UDP PROJECT REPORT
DESIGN & FABRICATION OF AUTOMATIC PAPER CUTTING MACHINE USING GENEVA MECHANISM
By
DOLERA KRUNAL (130040119025)
FATEPARA PIYUSH (130040119027)
GORFAD NILESH (130040119037)
Under the guidance of
Prof. Dilavar Dodia
A project report submitted to
Gujarat Technological University in
Partial Fulfillment of Requirements for the
Degree of Bachelor of Engineering in Department of
MECHANICAL ENGINEERING
OCTOBER 2016
CERTIFICATE
This is to certify that research work embodied in this thesis entitled “DESIGN & FABRICATION OF AUTOMATIC PAPER CUTTING MACHINE USING GENEVA MECHANISM” Was carried out by DOLERA KRUNAL (130040119025) FATEPARA PIYUSHKUMAR (130040119027) GORFAD NILESH (130040119037) At B.H. GARDI COLLEGE OF ENGINEERING & TECHNOLOGY for partial fulfillment of Bachelor of Engineering degree to be awarded by Gujarat Technological University. This research work has been carried out under my supervision and is to my satisfaction.
Date: / / 2017
Place: Rajkot
Internal guide : H.O.D.
Prof. D.D.DODIA Prof. V.H.Oza
SIGN:
SIGN:
CANDIDATE DECLARATION
I declare that the dissertation report presented here for Bachelor of Engineering. (Mechanical) entitled “DESIGN & FABRICATION OF AUTOMATIC PEPER CUTTING MACHIME USING GENEVA MECHANISM” is my own work conducted under the guidance of Prof.D.D. DODIA
I further declare that to the best of my knowledge, this dissertation report does not contain any part of work, which has been submitted for the award of any degree either in this university or in other university/ deemed university without proper citation.
Signature of Student:
Name of Student: DOLERA KRUNAL
FATEPARA PIYUSH
GORFAD NILESH
Enrolment No: 130040119025
130040119027
130040119037
Name of Guide: Prof. DILAVAR DODIA
Signature of Guide:
Department of MECHANICAL Engineering
B.H. GARDI COLLEGE OF ENGINEERING & TECHNOLOGY
ACKNOWLEDGEMENT
“SUCCESS IS THE MIXTURE OF GUIDELINES, HARDWORK,
INTELLIGENCE ANDCO-OPERATION.”
We pray for the blessing of divine authority governing this world and think him for all the courage and power that he gave in course of progress of our project.
We are grateful to prof. H.O.D. V.H.Oza SIR Mechanical department for giving us such a nice opportunity for developing ourselves. We sincerely thank to our collage guide Prof. DILAVAR DODIA SIR for his personal guidance care and enthusiasm that helped us to make our report concrete one. We would like to be thankful to our collage us for cooperation in completing this report work. Last but not least. We would like to be thankful for our family members, friends and well-wishers who directly or indirectly helped us a lot. We have to express our feelings.
Dolera krunal (130040119025)
Fatepara piyush (130040119027)
Gorfad nilesh (130040119037)
DATE:___/___/2017 NAME & SIGN OF STUDENT
TABLE OF CONTENTS
CERTIFICATE……………………………………….……………….ii
CANDIDATE DECLARATION.……………………………………..iii
ACKNOWLEDGEMENT…………………………………………… 4
LIST OF FIGURE………………………………………….…………..7
LIST OF TABLE……………………….……………….………………8
ABSTRACT………………………………………………………………9
CHAPTER-1 INTRODUCTION……………………………………..10
CHAPTER-2 LITERATURE REVIEW……………………………..11
CHAPTER-3 CANVAS ACTIVITY REPORT………………………15
5.1 OBSERVATION MATRIX/EMPATHY SUMMARY…………..15
5.2 AEIOU SUMMARY……………………………………………..17
5.3 IDEATION CANVAS……………………………………………19
5.4 PRODUCT DEVELOPMENT………………………………..…20
5.5 BUSINESS MODEL CANVAS……………………………..….22
CHAPTER-4 DESIGN CALCULATION OF MACHINE COMPONENTS..……24
3.1 DESIGN CALCULATION OF CHAIN DRIVE…………..……24
3.2 DESIGN OF GENEVA MECHANISM…. ………………..….….31
3.3 DESIGN OF SHAFT………………………….…………..……….33
CHAPTER-5 MODELING IN NX…………………..………………35
CHAPTER-6 PLANE OF WORK………………………………..……38
6.1 DRAFTING OF MODEL………………………………..…….38
6.2 PURCHASE OF MATERIAL…………………………………38
6.3 DEVELOPMENT OF MODEL……….………………………38
CHAPTER-7 CONCLUSION…………..……………….…….….…40
APPENDIX-A ORAGINALITY REPORT…….…………………41
LIST OF FIGURES
Fig. No. Figure Description Page no.
