UNIVERSITY OF MORATUWA

Faculty of Engineering

Non-GPA Module 3992: Industrial Training

TRAINING REPORT

Dynamic Technologies (Pvt) Ltd

From 20/10/2014 to 10/04/2015

Srikandaraj.S

110554K

Department of Mechanical Engineering

2

i

PREFACE

This report on Industrial Training covers all aspect of Mechanical Engineering Principal

covered at the company during the 25 weeks of training started at 20th October 2014 and ended

on 10th April 2015.The report includes manufacturing of Pneumatic conveying equipments

and its processes involved during working conditions. Details on practices involved in using

Design software is also described in the context along with the manufacturing processes. The

report also describes the Activities and documentations that were carried out during the ISO

documentation process and management activity.

ii

ACKNOWLEDGEMENT

The success of this training would not have been possible without the ceaseless co-

operation of some valuable people, whose guidance and encouragement let me to reach my

final goal.

My ever gratitude goes to Mr. Asoka Dharmawardana, CEO of Dynamic Technologies

Pvt Ltd for giving us the training opportunity at the company.

I would also like to thank to our Engineer in charge Mr. Prasad Weerasinghe and Hirosh

Wickramasinghe for their friendly support and guidance that helped me to complete this

training successfully.

I would like to convey my heartfelt gratitude to the staff of Dynamic Technologies Pvt

Ltd for spending their valuable time to provide precious information to complete the training.

Also special thanks go to Industrial Training Division of University of Moratuwa, and staff

members of NAITA.

Finally my gratitude goes to my team members, parents and my dear colleagues for the

encouragement and the massive support given in the successful completion of this Training.

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Contents CHAPTER 1 ........................................................................................................................................... 1

1.1 Introduction to the Training Establishment .................................................................................. 1

1.2 SWOT Analysis ............................................................................................................................ 2

1.2.1 Strength of the company ....................................................................................................... 2

1.2.2 Weaknesses ........................................................................................................................... 3

1.2.3 Opportunities ......................................................................................................................... 4

1.2.4 Threats ................................................................................................................................... 4

1.3 Production and Improvements ...................................................................................................... 5

CHAPTER 2 ........................................................................................................................................... 6

2.1 Screw Conveyor Design ............................................................................................................... 6

2.2 Training on Pneumatic Conveying Process .................................................................................. 8

2.3 Silo Vent Filters Production ....................................................................................................... 10

2.4 Scissor Lift Design ..................................................................................................................... 12

2.5 Rotary Feeder design .................................................................................................................. 14

2.6 Solid works Sheet Metal Training and Production ............................................................... 15

2.7 ISO 18001 & ISO 9001 Audit Reporting Training..................................................................... 16

2.8 Blower Design ............................................................................................................................ 17

2.9 Tank Truck Parts, Pump and Compressor Manufacturing ......................................................... 19

2.10 Hydraulic Punch Design Research ........................................................................................... 20

2.11 Flipper Arm Design .................................................................................................................. 22

CHAPTER 3 ......................................................................................................................................... 23

3.1 Conclusion .................................................................................................................................. 23

ANNEXES .............................................................................................................................................. v

Annex - A ........................................................................................................................................... v

Annex - B .......................................................................................................................................... ix

Annex - C ........................................................................................................................................ xiii

Annex - D ........................................................................................................................................ xvi

Annex - E ........................................................................................................................................ xxii

iv

List of Figures

Figure 1-Screw Conveyor Assembly ..................................................................................... 6

Figure 2-Screw Conveyors .................................................................................................... 7

Figure 3-Screw Trough ......................................................................................................... 7

Figure 4-Silo Vent Filter ..................................................................................................... 10

Figure 5-Pleated Filter Elements ......................................................................................... 10

Figure 6-Square Silo Vent Filter .......................................................................................... 11

Figure 7-Simulation of Silo Vent ......................................................................................... 11

Figure 8-Scissor lift Assembly ............................................................................................ 12

Figure 9-Rotary Feeder Assembly ....................................................................................... 14

Figure 10-Rotary Feeder Impeller ....................................................................................... 14

Figure 11-Y joint Reducer ................................................................................................... 15

Figure 12-Y Joint Reducer .................................................................................................. 15

Figure 13-Blower Design Software ..................................................................................... 17

Figure 14-Master Copy Design ........................................................................................... 18

Figure 15-Impeller Design .................................................................................................. 18

Figure 16-RTL-80 Compressor ........................................................................................... 19

Figure 17-Foot Valve .......................................................................................................... 19

Figure 18-Discharge Valve .................................................................................................. 19

Figure 19-Hydraulic Punch ................................................................................................. 20

Figure 20-Stress Analysis of Hydraulic Punch ..................................................................... 20

Figure 21-Displacement Analysis ........................................................................................ 21

Figure 22- Second Alternative Design's Stress Analysis ...................................................... 21

Figure 23-Flipper Arm ........................................................................................................ 22

Figure 24-Flipper Arm Top Body ........................................................................................ 22

Figure 25- Foot Valve .......................................................................................................... vi

Figure 26-Discharge Valve ................................................................................................... ix

Figure 27-Vent ................................................................................................................... xiii

Figure 28-Female and Male Coupling ................................................................................ xvi

Figure 29-Female Coupling ................................................................................................ xvi

Figure 30-PTO Pump ........................................................................................................ xxii

v

List of Tables

Table 1-Scissor lift bill of material ...................................................................................... 13

Table 2-Part list Foot Valve................................................................................................... v

Table 3- Part list Discharger ................................................................................................. ix

Table 4- Part list Vent ........................................................................................................ xiv

Table 5- Part list Female Coupling .................................................................................... xvii

1

CHAPTER 1

1.1 Introduction to the Training Establishment

Dynamic Technologies (Pvt) Ltd was established in 1993 by a sole proper tier named Asoka

Dharmawardena. The headquarters of the company is situated at New airport road Ratmalana

and the second workshop is situated at gall road Ratmalana and the bouser and bulk carrier

manufacturing plant is situated at Pallekala Kandy.

