Professional Documents
Culture Documents
CONTENTS
Serial No
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. 23. 24. 25. 26. 27. 28.
Topic
Synopsis Abstract Acknowledgement Company Overview Watch Manufacturing Departments and their functions Parts of the Dial
Page No
i ii iii iv v vi vii 1-12 1 1 1 1 2 3 4 6 7 8 9 12 1-27 1 1 2 13 16 viii ix
PHASE I
EC 6 Press Machine Description Technical specification of ESSA EC 6 Parts of ESSA EC 6 Clutch Mechanism Alternative Solution- Pneumatic Clutch and Brake ORTLINGHAUS CLUTCH/BRAKE UNIT Part list of Clutch/Brake Unit ASSEMBLY Development of design PART DESIGNS ASSEMBLY DRAWINGS
PHASE II
Design Analysis Suspected vulnerabilities in the mentioned parts STRESS ANALYSIS- FABRICATED PLATE STRESS ANALYSIS- ECCENTRIC BLOCK STRESS ANALYSIS- SHAFT ASSEMBLY Conclusion Bibliography
Synopsis
NEED FOR THE PROJECT
The existing EC 6 Press Machine in Titan Industries uses a rolling-key mechanism to transmit the drive to the shaft-assembly of the machine from the electrical motor through the flywheel. However, this arrangement caused a lot of problem in the manufacturing cycle of the industry due to erratic breakdown of the rolling-key mechanism. Hence a change in the existing mechanism was required for decreasing the time consumption in production due to constant breakdown of the machine.
TECHNICAL DETAILS
The spring attached to the rolling-key in the existing model of the EC 6 Press Machine generally fractures during its use frequently causing a breakdown. This flaw in the machine can be corrected by replacing the rolling-key by a pneumatic clutch. The pneumatic clutch is engaged by supplying compressed air at 5 bar pressure which transmits the power from the flywheel to the shaft assembly which in turn will rotate the cam and the cam transmits the required reciprocating motion to the tool of the machine.
# All the designing jobs involved are carried out in AutoCAD Inventor Professional Suite 2011.
ABSTRACT
This brief about the project carried out at Titan Industries Limited (watches division), Hosur, is to address the frequent breakdown of EC 6 press in the Module plant. The following activities were carried out in the course of the project: Detailed study was carried out on the existing process to identify the major cause for the breakdown of the machine. Rolling key clutch mechanism was identified as the constraint for increase in frequent problems that lead to the breakdown of the EC 6 press. Brainstorming was carried out to generate ideas and alternatives were short-listed for analysis. The alternatives were analysed based on cost, investment, lead-time and change in process design and ranked with the input from functional experts. The optimal solution was selected based on the rankings. The optimal solution found was Pneumatic Clutch/Brake Mechanism. The rolling key mechanism was replaced by the Pneumatic Clutch/Brake Mechanism and the modified version of the press machine was made with modifications in the shaft assembly and a new fabricated plate was introduced to give the brake plate of the shaft assembly a permanent fixture. The designing was done part wise and then all the parts were assembled together. Once the designing job was over stress analysis of the various parts and sub-assemblies were carried out. Based on the stress analysis reports the various changes were made in the dimensions in the design to eliminate all the anomalies.
ii
ACKNOWLEDGEMENT
iii
The success of any project depends largely on the encouragement and guidelines of many people. I take this opportunity to express my gratitude to the people who have been instrumental in the successful completion of this project. I would like to show my greatest appreciation to Mr Ganesan N, (Project Guide) Manager
Maintenance (Module & Assembly), Titan Industries Limited, Hosur for accommodating my
request and giving me this challenging project to undertake. Without his encouragement and guidance this project would not have materialised. I would also like to take this opportunity to forward my deepest appreciation to Mr Sathish P,
Senior Engineer- Maintenance (Module & Assembly), who motivated and encouraged me
throughout the project and provided me with adequate time and resources to successfully complete the project. The guidance and support received from all the members who contributed and who are contributing to this project, was vital for the success of the project. I am grateful for their constant support and help.