2.1 Mechanism of Geneva wheel 11
2.2 Layout of a four slot Geneva wheel using Cadence 12
2.3 External Geneva mechanism 13
3.1 Observation matrix/empathy summary 15
3.2 AEIOU summary 17
3.3 Ideation canvas 19
3.4 Product development canvas 20
3.5 Business model canvas 22
4.1 Profile of chain sprocket 24
5.1 Design of Geneva sprocket 35
5.2 Design of Geneva driver 35
5.3 Assembly of Geneva mechanism 36
5.4 Design of chain sprocket 36
5.5 Assembly of all parts of the machine in NX 37
6.1 Geneva Mechanism 38
6.2 Assembly of all parts of the model 39
LIST OF TABLES
Table No. Table Description Page no.
4.1 Power rating (in kW) of simple roller chain 25
4.2 Characteristics of roller chains according to IS: 2403-1991 26
4.3 Selected parameters of roller chain 26
4.4 Factor of safety (n) for bush roller and silent chain 27
ABSTRACT
In current there are many machines based on paper cutting but it has some demerits like large in size, costly, need skilled people to operate. The main aim for this machine is to reduce timing for paper cutting and neglect the time for marking the paper. This aim is achieved by use of Geneva mechanism. The use of Geneva mechanism is very useful in small scale industries.
The design and fabrication of paper cutting machine using Geneva mechanism is very useful to cut papers in equal and accurate dimensions. Geneva drive is an indexing mechanism that converts the continuous motion into intermittent motion. Due to the intermittent motion, the paper is moved between the time intervals of cutting periods. Then the paper cutting is achieved by the crank and lever mechanism. The cutter will be back to its original position by the spring effect. This project is designed with using Geneva mechanism and paper cutting machine. Paper cutting machine designed with mechanical arrangement in which movements are controlled by Geneva mechanism. In this paper cutting machine using Geneva mechanism consist of two sections. One is automatic paper cutting machine and second section is conversion of rotary motion into intermittent motion of paper roller. The first section consists of Geneva wheel disc keyed with a shaft of one end and the other ends is connected to the chain sprocket wheel. The Geneva wheel shaft is supported on two Plummer block bearings. This sprocket wheel transmits the rotary motion to the Geneva wheel.
CHAPTER-1 INTRODUCTION
1.1OBJECTIVE
Our objective is to design and fabricate automatic paper cutting machine. This would help in cut the paper in accurate and equal dimensions and reduce the time for marking the dimension.
1.2 BRIEF INTRODUCTION
Now days, there is lot of competition in the market. So there is need of developing a new method or process for effective manufacturing. That process or methods should fulfill the requirement about accuracy Productivity etc.
It is necessary to reduce the total matching time. There are various Ways by which the total matching time can be effectively minimized. There are various time consuming steps or sub process, which can be, minimize by various methods.
This project is designed with using Geneva mechanism and paper cutting machine. Paper cutting machine designed with mechanical arrangement in which movements are controlled by Geneva mechanism.