The company specializes in manufacturing the following

* Trailers

* Road Tankers and tanker equipment

* Cement Bulk Carriers

* Truck Bodies

* Bulk Material Handling Equipment

* Silos, Bins, Hoppers, Screw Conveyors

* Pneumatic Conveying Equipment

* Machinery Fabrication

The main clients of the company are mostly cement producing companies such as Holcim and

Lafarge. The company also produces oil bousers for Ceylon Petroleum Corporation and private

petroleum companies. The company also producers pumps which are used in oil bousers (PTO

pumps) and compressors which are used in cement bulk carriers for pneumatic conveying

purposes.

The company manufactures and owns several cement bulk carriers which are used to transport

cement powders. The company also specializes in manufacturing screw conveyors, sliding

gates and various dust collecting system and air-condition ducts. The company also

manufactures customized machinery equipments according to the clients specifications.

As another new initiative the company has started manufacturing blower units with the help of

an Indian Consulting Company. The in house gantry cranes were also designed and

manufactured by the company itself and as another initiative the company also seeks to

manufacture gantry cranes for external clients.

The training for the undergraduate was conducted in the headquarters work shop where the

training schedule includes the aspects of manufacturing and machine design and as the

company has received the ISO 18001 and ISO 9001 a special training was given ISO

documentation and layout preparation of the workshops.

2

1.2 SWOT Analysis

1.2.1 Strength of the company

The company has specialized in making cement plant machineries, bulk carriers, oil bouser,

bouser valves and pumps. The workers are highly trained in the manufacturing process of the

above mentioned products. The company possesses highly trained engineers in producing

pneumatic conveying equipments.

Since the company is well established in the manufacturing and designing sector it has a well-

established supply chain. Apart from steel material which obtained from well-established

importers such as A.C.Paul, other equipments such as gear motors are directly imported

through a subsidiary company named Magnum Technologies hence delay time in receiving

material reduced.

The machinery available in the workshops are very well sufficient for the production of the

company and investments are frequently made for new machinery for example a 10 ton gantry

crane is being made in the Ratmalana II workshop for heavy lifting. In both the workshops

situated in Ratmalana separate machining facilities are available for machining purposes.

Machines available at the workshops are

Lathe Machine with various bed sizes

Bending and flanging machines

Automatic profile cutters

Milling machines

Vertical and horizontal boring machines

Steel plate rolling machine

H iron rolling machine

Shearing machine

Drilling machines

All the above machines are serviced properly and all the workers trained properly to use it

safely and efficiently. The company manages work by also hiring external contractors for

working in sites for the installation of manufactured equipments. Another important

fabrication aspect is welding in which the company has well trained and welders who

specialized in Arc, Tig and Mig Welding.

3

1.2.2 Weaknesses

One of the biggest inefficiency of the company is material wastage since no technique was

used to cut off steel plate is used properly. Most of the time the company orders are prioritized

as urgent and hence if material delay is encountered from a frequent supplier a more expensive

material is bought from a different supplier and hence higher cost is encountered.

Another inefficiency is the rise of labour cost due to lack of planning of the project. The

company does not use any project management softwares to have parallel ongoing project and

has to pull labour from one project to successfully finish another project. The idle time of

workers are also relatively high due to lack of planning and hence huge amount of overtime

has to be done to complete projects in time. The labour force is motivated to over time to

complete project hence the company is very lenient in its overtime policy for employees.

Quality control is another problem hence no records of control is properly maintained for future

references so that any problem regarding the manufactured projects could be easily rectified.

For example if a screw conveyor is made the dimensions of the plates must be checked with

the relevant drawings and deviations must be recorded and corrected. This practice would

highly reduce the mistakes that could occur in future projects.

Store keeping is one of the big issues in the workshop. Tools are not distributed to workers

based on projects and hence the tools get misplaced very often. The store keeping is not done

properly and no proper records are maintained on who is using the tool.

Even though products are designed using Solid Works, Auto CAD and Inventor no proper

simulations were done on the projects to look upon on structural strength and its feasibility and

hence most of the products are over designed. Over designing products has incurred huge cost

on usage of material.

4

1.2.3 Opportunities

Huge opportunities exist on the sector of machinery manufacturing for the company and bulk

carrier and bouser manufacturing. The has huge expertise manufacturing screw conveyors and

belt conveyors and these conveyors not only applicable for cement manufacturing and could

be used food processing machines, for example recently the company received orders to make

stainless steel shredder and hoppers from PRIMA and there many companies such as PRIMA

in need of efficient production technology.

Recently the company has sent its engineers to India to be trained in blower manufacturing

technology. These blowers are to be made using the Keith Blackman Blower technology. The

blowers will be mainly aiming dilute phase pneumatic conveying technology and HVAC

engineering. The demand for blowers have increased as new cement plants are being opened

in Srilanka.

1.2.4 Threats

Manufacturing industry is a highly competitive industry where new technologies in order

improve cost cutting and quality and also to improve the efficiency of production. But this

company does not have R & D facilities to create new products and machines and to do cost

cutting research. This one of the main threats as other companies such Load Star has a

modernized R & D facility.

5

1.3 Production and Improvements

New investments has be bought into the company to increase efficiency and cut costs for

example screw flights are manufactured manually in this company but it could improve its

efficiency by investing screw flight making machine which reduce the cost of making the screw

and the labour intensity of the production. It will also improve the quality of the products it

makes which increase the value of its brand name.

Another important factor is that the company invest more on safety and to develop the

workplace environment to easy place to work so that human resource would be retained for a

very long period of time.

6

CHAPTER 2

2.1 Screw Conveyor Design

Screw conveyors are manufactured in the company for cement manufacturing clients and food

manufacturing clients. The material used for manufacturing the screw conveyors are Mild Steel

plate and stainless steel plates. The most important aspect of the screw conveyor is the pitch of

each flights and the trough size.

