THIRD YEAR PROJECT FINAL PRESENTATIONTHE MAUFACTURE OF A PYRAMID TYPE SLIP ROLLS

BY

Joseph Stynes X00105837

Project supervisorTom Healy

1/ The rollers are positioned in a pyramid configuration2/ The top roller is vertically adjustable3/ Two bottom feed rollers rotate in the same direction

What is a pyramid type slip rolls ???

Feed rollers

Top feed rollerMaterial being

rolled

Original concept sketch for pyramid type slip rolls

Original concept design

Development of final design

Four phases of manufacture

1/ Cutting of all materials to specified dimensions2/ Machining all components to specified dimensions3/ Fabrication and Welding4/ Assembly

Commencement of manufacture

Manufacturing of components

Assembly of finished components

Final assembly of finished components

Commencement of testing phase of project

Testing criteria1/ Testing of a range of different materials2/ Testing of a range of different thicknesses of materials3/ Theoretical testing of machine using the formulae for simple bending theory4/ Practical testing of machine using a range different materials in various thicknesses5/ Establishing whether the theoretical testing is validated by the practical testing6/ Record and tabulate practical testing results

Sample theoretical calculation using bending theory formulae

Mild steel

b = 0.5m / d = 0.003m / y = 0.0015m / Yield (σ) = 210mPa

I = 𝒃𝒙𝒅𝟑𝟏𝟐 𝒔𝒐 𝑰= (𝟎.𝟓𝒎)𝒙(𝟎.𝟎𝟎𝟑)𝟑𝟏𝟐 𝒔𝒐 𝑰= 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

𝝈𝒀= 𝑴𝑰 so M = 𝝈𝒀 𝒙 𝑰 𝒔𝒐 𝑴= 𝟐𝟏𝟎 𝒙 𝟏𝟎𝟔𝑵𝒎𝟎.𝟎𝟎𝟏𝟓 𝒎 𝒙 𝟏𝟏𝟐𝟓 𝒙 𝟏𝟎−𝟏𝟐𝒎𝟒

Therefore M = 157.5 Nm

M = 𝑭𝟐 𝒙 𝟎.𝟎𝟒𝒎 so M = 0.02F so F = 𝑴𝟎.𝟎𝟐 so F = 𝟏𝟓𝟕.𝟓 𝑵𝒎𝟎.𝟎𝟐 𝒎

Therefore F = 7875 N

Table of results for practical testingTABLE OF RESULTS FOR 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)

Finished rolled test pieces

Compliance with project deadlines according to the manufacturing plan

MANUFACTURING PLAN FOR PYRAMID TYPE THREE ROLL SLIP ROLLSCOMPONENT MANUFACTURING PROCESSES TIME TAKEN (Hours) WEEK STATUS

RHS BASE FRAME CUTTING, DRILLING, WELDING 2 14 CompletedTHREADED INSERTS FOR RHS FRAME CUTTING, DRILLING, TAPPING, WELDING 2 14 Completed

IDLE END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 15 CompletedGEAR END PLATE CUTTING, DRILLING, TAPPING, MILLING 12 16 Completed

TOP ROLLER CUTTING, TURNING, 4 16 CompletedBOTTOM FRONT FEED ROLLER CUTTING, TURNING, MILLING 6 17 CompletedBOTTOM BACK FEED ROLLER CUTTING, TURNING, MILLING 6 17 Completed

GEAR KEYS FOR BOTTOM FEED ROLLERS CUTTING, MILLING, FILING 4 17 CompletedINTERMEDIATE GEAR SHAFT CUTTING, TURNING, MILLING 2 18 Completed

INTERMEDIATE GEAR SHAFT KEY CUTTING, MILLING, FILING 1 18 CompletedBRASS TOP ROLLER GUIDES CUTTING, DRILLING, FILING, MILLING 6 18 CompletedBOTTOM LOCKING BLOCKS CUTTING, DRILLING, COUNTERSINKING 4 18 Completed

TOP LOCKING BLOCKS CUTTING, DRILLING, COUNTERBORING 4 18 CompletedTHREADED ROUND SCREWJACK GUIDE CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed

SCREWJACK TURNING HANDLES CUTTING, WELDING 2 19 CompletedSCREWJACK TURNING HANDLE BODIES CUTTING, DRILLING, TAPPING, WELDING 2 19 Completed

RETAINING RING FOR BRASS GUIDES CUTTING, DRILLING, WELDING 2 19 CompletedTHREADED ROD CUTTING 1 19 Completed

CRANKING HANDLE CUTTING, DRILLING, WELDING 2 19 CompletedCRANKING HANDLE BOSS CUTTING, DRILLING, FILING,WELDING 2 19 Completed

PRESSING BEARINGS HYDRAULIC PRESSING 1 19 CompletedASSEMBLY ASSEMBLING OF COMPONENTS AND TORQUEING OF BOLTS 4 20 Completed

TESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 21 CompletedTESTING OF FINISHED MACHINE TESTING THE THEORETICAL ABILITIES OF THE MACHINE 6 22   Completed

The finished manufactured artefact

Thank you for listening

Any questions ???