paper cutting & rewinding machine project report sreesangh p ghosh

PAPER CUTTING & REWINDING MACHINE Project Report

2012-13

ACKNOWLEDGEMENT

I am very glad to represent project report on "PAPER CUTTING AND REWINDING MACHINE" fully designed, fabricated and tested in our polytechnic as part of our curriculum is awarding the Diploma in Engineering. I have tried my level best to focus upon each and every parameter. In concern with this topic the detail, necessary figure, definition, tabular analysis has been enumerated in very easy, simple, compact and lucid manner.

I have been able to achieve this task by the dynamic guidance of honorable SIVARAMAN sir; I have no wards to express my gratitude towards his kind, persistent inspiration, parent advice and outstanding treatment while clarifying my confusion.

I also extend my sincere thanks to our esteemed Head of Mechanical

Engineering Department Mr. M.R JAYACHANDRAN, whose guidance and constant inspiration where a great use in working of this project. We are also grateful to our tutor MR. P.P. DEVADAS.

I am also grateful to our honorable work shop superintendent

Mr.N.M.SATHEESAN and members of staff of our workshop for providing numerous facilities and guidance due to which this difficult task turned in a convenient task.

The permission granted to us by the honorable principal

Mr.V.V.SADASIVAN, to do the project work in greatly acknowledged. Last but not least, I am very thankful to my project partners without whose

kind cooperation it was difficult and impossible to go through the leaps and bounds while preparing this project. Also thanks to them who directly or indirectly co-operated and contributed during work.

Department of Mechanical Engg. S.R.G.P.T.C Triprayar Page 1


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ABSTRACT

Paper Cutting & Rewinding Machine is one of the simplest machine which cuts

rolled paper in needed amount and re-winded form. The conventional paper rewinding

machine has complex mechanism and bulk size. We made some modification to the

conventional machine and eliminating its defects. The main peculiarity of machine is its

simplicity, reduced size, weight. And also reduces floor space. This project can be

directly implemented to paper cutting and rewinding machines in Paper mills. This

machine can also use in textile mills, plastic and rubber sheets cutting and rewinding

process in various industries by changing its cutting components.

By applying these modifications to the conventional machine reduce

maintenance and servicing cost, floor area and overhead expenditures. It is well suited

for small scale industries.



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CONTENTS

TOPIC NO. TOPIC NAME PAGE-NO.

1. COMPONENTS OF MACHINE 4

2. MANUFACTURING PROCESS 8

3. STRUCTURE FABRICATION PROCESS 8

4. ROLLER MACHING PROCESS 10

5. CUTTER CLAMP MAKING PROCESS 12

6. DRIVING MECHANISM 13

7. WORKING OF MACHINE 14

8. ADVANTAGES 15

9. SPECIFICATIONS OF MACHINE 15

10. MATERIAL REQUIREMENT & COST 16

11. BIBLIOGRAPHY 17



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COMPONENTS OF PAPER CUTTING & REWINDING MACHINE

The main components of Paper Cutting & Rewinding Machine are listed

below. 1) BASIC FRAME

The entire unit is mounted on a rigid frame. The frame is made of

mild steel C- Channels (75X40 mm) connected in rectangular form and weld at their joints.

2) ROLLERS

The paper rotating element in this device is the ϕ 89 mm outer

diameter rollers with ϕ 40 mm outer diameter journals, which made up of three components.

1) G. I Hollow Pipe of ϕ 89 mm outer Diameter. 2) M.S Rod of ϕ 40 mm Diameter. 3) M.S Circular Plate of ϕ 81 mm Diameter.

The rotation of motor is transferred to the one of the four rollers on which cut paper is mounting in operation. The rotating roll makes all other three rollers to rotate. The roller is supported at its two ends by Plummer block with ball bearing blocks. The main functions of roller are to favor the cutting operation by moving paper and rewind it to rolls.



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4) PLUMMER BLOCK

The roller is supported at the two ends with the help of Plummer block fitted with ϕ 40 mm diameter Ball bearings. The bearings are cleaned and greased for easy rotation of roller.

5) BEARINGS

Ball bearing is a type of rolling-element bearing that uses balls to maintain the separation between the bearing races.

The purpose of a ball bearing is to

reduce rotational friction and support radial and axial loads. It achieves this by using at least two races to contain the balls and transmit the loads through the balls.

In most applications, one race is

stationary in Plummer block and the other is attached to rollers journal. As one of the bearing races rotates it causes the balls to rotate as well. Because the balls are rolling they have a much lower coefficient of friction than if two flat surfaces were sliding against each other.