Company Overview
Titan Industries is the organisation that brought about a paradigm shift in the Indian Watch market when it introduced its futuristic quartz technology, complemented by international styling. With Indias two most recognized and loved brands Titan and Tanishq to its credit, Titan Industries is the fifth largest integrated Watch manufacturers in the world. The success story began in 1984 with a joint venture between the Tata group and the Tamil Nadu Industrial Development Corporation. Presenting Titan quartz watches that sported an international look, Titan Industries transformed the Indian Watch market. After Sonata, a value brand of functionally styled watches at affordable prices, Titan Industries reached out to the youth segment Fastrack, its third brand, trendy and chic. This company has sold over 100 million watches world over and manufactures 12 million watches annually. With a license for premium fashion watches of global brands, Titan Industries repeated its pioneering act and brought international brands into Indian market. Tommy Hilfiger and Hugo Boss, as well as the Swiss made watch-Xylys owe their presence in Indian market to Titan Industries. Entering the largely fragmented Indian jewellery market with no known brands in 1995, Titan Industries launched Tanishq, Indias most trusted and fastest growing jewellery brand. Gold Plus, the later addition, focuses on the preferences of semi-urban and rural Indian. Completing the jewellery portfolio is Zoya, the latest retail chain in the luxury segment. Titan Industries has leveraged its manufacturing competencies and branched into Precision Engineering Components and sub-assemblies, machine building and automation solutions, tooling solutions and electronic sub-assemblies in 2002. Titan Industries has also made its foray into prescription eyewear, launching the Titan Eye+ chain of world class optical stores in 2007. With over 500 retail stores across a carpet area of 6, 60,000sq.ft. Titan Industries has emerged as Indias largest retail network. The company has over 290 exclusive World of Titan, Helios a Fastrack showroom and 745 after-sales-service centres. Titan Industries is also the largest jewellery retailer in India with over 140 Tanishq boutiques, Zoya and Gold Plus stores and over 75 Titan Eye+ stores. Backed by over 4,300 employees, two exclusive design studios for watches and jewellery, over 5 manufacturing units and innumerable admirers world over, Titan Industries continues to grow and set new standards for innovation and quality. The organisation is all geared to the Titan and Tanishq success story with each new offering.
iv
Watch Manufacturing
The Watch Manufacturing comprises of 3 basic units:
1. Module Unit 2. Casing Section 3. Strapping Section While the casing and strapping sections deals with the external components of the watch, the module manufacturing unit handles the internal components of the watch. Depending on the style and size, the modules are classified as a variety of series. At Titan Industries these are 5000, 6000, 7000 and 7100 series. Brief description of the components of Watch modules are as follows: 1. MINERAL GLASS: This is the component located at the extreme end of the front face of a module. This is attached to a bezel ring by means of a mineral glass gasket. 2. BEZEL RING: The ring is used to hold the mineral glass and is attached to the case centre by means of a bezel ring gasket. 3. CASE CENTRE: The case centre has components both within and outside it. It has a crown that can be pulled and turned over a case pipe. 4. SPRING BAR: This is a thin metal bar that is in either side of the module, it is used for strap attachment. 5. HANDS: Every analog watch has the hour hand, the minute hand. The second hand is optional and depends on the style and model of the watch module. 6. DIAL: There are a variety of dials with colours, numbering styles and dates, etc. depending on the series. EXAMPLE- In the 5000 series, model 5120 has 2 hands 7120 has no date. 7121 has date only. 7122 has date & mouth. 7. MOVEMENT MODULE: This is a long stem that does the job of a crown before watch module is cased. The movement module is also used to raise the module while shifting it to different sections during manufacturing. This is set in a plastic movement holder. 8. MAIN PLATE: It is used to support the whole assembly. 9. BACK COVER: The back cover of a Watch is attached to a plastic movement holder by means of a back cover gasket. The movement module or the main plate of the watch has 2 sides: DIAL SIDE BRIDGE SIDE
vi
vii
Phase I
EC 6 Press Machine
Description
Essa EC 6 Press Machine is the main press used in the press shop to manufacture a number of components in the watch assembly. The standard components that are made using EC 6 arc, yoke, Battery Bridge, coil guard, center second stop lever, setting lever, etc. Essa EC 6, as in the name, is an Eccentric Crank drive with a maximum working pressure of 6 tonnes. The transmission of energy stored in the flywheel to the press is by means of a Rolling Key clutch mechanism. It is a light duty press providing shorter and quicker strokes.
(1
Parts of ESSA EC 6
Base: The all machine tool base is one of the
parts of the press. It is the main supporting member for workpiece holding dies and different controlling mechanisms of the press. Size of the table, limits the size of the workpiece that can be processed.
Phase I
CLUTCH MECHANISM
Rolling Key Clutch: The clutch mechanism used
in the ESSA EC 6 is a rolling key clutch. Rolling key clutch is a type of full revolution clutch. It is a simple mechanical design that operates by means of engaging a rolling key. Once engaged, it disengages only after a full revolution of the shaft. The engaging mechanism is actuated manually by means of a lever. An obvious disadvantage is the inability to stop the press before top of stroke in the event that a misfeed is detected.