Figure 1-Screw Conveyor Assembly

The manufacturing process of the screw conveyor is quite complex. The pitch and the height

of the flight are determined by the flow rate required by the client through the conveyor. The

main components of a screw conveyor are,

Screw flight

Screw trough

Flight carrying pipe

The end shafts

Inlet and outlet

Hanging bearing

Pillow blocks

Inspection door

7

Mostly the screw conveyors manufactured in the

company uses Mild steel plate to produce screw

flights for normal usage but if the usage involves

heavy corrosive environment the a special hardox

plate is used and if the conveying involves food

processing stainless steel is used as the material.

When stainless steel is used as material to produce

the screw conveyor special care has to be taken

when welding the material. Stainless steel welding

rods are used and at the end a special acid is used

to wipe away the burned marks off the material.

Each of the screw flights are cut separately using the plasma arc profile cuter as circular shape

and then each flights are pulled using workshop made manual puller to the required pitch and

then each of the flights are welded together and a spiral of flights are formed. Then the screw

pipe is set on a stand and the spiral of the flights are inserted onto the pipe.

Then one end of the spiral shape is welded to one end of the pipe and the other end is puled

using a chain and a lever block until the correct pitch is accurately obtained. Welding tacks are

put in important places of the flights to maintain pitch until complete welding is done.

The end shaft that is used to end of the pipe to couple the screw with the motor is machined at

the machine shop. The end shaft machined with a taper at the inserting side of the shaft so that

the pipe could be inserted easily inside the pipe. The shaft inserted tight fit into the pipes and

then welded together. A hydraulic jack is used to insert the

shaft inside the pipe.

The screw trough is the outer body of the screw and it is

formed in circular shape or half circular shape depending on

the clients request. If a circular trough is required a pipe is

used to form the trough if a half circular trough is required

Mild steel plates are rolled to obtain the required shape and

flanges are welded to each end of the screw trough. A cover

has to be made to cover the top of the half circular trough

and mostly circular trough screw conveyors are used in

inclined position conveying.

Figure 2-Screw Conveyors

Figure 3-Screw Trough

8

2.2 Training on Pneumatic Conveying Process

A special training was given on Pneumatic conveying systems where air is used to convey

particles from one place to another. This process is mostly used in cement production where

most of the raw materials are in powder form. The ideal candidate for pneumatic are free

flowing non-abrasive and non-fiber material.

There are four distinct zone in a pneumatic conveying system.

1. The prime mover

2. Feeding, mixing and acceleration zone

3. The conveying zone

4. Gas-solids separation zone

The prime mover consists of blowers, fans and compressors which provides the necessary

energy to the conveying gas to carry to solid particles. A wide range of pressure is used to for

the transportation of solids and additional functions such as drying cooling and filtering could

be implemented in the in prime mover component.

Feeding is done through various mean depending on the density of the conveying material, the

feeding could be done through blow tanks for dense phase systems and rotary feeders are used

in dilute phase pneumatic conveying systems. In this particular zone solid are introduced into

the flowing gas and large change of momentum occurs. Acceleration of the particles are also

done using in between air flows inside in the pipes.

Once the solids have passed the feeding and the acceleration zone they enter into the conveying

zone. The conveying mainly consist of piping and consideration has to be given to reduce ware

and frictional losses and maintain the required pressure requirement. The conveying zone

consists of the following areas,

1. No of bends

2. Diverter valves

3. Dampers

4. Air slides

5. Small acceleration zones

Small acceleration zones are present after every bends to compensate losses at the bend.

Diverter valves are used to change direction in conveying process. Air slides is another

important aspect.

9

In normal condition the a 45 degree angle inclination is required for the gravitational fall of

particles but when particle are levitated using air the flowing inclination could be reduced to 4

degree of angle. This reduction has reduced the cost of building the pneumatic convey system

and has improved the efficiency.

The gas solid separation consists of silo vent filters and conical filters. This stage consists of

several stages of separation zone depending on particle sizes that are being filtered. Conical

filters are used to separate heavy particle and used at the beginning of the zone and silo vent

filters used on top of silos and are used to separate very fine particles.

There two different modes of pneumatic conveying they are

1. Dilute phase systems

2. Dense phase systems

In Sri lanka most of the systems involves dilute phase pneumatic conveying systems. In this

system blowers are used as prime movers and the particles inserted in to the moving air by

means of rotary feeders. The rotary feeders air lock feeders where the particle is fed into the

system using air lock mechanism.

In the dense phase system particles are conveyed using air compressors and a special blow tank

is used pressurize the particles. The particles conveyed in pockets through the pipe and this is

achieved by means of air knife. In the blow tank the particle are in a fluidized stage by means

of flowing air.

Dese phase systems are used in high pressure low flow rate application. In these system wear

and frictional losses are less as the system is a slow system and much cost effective. High

pressure multi impeller blowers could also be used to power the particles.

Dilute phase systems are used in high velocity low pressure application and special feeding

systems are implemented to feed the particles inside the moving air. In this system wear and

frictional very due heavy impact of particles with the wall of the system.

10

2.3 Silo Vent Filters Production

Silo vent filters are used on top of the cement silos to filter fine cement dust particles at the exit

of the pneumatic conveying system. Pleated filter elements are used to at this silo vent filers

manufactured in the company.

These filter elements are air tightly fitted to tube sheet using pieces of c-channels and the

sometimes venturi element is fixed with the tube sheet to fix the pleated elements. The filter

elements are cleaned using reverse jet air flow from compressor to blast of the dust particles

adhered to the filter elements. A solenoid valve is used to control the air flow time and circuit

is placed in an enclosure box.