In this paper cutting machine using Geneva mechanism consist of two sections. One is automatic paper cutting machine and second section is conversion of rotary motion into intermittent motion of paper roller. The first section consists of Geneva wheel disc keyed with a shaft of one end and the other ends is connected to the chain sprocket wheel. The Geneva wheel shaft is supported on two Plummer block bearings. This sprocket wheel transmits the rotary motion to the Geneva wheel.
CHAPTER-2 LITERATURE REVIEW
2.1 From paper: Design of a Micro machined Geneva Wheel as a mechanism to obtain intermittent motion from a constantly rotating source Varadarajan Vidya (Department of electric engineering) and Palani Kumaresan (Department of Mechanical Engineering) University of California, Berkeley
The basic structure of a four slot Geneva wheel is shown in Fig.1. The system consists of a constantly rotating disk coupled with a slotted disk, which gives rise to the desired discrete motion. A rotation of 2p radians of the former causes 2p/N radians of rotation of the latter, where N is the number of slots available on the slotted disk. Thus, one complete rotation of the slotted wheel requires N complete rotations of the other disk, thereby also increasing the total time period. The conversion mechanism of this disk system is as follows.
Fig2.1: mechanism of Geneva wheel
Wheel design
Two types of slot designs for the Geneva wheel were considered. The designs were laid out using the Cadence software for MEMS layouts. Since the technology file available with the software allowed for only three levels of polysilicon, the structural poly0 level was not laid down.
Fig2.2: Layout of a four slot Geneva wheel using Cadence
The layout of a four slotted wheel in Cadence is shown in Fig. with projections on the constantly rotating wheel to so that it can be moved with a probe. The constantly rotating disk can be rotated using a Sandia microengine driven by comb-drives. The gears of the microengine can be made to mesh with the gears of the constantly rotating wheel that can be provided on it. To avoid unintentional rotation of the Geneva wheel, a truncated wheel (with a chopped arc angle of 4p/N radians) is placed on the constantly moving disk, which stops any rotation of the Geneva wheel when the pin is moving freely and is not engaged with any of the slots.
The design should therefore, have the truncated disk and the Geneva wheel on the same polysilicon layer and the constantly moving disk in another layer, which would mesh with the microengine. The Geneva wheel and the chopped disk are made on the Poly2 layer and the constantly moving disk lies below in the Poly1 layer. The engaging pin on this disk is placed on Poly2 layer. The pins holding the Geneva wheel and the other disks are then placed on Poly3 layer, which gets contacted to the Poly0 layer and allows rotation of the disks after release.
A gear can be fabricated on poly1 layer concentric with the Geneva wheel, which can then be meshed with a rack to convert the intermittent rotation of the disk into discrete linear motion. This can then be applied to micro mirrors and other systems requiring such motions.
2.2 From paper: VIRTUAL MANUFACTURING OF CLASSIC EXTERNAL GENEVA MECHANISM by Iulian STANASEL1, Florin BLAGA2 1University of Oradea, stanasel@uoradea.ro 2 University of Oradea, fblaga@uoradea.o
Fig2.3: External Geneva mechanism
GENEVA mechanism is used as a mechanism for transforming rotary motion into intermittent motion running with acceleration jumps at the beginning and the end of the active phases [1]. The mechanism provides a precise positioning movement and its blockage, which makes it usable in many areas [2]. Synthesis of mechanism aims to determine the size and number of channels constructive established by different coefficients and in function of acting time [3]. Geneva mechanism (Fig.) consists of, the crank (1) and the wheel (2), which has several slots. Movement is
Transmitted from the crank to the wheel through the bolt (3), which keeps moving the wheel (2) until the exit from the slot.
CHAPTER-3 CANVAS ACTIVITY REPORT
3.1 OBSERVATION MATRIX/EMPATHY SUMMARY
Fig3.1: observation matrix/empathy summary
3.1.1 OBSERVATION:
When we started observation for the project we came to know many different things out of this is important observation were noted and are as the time requirement for paper cutting in small scale industries is more, the size of continupus paper cutting machine is very large, price of that machine is aslo high.