Phase I
Alternative Solution
Pneumatic Clutch and Brake
Air actuation is the most common method for industrial equipment. Most industries have supply of compressed air that can serve the actuation of clutches and brakes. Pressures to 200 psi are used to inflate tubes or act on pistons to engage or disengage friction surfaces. Some are air-engaged and spring-disengaged; others are spring-engaged and air-disengaged. Some combination clutch-brakes use air-pressure to engage the clutch, and spring pressure to disengage the clutch while simultaneously engaging the brake. The greatest asset of an air-actuated clutch or brake is low heat generation in the actuator. Unlike an electric unit, there is no heat generation during a long period of engagement. Static pressure stays constant after the piston chamber is filled, so the power needed to sustain torque is almost nothing. As with the mechanical actuation, a degree of touch control or feel can be gained with air clutches and brakes by channeling the pressure through hand or foot-operated throttles. Where remote control is desired, electrically actuated solenoid control valves may be used to pressurize a clutch or brake.
providing air to either component. A 5-way valve is used where the clutch and brake require different pressures. Generally, a control valve is located as close to its clutch or brake as possible to assure least lag-time. Quick-exhaust valves: Installed at the clutch or brake inlet port and used where long lines are necessary, these valves improve response time because air need not travel back to the control to be exhausted. Instead, it exhausts at the quick exhaust valve whenever supply pressure drops by, say, 3 to 5 psi. Exhaust mufflers: To quite noisy valves, they typically reduce noise levels by up to 16 dB.
A disadvantage of air-actuated clutches and brakes is the support equipment needed the maintenance costs that go with it. The clutches and brakes themselves, however, use actuators that are typically no more complex than a cylinder and piston sealed with O-rings or U-cups. Thus, no special skills are needed to maintain them.
Supporting components
To operate efficiently, air-actuated clutches and brakes need several supporting components: Pressure regulators: Selected in accordance with their low capabilities, these valves set pressure ranges so that clutches and brakes deliver correct torque. Filters: Installed ahead of the pressure regulator, a filter needs atleast 5 micron filtration capability. Lubricators: Located between the pressure regulator and control valve, a lubricator injects oil into the air when pressure drops. Control valves: Depending on the clutch or brake configuration, the control valve may be 3,4 or 5-way solenoid type. A 3-way valve controls either a clutch or brake. A 4-way valve controls a combination clutch-brake,
Phase I
Braking
Initially the pressure spring 4 press against piston 3 in the cylinder. This causes brake plate 2 to be pressed against the stop plate, thus bringing about the braking action in the unit.
Functional description
Ortlinghaus 0-420 series is a clutch and brake mechanism combined in a single unit. The normal operating pressure of the unit is 5.5 bar and maximum permissible pressure is 6 bar.
Phase I
Table: Part list of Clutch/Brake Unit
Item
1 1.1 2 2.1 2.2 2.3 3 3.1 3.2 3.3 4 4.1 4.2 4.3 4.4 4.5 4.6 4.7 5 5.1 5.2 5.3 6 6.1 6.2 6.3 12 12.1 12.2 12.3 12.4
Individual part
Hub Hub Ring Ring Dowel pin Bolt Springs Spring mounting plate Spring Dowel pin Clutch plate (12-point suspension) Base element Sleeve Bolt Strap Circlip Bolt Tensioning sleeve Piston Piston Grooved ring Grooved ring Brake plate (12-point suspension) Base element Sleeve Bolt Friction pad version Housing plate section Sleeve Bolt Friction pad
Phase I
ASSEMBLY
Installation of Clutch
The Ortlinghaus 0-420 Clutch/Brake unit can be installed by two methods: By 12-point plate suspension By 2-point plate suspension In 12-point plate suspension method, the plates are mounted on the machine through 12 holes provided in them. In 2-point plate suspension method, the plates are mounted through 2 lugs at opposite ends of the plate. In EC 6 conversion 12-point plate suspension has been selected on the basis of the following criteria: High frequency of operation (engaging and disengaging). Heavy stresses generated on the clutch and the brake plates by the flywheel. Ease of mounting on the machine base. To distribute the load uniformly on the base. Design size N-m Design Size N-m
Twelve-point suspension
In 12-point suspension, the plates are provided with 12 holes. The brake plate halves are held by spring pressure and clutch halves by means of the securing straps. The brake plate half will fall out if compressed air is applied to the clutch/brake unit, so it has to be tightened up using bolts. Apply compressed air to the clutch/brake unit. Insert sleeve 1. Tighten self-locking bolt 2 to the prescribed torque (refer table 4). Turn flywheel until a securing hole is located opposite a recess in the brake plate. \ Insert one of the clutch plate halves if the clutch plate has been removed. Insert sleeve 1. Tighten self-locking bolt 2 to the prescribed torque (refer table 4). Insert remaining five sleeves and tighten bolts. Proceed in the same way with the other plate half.