Ball bearings tend to have lower load capacity for their size than other

kinds of rolling-element bearings due to the smaller contact area between the balls and races. However, they can tolerate some misalignment of the inner and outer races.



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6) INDUCTION MOTOR

An induction or asynchronous motor is an AC motor in which all electromagnetic energy is transferred by inductive coupling from a primary winding to a secondary winding, the two windings being separated by an air gap.

The machine is powered by 1 Hp motor with 1440 rpm. This makes

one roll rotates and rotating roll makes other rollers to rotate and not only wound the paper but also pull the paper to make the operation going. 7) SINGLE V-BELT AND PULLEY SYSTEM

Vee belts (also known as V-belt or wedge rope) solved the slippage and alignment problem. It is now the basic belt for power transmission. They provide the best combination of traction, speed of movement, load of the bearings, and long service life. They are generally endless, and their general cross-section shape is trapezoidal (hence the name "V").

The "V" shape of the belt tracks in a mating groove in the pulley (or

sheave), with the result that the belt cannot slip off. The belt also tends to wedge into the groove as the load increases-the greater the load, the greater the wedging action, V-belts may be homogeneously rubber or polymer.

Belts are looped over pulleys. The belt drives the pulleys in the same

direction. As a source of motion, the belt is one application where the belt is adapted to continuously carry a load between the motor and pulley fitted on the roller.



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8) CUTTER CLAMP (C-CLAMP) WITH BOLTS c-clamp with the two bolts are used to clamp the cutter to the frame and one extended piece of flat for mounting of cutter.

9) NUT AND BOLTS Bolt, is a type of fastener characterized by a helical ridge,

known as an external thread or just thread, wrapped around a cylinder.

A nut is a type of fastener with a threaded hole. Nuts are almost always used opposite a mating bolt to fasten a stack of parts together. They are made up of Mild Steel. Nuts and Bolts of different size is used for fixing the Plummer block to the main frame and to install the cutter clamp.



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MANUFACTURING PROCESS

I. STRUCTURE FABRICATING PROCESS :-

For structure fabrication, the c-channel of size 75 X 40 mm is used. The approximate wt. of it per meter is 6.8 kg. Steps in fabrication of structure are given below.

Step One:

First cut the c-channel in pieces of length 71" (i.e. 6 feet [180 mm]- two pieces)

and in 36" (i.e. 3 feet[91.5 mm] - three pieces). Then Put the two lengths of 6 feet parallel to each other at a distance of 3 feet from each other. Then put the lengths of 3 feet on either end of two parallel lengths and weld them as shown below. The two diagonals must be same.

Step Two:

Then cut four pieces of c-channel of length 24" (i.e. 2 feet[61 mm]) and weld

two of them on one end of rectangular structure vertically using engineers block. Then weld remaining two pieces vertically at a distance of 30" from previous pieces. Step Three:

Then brought the two pieces of flat of size 75 X 12 X 760 mm and weld them on

the top of four columns as shown.



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Step Four:

Then cut another two pieces of

length 48" (i.e. 4 feet[122 mm]) and weld them vertically at a distance of 16" from previously welded columns. Afterwards weld the previously cut piece of 36"[41 mm] on top and in between the upper ends of these columns. Step Five:

Then cut two pieces of C-channel of length 15". And four pieces of 4" length.

Then at a distance of 4.5" from nearest end weld them to form a frame as shown below.



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II. ROLLER MACHINING PROCESS

Roll is mead up of hollow pipe, solid circular plates & solid shaft journal. So we have to manufacture each part as per required size and then assemble it as a roll. Steps in this task are:-

Step one:

First, brought the hollow pipe of required dimensions. I.e. of required outer, inner and length. If it not available, then cut it on hacksaw machine.

Step two:

Then brought two circular plates of 10 mm thickness, face them from both

sides by holding them on lathe machine. And turn out to the diameter as equal to inner diameter of hollow pipe so they can fit into pipe for welding purpose.

Step three:

Take solid bar of M.S. of 50 mm diameter cut it to length 110 mm. Hold this bar on lathe chuck and turn it out up to the diameter 38 mm so that it can be fit in pedestal self-aligning bearing block.

Step four:

Now, weld the turned solid bar to each of two s o l id circular plates axially.



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Step five:

Now, weld these plates in the bore of hollow pipe.