Circular cylinder is obtained by rolling a steel of 4mm thickness and welded at the end and the

small cylinder to for compressed gas to exist is obtained by using a pipe. Another special design

is the inspection door where it is designed to sealed even when the door not tight locked by

butterfly nuts. The operator need to pull the door forward before you could open it wide. This

door ensures that the filter element does not get wet by any means of water get inside the filters.

The top lid of the silo vent filter is manufactured using sheet metal spinning and a rolled circular

sheet is welded to the end of the spinned lid. The manufacturing of the circular type silo vent

filters are complicated and its very time consuming to weld the holders of the air cylinder and

the inspection door and hence a new design has is been done and the shape was of silo vent

filter is made in rectangular shape so that the parts that has to be welded to filter could be easily

placed at the exact position.

Figure 4-Silo Vent Filter Figure 5-Pleated Filter Elements

11

The new design was tested using the Solid works simulation by applying load 500N to the

casing to observe any failure structure and was optimized to bear the load of the air cylinder

which is attached to the silo vent filter.

A problem was encountered after the design at bottom flange of the filter. Usually silo tops are

in conical shape and in the original circular shaped silo vent filter fixing it to the top of the silo

vent filter will not be an issue as it is circular shaped but in the square shaped silo vent filter a

transition of rectangular to circular has to be made in order fix the new silo vent filter.

Figure 6-Square Silo Vent Filter Figure 7-Simulation of Silo Vent

12

2.4 Scissor Lift Design

Figure 8-Scissor lift Assembly

A scissor lift was being asked to be designed by the trainees and as a team the above scissor

lift was designed. The lift is capable of lifting 5 ton of weight. The calculation was done based

on virtual work theory experiment which is annexed in this report.

Safety was the main aspect when designing this scissor lift and hence two hydraulic jacks were

placed in two different optimum weight handling places. From designing this scissor lift more

knowledge was gained on using standard components such as I beams and box bars. ISO

standard structural elements are used here.

More knowledge was also obtained in using and handling Solid works when modelling this

software and using standard element from Solid works tool box. The calculation as mention

above was taken from journal paper and the research emphasizes on the optimum placement of

the hydraulic cylinders for optimum weight handling.

13

Total material cost was 434000/- LKR and a bill of material was also prepared using the

current market price of structural elements.

Table 1-Scissor lift bill of material

From this designing assignment a better knowledge was obtained on the aspects of

fabrication and costing when commencing new projects.

14

2.5 Rotary Feeder design

3 Rotary feeders were overhauled for repairing

purposes. Rotary feeders were an important

aspect in pneumatic conveying systems. In the

dilute phase pneumatic conveying system

particles are fed through rotary feeders. It also

functions as an air locking mechanism where

backward air flow in to the hopper is blocked

and particles carried in feeder pockets and fed

into the flowing air of the pneumatic conveying.

The obtained rotary feeders showed heavy ware on the edges of the rotating impeller inside

feeder casing. The project involved in filling the edges using welding and machined in the

lathe.

The shaft, coupling to the motor also has to be machined as it showed heavy ware due to

unsymmetrical loading and a new bearings also was installed. From this project knowledge

was obtained on overhauling heavy equipment and

filling of worn components. A separate solid works

drawing was asked to drawn for future references.

This figure shows filling of the worn edges and

machining. A special rubber material is also fixed to

the edges of the impeller of the rotary feeder.

Figure 9-Rotary Feeder Assembly

Figure 10-Rotary Feeder Impeller

15

2.6 Solid works Sheet Metal Training and Production

Various shapes of reducers were asked to be drawn, by

the engineer to provide drawings for production. Solid

works sheet metal was used to draw and obtain flat

pattern drawings for the purpose of manufacturing.

One of the challenging task to draw was the Y joint

reducer where it was challenging to draw combining

both the shape of Y joint and the reducing aspect.

Another important factor is that various commands

such as Edge flange, Flat pattern, and Loft pattern to sheet metal conversion were learned in

this training.

Opportunity was also given to participate in the manufacturing process of the sheet metal

reducers with the help of workers.

Through the production training various skills were obtained such as using the sheet metal

bending machine and rolling machine to form the required profile.

Another problem occurred during the production of the Y Joint reducer because of its complex

profile. While bending the edges of the side curve the correct profile could not be obtained and

hence the side bend was adjusted by using the hammer after welding it to the main structure.

The training obtained from this exposure provided us with knowledge on sheet metal

fabrication and its importance.

Figure 11-Y joint Reducer

Figure 12-Y Joint Reducer

16

2.7 ISO 18001 & ISO 9001 Audit Reporting Training

The company taken the ISO certification a year back and training opportunities were given by

an Indian consultant and were taught on producing various documentation for ISO audit

purposes. The documents that were prepared for the Rathmalana branch were,

Hot work Permit

Height work permit

Job safety analysis form

Fire Training guide

Quality Control Reports

Tool Box Meeting

Apart from only doing documentation we were asked to draw a new layout of the workshops

Rathmalana 1 and Rathmalana 2. The layout has to be drawn in a manner so that movement

inside the work safe and easy.

ISO 18001 is all about Occupational health safety standards and we were asked to prepare a

list of safety issues related to current work shop condition in order to rectify it and improve the

safety condition.

ISO 9001 is all about quality control on production and a Microsoft Access based quality

control creating system was developed in order to make documentation easy for the engineer

or supervisor.

We also prepared a list of machines available in both the work shop and created safety report

on all machines and conducted an awareness program for the workers with the help of the

safety officer.

Vital amount of knowledge on ISO 18001 and 9001 was provided to us with management

advices was provided to us by the Indian consultant.

17

2.8 Blower Design

The company has initiated new plans to start manufacturing blowers for the industry. An Indian

company was consulted for the new plan and has obtained rights to manufacture blowers based

on Keith Blackman series blower specification. Training opportunity was given to design

blowers using solid works based on Keith Blackman specification. A software was given by

the Indian company which shown below

From the above software a blade no could be obtained based on the impeller diameter and using

the diameter and using Keith Blackman hand book the correct profile of the housing and the

impeller could be selected. A master copy of the profile of the housing was also given by the

Indian company so that the relevant scaling factor could be used to construct the housing.