3.1.2 SCOUTED CHALLENGES
The scouted challenges are listed below:
• Size of paper cutting machine is large
• Need skilled people to operate the machine
• More time required for paper marking & cutting
• Noise generated by machine
• More paper wastage
• Less cost effective
3.1.3 TOP 5 PROBLEM ON THE BASIS OF DESIRABLE, FLEXIBILITY AND VIABILITY
After analyzing all the problem top 5 problem were selected and the problem are:
• Marking required for paper cutting
• Large size of the machine
• High cost of machine
• Skilled people required to operate the machine
• More paper wastage
3.1.4 FINAL PROBLEM SELECTED 1 FROM TOP 5
• Thus the finalize problem is, the marking of paper is requires for paper cutting and the size and the cost of the machine.
3.2 AEIOU SUMMARY
Fig3.2: AEIOU summary
3.2.1 ENVIRONMENT
• Except noise pollution mostly pollution free
• Paper wastage
3.2.2 INTERACTIONS
By interacting different people in different areas which listed below,
• Supplier
• QC & production person
• Consumer
3.2.3 OBJECTS
The Objects are used in our project are Sprocket Roller, chainPaper, rollerPaper , paper cutter, Geneva mechanism, Shaft & spring
3.2.4 ACTIVITIES
The activities Detail study, designing, Modelling, Collecting components, Commissioning
3.2.5 USERS
The users of our project can be Industries, Book seller, Writer, Stationers, Students, School & colleges.
3.3 IDEATION CANVAS
Fig3.3: ideation canvas
3.3.1 People:
End users like students, designer, industries, book sellers.
3.3.2 Activities:
As we discus earlier for this project are Detail study, designing, Modeling, Collecting components, Commissioning
3.3.3 Situation/Context/Location:
This word means that how our project applicable in different areas means circumstances and location. And the locations are industries, stationeries, and school & colleges.
3.2.4 Props/Possible Solution:
Props / possible solutions are continuous cutting of paper, low cost and compact size of machine, cut paper in equal and accurate dimensions and reduce the time for marking the dimensions of paper.
3.4 PRODUCT DEVELOPMENT CANVAS
Fig3.4: product development canvas
3.4.1 Purpose:
Our project will fulfill following purposes:
• Reduce time for marking of paper
• Low cost
• Compact size
• Cut paper in equal & accurate dimensions
3.4.2 People:
The end users that we are having for our product are book sellers, writers, students and stationers.
3.4.3 Product experience:
• Easy to control
• Light weight
• Simple in operations
3.4.4 Product Function & Future:
• For equal size paper cutting
3.4.5 Components:
The components are used in our project are Sprocket, Roller chain, Paper roller, paper cutter, Geneva mechanism, Shaft & spring
3.5 BUSINESS MODEL CANVAS
3.5.1 Key Partners
• Geneva Mechanism
• Chain Drive
• Electric motor
• Paper roller
• Paper cutter
3.5.2 Key Activity
• Welding
• Drilling
• Design & Analysis
3.5.3 Key Resource
• Wooden factory
• Contributor
• Wooden manufacturer
• Auto Part Manufacturer
3.5.4 Value Propositions
• Eco Friendly
• Sustainable
• Economic
• Easy to Operate
3.5.5 Customer Relationship
• Paper Industries
• Stationary
• Book Seller
• Student
3.5.6 Channels
• Distributor
• Evaluation
• Advertisements
3.5.7 Customer Segment
• Feedback
• Mfg. Industry
3.5.8 Revenue Streams
• Magnify Year Value
• Be Flexible
• Recurring Revenue
• Attract Investors
• Transaction Revenue
3.5.9 Cost Structure
• Manufacturing
• Transportation
• Transmission Converter
• Maintenance Cost
CHAPTER-4 DESIGN CALCULATION OF MACHINE COMPONENTS
4.1 DESIGN CALCULATION OF CHAIN DRIVE
Fig 4.1: profile of chain sprocket
The velocity ratio of chain drive is V.C.=1
From the book of machine design by R.S. Khurmi and J.K. Gupta
For moderate speed selected teeth is 18, so teeth of the sprocket are 18.