Step six:

The roll is completed, but because of welding different parts it need to be turned again using lathe machine. Hold the journal on one side in chuck and turn the other journal as well as hollow pipe part of roll. Do the same operation by holding other journal in chuck so the roll will rotate along its axis accurately.

GROOVE FOR WELDING THE M.S ROD AT CENTRE-



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III. CUTTER CLAMP MAKING PROCESS

The c-clamp with the two bolts to clamp and one extended piece of flat for mounting of cutter is welded. It is used to hold the cutter. Step One:

First take the flat of 25 X 10 and cut it by bend saw in size of 90 mm,

65mm, 60 mm and 40 mm. Step Two:

Weld the pieces of 90, 65, and 60 mm to form C. Then take the piece of 40 mm

in length and weld it on the 65 mm side of clamp. Step Three:

By using drilling machine, make three holes of 10 mm at the points shown below in the complete assembly of cutter. Afterwards perform the tapping operations using tap of ½ inch.



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IV. DRIVING MECHANISM

As our project as a demo and also designed for small weight

we use the 1 Hp A.C. motor. It is having the 1440 rpm speed. We use two pulleys of three [7.62 mm] & eight [20.32] inch diameter respectively on motor and roller. One on the motor shaft and another is on the shaft of roll. The numbers of belts required for given application is one. V-belt is used for this purpose.



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V. WORKING OF MACHINE As we give number of modifications it is necessary to briefly

explain working procedure of machine. When the paper being manufactured in paper mill it is not of standard size an also get torn out at the edges. And here is the need of re-winding machine. The roll of paper manufactured is mounted on the roll (A). In our machine we have given the self-aligning bearing with inner extended ring for ease in mounting and urn-mounting.

Then paper is passed around roll (B) to ensure that paper remain

straight and tight. Then it passed through the cutter and grooved roll on top of machine, where it is cut. Because of our modification to this cutter roll the wt. of machine is decreased.

Then the paper which is cut is come to the roll at bottom, The roll is

powered by 1 Hp motor with 1440 rpm. This rotating roll makes other roll (C) to rotate and not only wound the paper but also pull the paper to make the operation going.



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Advantages

1) It is more compact as compared with conventional one. 2) Operation is simple Because of eliminating complex mechanisms. 3) Saving of floor space as motor is adjusted inside the structure. 4) New cutter clamping assembly given will eliminate the biggest disadvantage of machine i.e. high weight.

SPECIFICATIONS OF MACHINE

Length 6 feet ( 152.4") = 387.096 mm

Width 0.914 feet ( 36") = 91.44 mm

Height 4 feet ( 48" ) = 121.92 mm

Components 4 Hollow rolls, 8 Plummer blocks,8 bearings

Motor 1 Hp, 3 phase, induction motor



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MATERIAL REQUIREMENTS & COST

SL No. DESCRIPTION QTY. RATE AMOUNT

1 760 X ϕ 89 mm G.I Pipe(4 No’s ) 25 Kg. Rs. 81 per Kg. Rs. 2025.00

2 M.S. Rod

135 mm X ϕ 50 mm

24 Kg.

Rs. 58 per Kg. Rs. 1392.00

3 M.S Circular Plate 12mm X ϕ 90 mm

(8 No.) 7 Kg. Rs.58 per Kg. Rs. 406.00

4 M. S. Flat 12 X 75 X

760 (2 No

11 Kg.

Rs. 58per kg.

Rs. 638.00

5 C-channel 75 X 40 ( 12.2 meter )

76 Kg.

Rs. 58 per kg.

Rs.4400.00

6 Plummer Blocks

No 208 i.e. ϕ 40 mm

8 No. Rs.200 per block

Rs.1600.00

7 Bearings ϕ 40 mm Inner 8 No. Rs.30 per Bearing Rs. 240.00

8 Pulleys 3"

Pulley 8"

1 No.

1 No.

Rs. 240 per Pulley

Rs. 540 per Pulley

Rs. 150.00

Rs. 540.00

9 V- Belt of B-type 1 No. Rs.180 per Belt Rs.180.00

10 Paper 4.1 kg Rs. 35 per kg. Rs.131.00

11 Motor 1 Hp Induction Motor (2nd Hand) 1 No. Rs. 2500 Rs. 2500

12 Travelling Charge --- ------ Rs.1,160.00

Total Rs.14,962.00



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BIBLIOGRAPHY

Forbes Marshall- Engineering Data Book Workshop Technology- B.S. Raghuwanshi (Vol. I & II)

Production Management- ICFAI University

Elements of machine design- V. B. Bhandari

Strength of materials- R. K. Bansal