The master copy was cross checked by actually drawing fan under the specification provided

by the software provide and there were no noticeable difference between the scaled drawing

and the real drawing created using Auto CAD.

Figure 13-Blower Design Software

18

A Solid works drawing of the impeller was also obtained to

observe the reliability of the obtained data from the software as

well as the handbook.

The Engineer in charge Mr.Hirosh Wickramasinghe shared his

knowledge on manufacturing blowers as he was trained by the

Indian consulting company. We were taught on different sub parts

that accompany the blower unit which increases its efficiency.

The training also provided guidance in the selection of material and structural design to cope

with the vibration produced by the fan and also to produce fans with less noise.

Figure 14-Master Copy Design

Figure 15-Impeller Design

19

2.9 Tank Truck Parts, Pump and Compressor Manufacturing

The company producers the following which are regularly manufactured in the company for

assembling purposes for the bousers and bulk carriers which they make in the Pallekala

workshop.

Foot Valve

Discharge Valve

Tank Vents

Female and Male coupling

PTO Pumps

RTL -80 Compressor

Training opportunities were in the production of each

products mentioned above. The production and features detail

of these products annexed in this report separately as a

production report.

These products were made based worker experience and no

documentation existed in the company for any references and

we were asked by the engineers to create a production report

on the above mentioned products.

Measurements were taken from the samples and complete

drawings were created for these components and a report was

written mentioning the manufacturing techniques and features

of the products designed.

Information on testing of these parts are also mentioned in the

report. Knowledge on production of these parts obtained by getting involved in the production

and testing of these part with responsible workers. The workers eagerly assigned us tasks to

experience the methodology of the manufacturing practice of these products.

Figure 16-RTL-80 Compressor

Figure 17-Foot Valve

Figure 18-Discharge Valve

20

2.10 Hydraulic Punch Design Research

A 40 Ton hydraulic Punch was asked to be designed

using the off cut pieces of steel plates and steel blocks.

The engineer in charge was Mr. Prasad

Wickramasinghe.

Two alternatives were proposed one is to use 25mm

plates to create the outer structure or to a solid steel

block to create the structure.

According the proposed design the hydraulic cylinder

will have a diameter 110mm and will joined to the

structure using thread connection for high stability

A 50 ton weight was applied to the structure when the simulation is done using solid works

simulation the mesh setting given was very fine to obtain accurate results but the time

consumed for processing was very high. The stress plot above shows a shear strength failure at

the inside edge of the structure.

Optimization was carried out to reduce impact due to stress on that area but with addition of

material cost and weight increased. Weight of the total assembly according to Solid works was

100kg which could still be lifted using a fork lift and could be made portable.

Figure 19-Hydraulic Punch

Figure 20-Stress Analysis of Hydraulic Punch

21

Another problem involved with the

structural strength is that the plates are

going to be welded to each other. The

connection type resembled in the solid

works simulation is rigid connection

which 100% match the welding

connection and hence in practical

situation the load which the structure

withstand is much less than the expected

40 ton weight.

This figure shows the simulation done for a solid steel

block and it shows a more positive results but still

using plates is cheaper to make than using a solid steel

block. If a more strong material than Mild Steel is

used one could expect a much positive result.

From this research thorough knowledge of using solid

works simulation and motion study was obtained.

Figure 21-Displacement Analysis

Figure 22- Second Alternative Design's Stress Analysis

22

2.11 Flipper Arm Design

Flipper arms are manufactured in the company for

Srilankan Ports Authority. Flipper arms are merely guiding

arms used in cranes lifting container boxes. One of the

important aspects that needs to be taken care of when

manufacturing the product is that inside edge of the flipper

should be exactly 90 degrees otherwise the container box

will not properly align with the crane hooks.

Knowledge on making jigs were obtained from the project

where 90 degree jig has to be made by using a sample

flipper arm sent by the client

The required amount material was calculated and amount

of steel plates needed for project was submitted. Training

was obtained on using the profile cutter using Auto cad drawings.

One of the biggest problems that has happened on one of the previous manufacturing process

was that the when welding has been done to the bush due to heat a small deflection has taken

place and hence the inside edge was not aligning properly with the container box.

In the current project the trainees were an opportunity to supervise and make a quality control

report to the engineer. Each dimensions of the drawing were cross checked with original sample

and reported. The project also provided great amount training in fabrication of steel plates for

example arc welding, plasma arc cutting and grinding.

Full guidance of the workers given in the fabrication

process of the flipper arm. The bush that connects the

shaft is machined properly so that no misalignments and

this in order to prevent the previous error the bush will

not be welded at the work shop but will be welded on

site while assembling it to the crane.

Another important thing considered is that in order to

have proper alignment the steel plates were tacked

together prior drilling holes for bolts.

Figure 23-Flipper Arm

Figure 24-Flipper Arm Top Body

23

CHAPTER 3

3.1 Conclusion

A vast amount of knowledge on mechanical engineering principal and practices was obtained

from the Industrial Training at Dynamic Technologies Pvt Ltd. A thorough understanding

pneumatic conveying and its principals were obtained from this training session. The company

staff were eagerly sharing the knowledge which they accumulated along all these years with

us.

A thorough knowledge on manipulation soft wares such as Solid Works and Auto Cad was

obtained during the training process and were taught on the industrial application of the theses

software. More emphasis were given structural simulation studies using Solid works

Simulation 2014.

The workers eager to share their knowledge on manufacturing activities there were keen to

make us get involved in manufacturing procedure of the products.

A thorough knowledge on ISO 18001 and 9001 certification was provided to us from the Indian

consultant and we were able to contribute the company our share of work on ISO

documentation requirements and workshop layout arrangements.