Design power = Rated power × Service factor
We have selected rated power is 0.5Kw
And service factor is
KS = K1.K2. K3
K1 = load factor
Value of k1 is 1 for continuous load
K2 = lubrication factor
Value of k2 is 1.5 for periodic lubrication
K3 = rating factor
Value of k3 is 1.5 for continuous service
1) KS = K1.K2. K3
Ks =1×1.5×1.5
Ks = 2.25
2) Design power = rated power × service factor
=0.5 × 2.25 =1.125 kW
so the selected type of chain pitch, roller diameter, minimum width of roller,etc are as below,
so for power rating 1.125kW the selected chain is 08B and speed of sprocket is 200rpm.
Table 4.1: power rating (in kW) of simple roller chain
So, selected chain is 08B,
Table 4.2: characteristics of roller chains according to IS:2403-1991
The parameter of the chain 08B is
Sr. no. Parameter name Value
1. ISO chain number 08B
2. Roller diameter (d1) mm maximum 8.51
3. Width between inner plates(b1) mm maximum 7.75
4. Transverse pitch (p1) mm 13.92
5. Breaking load (kN) minimum for simple chain 17.8
Table 4.3: selected parameters of roller chain
3) Pitch circle diameter =p/sin(180/T)
=12.70/sin(180/T)
=73.13mm =0.07313m
4) Pitch line velocity = πdn/60
=3.14×0.07313×200/60
=0.7654 m/s
5) Load on the chain
W = rated power / pitch line velocity
=0.5/0.7654
=0.653229 kN
=653.229 N
6) Factor of safety = breaking load(Wb)/load on the chain(W)
=17.8×10^3 / 0.653229 ×10^3
=27.249
Table 4.4: factor of safety (n) for bush roller and silent chain
For the pitch 12.70 and 200rpm the factor of safety is minimum 7.8, the FOS of this designed chain is more than that value so, design is safe.
7) Centre distance between sprockets,
From the design of chin drive the minimum center distance between the sprocket should be 30 to 50 times the pitch. So, let us take 30. So,
X=30p
X=30×12.70
X=381mm
8) The number of chain links,
K = T1 + T2/2 + 2X/p + {[T2 – T1 /2π] ^2} (p/X)
K= 18+18/2 + 2×381/12.70 + 0
K= 78
9) Length of chain,
L=K×p
L= 78×12.70
L=990.6mm
L=0.9906m
10) Tooth flank radius (Re)
Maximum = 0.08d1(T^2 + 180)
=0.08(8.51) (18^2 + 180)
=342.123
D1=roller diameter
T= number of teeth
Minimum = 0.12 d1 (T + 2)
= 20.424
11) Roller seating radius (Ri)
Maximum = 0.505d1 + 0.063(d1) ^1/3
=0.505×8.51 + 0.063(8.51) ^1/3
=4.4261
Minimum = 0.505d1
=0.505 (8.51)
=4.2975
12) Roller seating angle (α)
Maximum = 140 – 90/T
= 140 – 90/18
=135
Minimum = 120 – 90/T
=120 – 90/18
=115
13) Tooth height above the pitch polygon(ha)
Maximum = 0.625p – 0.5d1 + 0.8p/T
=0.625(12.70) – 0.5(8.51) + 0.8(12.70)/18
=4.0769
Minimum = 0.5(p-d1)
=0.5(12.70-8.51)
=2.095
14) Top diameter (Da)
Maximum = D +1.25p –d1
=73.13 +1.25(12.70) –8.51
=80.505mm
Minimum = D + p (1 – 1.6/T) – d1
=73.13 + 12.70(1 – 1.6/1.8) – 8.51
=76.201mm
15) Root diameter (Df)
= D –Ri
=73.13 -2(4.4261)
=64.277mm
3.2 DESIGN CALCULATION OF GENEVA MECHANISM
Equations taken from wales, Ronald A, Handbook of Machining and metal working calculations, MC-Graw hill professional, 2009
a=drive crank radius which is taken as 80mm
n=driven slot quantity which is 5 slots,
p= drive pin diameter which is 10mm
t=allotted clearance which is taken as 10mm
1) canter distance
c = a/sin(180/n)
c = 80/sin(180/n)
