooperation, encouragement and feedback on this project

report.

The dossier of knowledge that we have gained from

them will surely be an asset for us in our professional career

ahead.

Last but not the least I would like to thank all those

people who were directly or indirectly involved with the

completion of the project.

REFERENCES

[1] www.excelcontrollinkage.com[2] www.wikipedia.com[3] www.mechindia.com[4] Automation, Production System, and Computer Integrated

Manufacturing by MIKELL P. GROOVER

[5]

Production Technology by R. K. Jain
http://www.excelcontrollinkage.com/http://www.excelcontrollinkage.com/http://www.wikipedia.com/http://www.wikipedia.com/http://www.mechindia.com/http://www.mechindia.com/http://www.mechindia.com/http://www.wikipedia.com/http://www.excelcontrollinkage.com/

automation in burnishing

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