There were other activities which were also done during the training period, they are

Motor winding introduction

Gantry crane manufacturing for the workshop

Interpenetration curve drawing using Solid works

Basic training on Aluminum sheet rolling machine

Flow simulation basics

Introduction to Ansys work Bench

Supervision and Managing work forces

The above mentioned were only basic introduction and observation activities and hence not

include in the context of training experiences.

The engineers in charge

Mr. Prasad Weerasinghe

Mr.Hirosh Wickramasinghe

Provided us with all the help in achieving the required goals throughout the training session.

24

Training was also given to us the following contexts as well

Managerial

Costing

Human Resource Management

Ware house management and Stock control

These were related to the ISO documentation practice.

The training obtained from the company is a valuable asset for Mechanical Engineering

Students who have and will undergo training at this place.

v

ANNEXES

Annex-A

Valve production

Foot Valve

Private valves are type of foot valve which are used in oil tanks in order to prime the pump and

to maintain continuous flow. The valves are based on the Emco tank truck valve configuration.

Features

o High quality die cast body and component materials to international standards for durability and performance

o Lightweight aluminum construction for increased payloads o Self-centering plunger and durable compression spring o Removable bonnet assembly enables easy seal change o Parts common to other valves in our range to minimize spares inventory o Hydrodynamic body design minimizes pressure drop to give high flow rate o Viton seals are standard for compatibility with high-octane fuels and additives

Table 2-Part list Foot Valve

NO Part Name Material Form of Material

1 Piston Rod Aluminum Casting

2 Spring Plunger Aluminum Casting

3 Spring - -

4 Piston(Rubber holder) Aluminum/Steel Casting

5 Foot Valve Rubber Rubber -

6 Piston nut Aluminum Casting

7 Filter Mesh Aluminum Mesh

8 Valve Housing Aluminum Aluminum

vi

Figure 25- Foot Valve

vii

Valve housing

Initially the castings are obtained from the supplier .Then each end of the valve is

machined to obtain the required thickness of the flange. The outlet and the inlet

openings were also machine to obtain the required thickness. The valve seat is

machined to reduce its surface roughness so that the rubber washer is properly seated

and prevent leakages.

Then four slots are cut in equal circular displacement around the inlet edge to fix the

spring holder through it and fix it with a twist. The filtering holes are then filed to obtain

the smooth edges. Since the housing is made of Aluminum the slots are cut using the

hack saw.

Using the tap drill 4 holes are drilled so that the plunger could be firmly fixed to the

valve body using an M6X1mm nut.

Spring Plunger

This part is also obtained as Aluminum casting and then the in groove of this plunger

is machined properly so that the spring could be placed inside with perfect fit. Outside

four slots are drilled and filed on the four protruding segments. These are made for

fixing the plunger with a valve housing and with the spring inside.

The plunger is fixed inside by using the twist and fix mechanism with valve housing.

Piston nut

The seat bottom nut casting was obtained and the bottom part is machined to obtain a

concave surface so that the rubber washer is fixed and aligned properly and the nut is

tapped to obtain a M18 nut thread with a pitch of 2.5mm.

Valve Seat Piston

The valve seat piston is also obtained as a casting and a circular groove was cut into the

piston so that the rubber washer could be placed in that groove tightly. The grooves are

fine finished properly so that the rubber washer could be placed tightly.

Piston Rod

The rod which is obtained as an Aluminum casting is also machined to obtain the

required diameter. The outer thread is also of the same type of pitch which is 2.5mm.

viii

The other parts such as

1. Spring.

2. Valve Rubber.

3. Filter Mesh.

Were supplied by external suppliers.

ix

Annex - B

Discharge valve

Discharge valve is a valve for controlling the rate of flow from the pipe or tank. This valve is

used in the oil, fuel and milk bowsers to discharge the inlet of the bowser. The idea behind the

discharge valve is that it provides the ability to adjust that flow in order to respond to situations

that require a change in the volume or speed of the flow.

Discharge valve mainly consists of nine parts.

Figure 26-Discharge Valve

Table 3- Part list Discharger

PART NO DESCRIPTION QTY

PART - 01 Valve Body 1

PART - 02 Barrel Nipple 1

PART - 03 Outer Cap 1

PART - 04 Key 1

PART - 05 Gland Cover 1

PART - 06 Tongue 1

PART - 07 Valve 1

PART - 08 Hexagonal Cap 1

PART - 09 Spring 1

x

Part 1 Valve Body

Valve Body acts as a housing for this valve. 1st the valve body was machined to get the desired

thread sizes. Then the Rough edges were removed by filing & smoothened the surface using

sand papers.

Material Aluminum

Manufacturing method Metal casting

Thread gauge 18 (inch) for Barrel Nipple & Hexagonal Cap

Thread gauge 18 (inch) for Gland Cover

Part 2 Barrel Nipple

This part is used to connect the pipe inlet with the valve body. This is a metal casted item. 1st

the Barrel Nipple was machined to get the desired thread size. Then the Rough edges were

removed by filing.

Material Brass

Thread gauge 18 (inch)

Part 3 Outer Cap

This part is used as a lid for this valve. 1st the Outer Cap was machined to get the desired thread

sizes. Then the Rough edges were removed by filing & smoothened the surface using sand

papers.

Material Aluminum

Manufacturing method Metal casting

Thread gauge 18 (inch)

Part 4 Key

This part acts as a connector between tongue & the opener. The desired shape was taken by

filing.

Material Brass

Manufacturing Method Metal casting

xi

Part 5 Gland Cover

This part is used to tighten the gland. This is made from a hexagonal brass shaft by machining.

Material Brass

Thread gauge 18 (inch)

Part 6 Tongue

This part is used to open the Valve by pressing. This is a metal casted item. Desired dimensions

were taken & the rough edges were removed by filing.

Material Brass

Manufacturing Method Metal casting

Part 7 Valve

This is a metal casted & machined equipment. A rubber sealer was attached to this for better

sealing purpose.