c = 136.104mm
2) Geneva wheel radius (b)
b= (c^2 –a^2) ^1/2
b = (136.104^2 80^2) ^1/2
b=110.11mm
3) slot center length (S)
= (a + b) – c
= (80+110.11) – 136.104
=54.006mm
4) slot width(W)
W = P + t
=10+10
=20mm
5) stop arc radius (Y)
=a- (P×1.5)
=80-(10×1.5)
=65
6) stop disc radius (Z)
= y + t
=65+10
= 75mm
7) clearance arc (V)
=b×z/a
=110.11×75/80
=103.228
3.3 DESIGN CALCULATIONS OF SHAFT
The sprockets are mounted on shafts,
1) Pitch circle diameter of sprockets
D = 73.13mm = 0.07313mm
2) Power rating P = 0.5 kW
= 500W
3) Speed N = 200rpm
4) Length of the shaft is taken as L = 150mm
=0.15mm
5) Torque transmitted by the shaft,
T = p×60/2πN
T = 500×60 / 2×3.14×200
T = 23.885 Nm
6) Tangential force on the sprockets,
Ft = 2T/D
= 2×23.885/0.07313
Ft = 653.220N
The load acting on the sprocket is W = 653.229N taken from chain design calculations,
The sprocket are mounted at the middle of the shaft so,
7) maximum bending moment at the center of the sprocket,
M = W×L/4
=653.229×0.15/4
M = 24.496 Nm
8) Equivalent twisting moment,
Te = (M^2 + T^2) ^1/2
Te= (24.496^2 + 23.885^2) ^1/2
Te = 34.213 Nm
Te = 34.213×10^3 Nmm
The another equation of equivalent twisting moment is
Te = π/16 × τ × d^3
d = 14.269mm
so, the diameter of the shaft is 14.269mm
CHAPTER-5 MODELING
1. Geneva driven wheel in NX software
Fig 5.1 Design of Geneva sprocket
2. Geneva driver in NX software
Fig 5.2: Design of Geneva driver
3. Geneva assembly in NX
Fig 5.3: Assembly of Geneva mechanism
4. Chain sprocket in NX
Fig 5.4: Design of chain sprocket
5. Full assembly of model in NX
Fig 5.5: assembly of all parts of the machine in NX
Chapter-6: PLANE OF WORK
6.1 DRAFTING OF MODEL:
• For employing the linear & for converting continuous rotary motion into intermittent motion we require Geneva mechanism in our project model.
• The paper moves into forward direction with the help of paper roller.
6.2 PURCHASE OF MATERIAL:
• After drafting the model we started purchasing of the materials that would be required in our model.
• Various material that we have purchased were as follow:
• 08B chain and Sprockets.
• Four Axles for uses as shafts.
• Wooden base and some wooden blocks uses as polls.
• Wooden block for Geneva mechanism.
• Paper roller.
• Paper cutter.
6.3 DEVELOPMENT OF PROJECT MODEL:
• After obtaining the required materials, we started manufacturing of the project model.
Fig. 6.1 Geneva Mechanism
Fig 6.2: assembly of all parts of the machine
CHAPTER-7 CONCLUSION
The design and fabrication of paper cutting machine using the Geneva mechanism is will be very useful in small scale industries. There are many machines based on paper cutting but it has some demerits like large in size, costly, need skilled people to operate. But our machine will overcome this demerit by compact in size, less cost, no need for skilled people and there is no need for electrical input. The design procedure is done for fabricating the Geneva wheel and other elements of this machine. The main aim for this machine is to reduce timing for paper cutting and neglect the time for marking the paper, this aim is achieved in our paper cutting machine using Geneva mechanism.