Rubber Seal Details O/D = 73 mm , I/D = 60.5 mm, h = 12 mm

Material Brass

Part 8 Hexagonal Cap

This part is used to guide the Valve seal & hold the Spring. 1st the Hexagonal Cap was

machined to get the desired thread size. Then the Rough edges were removed by filing &

smoothened the surface using sand papers.

Material Brass

Manufacturing method Metal casting

Part 9 Spring

This part is used to tension the Valve & its an imported item.

Material Spring steel

Number of Turns 10

Height 52 mm

Pitch 5.2 mm

I/D = 24 mm , O/D = 28 mm

Spring diameter - 2 mm

xii

Testing:

The important thing is to check the leakage in valve body. Therefore the main parts were

assembled to the valve body & pressurized it up to 1 bars of pressure. All the thread surfaces

must be sealed using Thread Seals before doing that. Then the valve surface was checked

deliberately. There can be some invisible holes in the valve body due to sand casting procedure.

We can see that the liquid is spreading through those holes because of the pressure. Those

spotted hole surfaces cleaned & added Metal filler. We can finally smooth the surface using a

sand paper after 24 hours.

Painting:

1st step is to apply primer coating for the Valve. Therefore the threads were fully covered by

using masking tape before this step.

Finally the Signal Red color was applied with a spray gun.

xiii

Annex - C

Vent production

Vent is generally used to aerate and de-aerate tanks of the fuel bowsers .it maintains a constant

pressure inside the tank during the discharge process. This product is consisting with 7 sub

parts, 2 springs and a steel net. This vent is only installed for the fuel bowsers. The base of the

body is made by Casted aluminum; Machining and joining processes are used in the

manufacturing process.

Figure 27-Vent

xiv

MATERIAL PROPERTY

There are 7 main parts in the vent. The exploded view of the vent is given below.

Table 4- Part list Vent

Part No Material Form of Material

Part 1 Aluminium Casting

Part 2 Aluminium Aluminium bar

Part 3 Aluminium Casting

Part 4 Aluminium Casting

Part 5 Aluminium Casting

Part 6 Aluminium Casting

Part 7 Aluminium Casting

Part 1

This part is obtained as Aluminum casting and facing and turning operations are done

to obtain the required dimensions.

Facing and Turning : Chuck rpm 270-470.

Part 2

Facing, turning and drilling : Chuck rpm 640-970.

This part is also obtained as aluminum casting and then the hole is drilled to the

required dimension shown in the drawing and facing and turning operations are done

to obtain the required diameter and the slots are cut into it.

Part 3

Facing, turning and tapering : Chuck rpm 270 4200

This part is also obtained as aluminum casting and facing, turning operations are done

in order to obtain the required diameter and threads were cut, one in the long hollow

section and the other on in the outer section of the part. Thread size is 3/8 of inch.

Part 4

Facing, turning and tapering : Chuck rpm 550 830

This obtained as a small aluminum castings and facing and turning operations are

done to obtain the required diameter and tapered four protruding edges.

xv

Part 6

This part is also obtained as aluminum casting and facing and turning operations are

done in order to obtain the required diameters and inside thread is cut into one edge

and knurling was done in the other edge.

The thread size is 5/8 of an inch.

Facing, turning and knurling : Chuck rpm 220 300

Part 7

This part is obtained as aluminum casting and facing and turning operations are done

to obtain the required diameter at each end. Threads are machined at the each end of

the part.

Thread sizes are 3/8 of an inch for the shorter edge and 5/8 of an inch for the longer

edge. The inside slots are smoothed using a file.

Facing and Turning : Chuck rpm 320- 480

xvi

Annex - D

Female and male couplings

In mechanical trades and manufacturing, each half

of a pair of mating connectors or fasteners is

conventionally assigned the designation male or

female. The "female" connector is generally a

receptacle that receives and holds the "male"

connector. The part bearing one or more

protrusions, or which fits inside the other, being

designated male in contrast to the part containing

the corresponding indentations, or fitting outside

the other, being designated female.

Features

Easy maintenance: Parts can be easily

replaced without getting much more time.

Easy to handle.

Having long lifetime.

Female Coupling

Female Coupling consists with three main parts. They are rolled section with five racks,

Adjustable handle with two clippers & bondable opening with seals.

Figure 29-Female Coupling

Figure 28-Female and Male Coupling

xvii

Table 5- Part list Female Coupling

PART NO DESCRIPTION QTY

PART - 01 Rolled Section 1

PART - 02 Inner Bracket 1

PART - 03 Outer Bracket 1

PART - 04 Adjusting Part 1

PART - 05 Rubber Seal 1

PART - 06 Clipper Mounting Bracket 1

PART - 07 Hexagonal Handle 1

PART - 08 Hexagonal Handle Mounting Bracket 1

PART - 09 Clippers 2

PART - 10 Rack 5

PART - 11 Pin - 1 2

PART - 12 Pin - 2 2

Part List

Part 1 Rolled Section

Rolled Section is used to connect Female Coupling with the pump outlet. 1st step is to cut

the required size of rectangular shape plate by using Shearing Machine. Then it will be

rolled until it gets the required size.

Plate thickness 3 mm

Welding rod E 6013

Part 2 Inner Bracket

This part is used to hold the outer bracket with the rolled section. The shape of this

bracket is formed by a die.

Plate thickness 3 mm

Welding rod E 6013

Dimensions before forming O/D = 210 mm , I/D = 105 mm

xviii

Part 3 Outer Bracket

This part is used to hold the rubber seal with the Inner Male Coupling. The shape of this

bracket is formed by a die.

Plate thickness 3 mm

Welding rod E 6013

Dimensions before forming O/D = 210 mm , I/D = 105 mm

Part 4 Adjusting Part

This part is used to mount the two handles & adjust the whole part with reference to the Male

Coupling. 1st step is to cut the required size of circular shape by using Gas Cutter. Then it was

machined to get the required size of teeth.

Welding rod - E 6013

Thread pitch 5 mm

Thread depth 3 mm

Thread gauge 5.0 (mm)

Part 5 Rubber Seal

This part is used to seal the opening between Female & Male Couplings.

This is a purchase item from Lancor Rubber (Pvt) Ltd.

Part 6 Clipper Mounting Bracket

This part is used to mount the Clippers with the Hexagonal Handle Mounting. 1st step is to

cut the required size of plate by using Shearing Machine. Then it was bended according to the

drawing by using Bending Machine. Finally holes were drilled.

Plate thickness 3 mm

xix

Part 7 Hexagonal Handle

This part is used to move the clippers up & down & also to rotate the Adjusting part. It is

made by using a hexagonal bar & the shape was taken by bending the bar using Hydraulic

Press & a die.

Part 8 Hexagonal Handle Mounting Bracket

This part is used to mount the Hexagonal Handle with the Adjusting Part. 1st step is to cut the

required size of plate by using Plasma Cutter. Then it was grinded until it gets smooth surface

finish & required shape. After that it was bended according to the drawing by using Bending

Machine. Finally holes were drilled.

Plate thickness 3 mm

Welding rod for Hexagonal Handle & this Mounting Bracket E 6013

Welding rod for stainless steel pins - E 308-16

Part 9 Clippers

This part is used to tight the Male & Female Couplings. 1st step is to cut the required size of

plate by using Plasma Cutter. Then it was grinded to get the required shape. Finally it was

welded to the Clipper Mounting Bracket.

Plate thickness 12 mm

Welding rod E 6013

Threaded Segments

This Threaded Segments are used to move the Adjusting Part up & down. There are 5

segments used in one component. 1st step is to cut the required size of plate by using Plasma

Cutter. Then it was welded to the Main Pipe & finally machined to get the required thread

size.

Thread pitch 5 mm

Thread depth 3 mm

Thread gauge 5.0 (mm)

xx

Pin 1

This pin is used to connect the Clipper Mounting Bracket & the Hexagonal Handle Mounting

Bracket. This is a machined part

Steel Rod diameter 12 mm

Material Stainless steel

Welding rod - E 308-16

Pin 2

This pin is used to connect the Adjusting Part & the Hexagonal Handle Mounting Bracket.

This is a machined part.

Steel Rod Diameter 12 mm

Material - Stainless steel

Welding rod - E 308-16

Male Coupling

Male Coupling is the fixed part & Female Coupling is the movable part. Male coupling

consists with three main parts. Each part is separately describe below.

Part 10 Rolled Section

Rolled Section is used to connect Male Coupling with the bowser inlet. 1st step is to cut the

required size of rectangular shape plate by using Shearing Machine.

Plate thickness 3 mm

Welding rod - E 6013

Part 11 Inner Bracket

This part is used to hold the outer bracket with the Rolled Section. It was manufactured by

using a 3mm thickness plate.

The shape of this bracket is taken by using a die.

E 6013 Welding rod is used for final welding.

Dimensions before forming O/D = 210 mm , I/D = 105 mm

xxi

Part 12 Outer Bracket

This part is used to hold the rubber seal with the Inner Male Coupling. It was manufactured

by using a 3mm thickness plate

The shape of this bracket is taken by using a die.

E 6013 Welding rod is used for final welding.

Dimensions before forming O/D = 158 mm , I/D = 93 mm

xxii

Annex -E

PTO Pumps and RTL Compressors

Blackmer PTO Pumps for Tank Trucks

Sliding Vane Pumps

Blackmer PTO sliding vane pumps are excellent at pumping clean, low viscosity fluids

including non-lubricating fluids. Ideal uses include refined fuel trucks and oil delivery tankers.

Basically, any truck tank, specialty truck, or tanker that hauls fuel oil, diesel, kerosene,

gasoline, avgas, LP gas, jet fuel, or light lube oils can benefit from using a PTO sliding vane

pump from Blackmer.

Figure 30-PTO Pump

Features

Unique sliding-vane pump design self-adjusts for wear to maintain flow rates.

Excellent self-priming and dry run capabilities.

Dual ended shaft on 2, 2.5 and 3 inch models simplifies installation.

Blackmer mechanical seal and ball bearing construction provide maximum reliability.

Symmetrical bearing support assures even loading and wear for long life.

Adjustable relief valve protects pump against excessive pressures.

External ball bearings are isolated from pump age by mechanical seals to maximize bearing

life and minimize contamination risk.

Easy maintenance: vanes can be easily replaced without removing pump from truck.

xxiii

Process Applications

Many of the chemicals used in industrial process applications are difficult to handle, often toxic

or corrosive in nature, difficult to seal, and expensive to purchase. These materials pose some

of the most demanding pump service of any industry. Blackmer sliding vane pumps are

available in compatible materials with shaft sealing options that make them the products of

choice for many chemical process applications.

The sliding vane operating principle imparts a very low rate of shear to the material being

handled and provides a smooth, almost pulsationless flow. Sliding vane pumps "self-adjust" to

compensate for "normal wear," providing like-new pump performance over the life of the

product. When repairs are required, maintenance is a simple, requiring few tools and minimal

training to ensure proper performance.

RTL-80 Compressor

RTL 80 compressor is a multi-cell compressor which works on the displacement principle.

They provide a constant low-pulsation supply. The machines are single-phase and have a

cylindrical bored housing. The vanes divide the crescent-shaped working chamber into cells of

different sizes. As the rotor turns, the cell volume on the intake side increases, and the resulting

under pressure draws air into the cell, which at this point is open to the intake suction nozzle.

As the rotor continues to turn, the cell is closed and the volume of the cell decreases.

RT- Rotor type compressor

L- Housing is cooled by air cooling

80- Size of compressor

Vacuum operation or Pressure Operation