1000 1000 1000 1500 2000 Strength Class: 10.9 Locking agent: loctite 262
Phase I
Installation conditions
Moving parts must be safeguarded by the customer against unintended contact, without significantly compromising the ventilation. The installation area, with its connection faces, and the product must be free of grease, dust or other combination. It must be ensured that the friction components are not contaminated by operating fluids such as oil or grease during installation or subsequent operation. If clamping rings are used for shaft connection then no oil must emerge from these after installation. There must be no damage present at the joints of the machine. Observe the fitting and position tolerances and the data on the product drawing. Otherwise small cracks or gaps from angular or radial misalignment of the shaft/machine are created. Ensure that there is adequate space available in the installation area.
Development of design
The existing EC 6 Press Machine utilizes a Rolling key mechanism to transmit the power from the motor to the shaft assembly through the flywheel. But the spring that is used to engage the key for the power transmission was more prone to failure causing frequent breakdowns of the production line. To prevent the breakdown of the machine and to continue with the production without any glitches the rolling key mechanism is replaced by a Pneumatic Clutch (single plate). The preliminary aim of the project is to design the modified version of the Press Machine by the modification of the frame and its parts and introducing the pneumatic clutch in the assembly replacing the rolling-key clutch mechanism.
Phase I
Part Designs
1. Bearing(Diameter- 85mm) It is designed to support the shaft from bending due the vertical component of the weight the parts assembled on it.
2. Bearing(Diameter- 100mm) It is designed to support the shaft from bending due the vertical component of the weight the parts assembled on it.
5. Brake plate pin It helps to attach the brake plate to the fabricated plate.
3. Bowl
It serves the purpose of holding the coupling attached to the shaft assembly.
6. Centre plate clutch It is the center plate of the clutch/brake unit used to transmit the torque during engagement of the clutch.
Phase I
7. Clutch key It helps to transmit the power from the clutch to the shaft assembly. 10. Eccentric Block It is a part of the shaft assembly which acts a cam to convert the rotating motion of the shaft as a reciprocating motion and transmit it to the punch.
10
8. Coupling 11. Fabricated Plate It acts a supporting element for the eccentric block. The brake plate of the clutch/brake unit is mounted on this plate for permanent fixture.
9. Cover Plate 12. Flywheel It separates the brake plate of the clutch/brake unit from the top base to reduce wearing of the unit. Stores energy provided by the electric motor and supplies the same energy to the clutch plate which in turn supplies it to the shaft during engagement.
Phase I
13. Guiderod It helps the ram of the machine to reciprocate as the shaft rotates and the eccentric block makes it reciprocate. 16. Sleeve It supports the shaft and separates it from the top base to reduce wear.
11
17. Spacer 14. Machine Base It supports the entire mechanism and houses the various assemblies and sub assemblies along with the electric motor and the belt drive to rotate the flywheel. It helps to keep an optimum space between the clutch/brake unit and the sleeve.
18. Top base It supports the shaft assembly and houses the guiderod which makes the ram reciprocate.
15. Round Pin It is used to attach the flywheel to the clutch plate of the clutch/brake unit.
Phase I
12
ASSEMBLY DRAWINGS
1. 2. 3. 4.
The simulations of the stress situations due to static as well as dynamic loading have been considered and the design has been tested.
3 & 4. Shaft and Shaft assembly: Bending of the shaft due to weight of the clutch/brake unit
and the flywheel assembled on it. The tension of the belt is also considered to simulate the load on the shaft. The stress analysis reports of the parts of the above mentioned parts and sub-assemblies are reports generated by the Autodesk Inventor Professional Suite 2011. The reports include deflection of the parts and the sub-assembly in under static and dynamic load situations. The bending and failure of the parts (if any) are also indicated.
PHASE II
STRESS ANALYSIS- FABRICATED PLATE Stress Analysis Report
Analyzed File: Creation Date: Simulation Author: Summary: Fabricated plate.ipt 09-07-2012, 02:21 Somnath Bhattacharjee Autodesk Inventor Version: 2011 (Build 150239000, 239)
Simulation: 1
General objective and settings:
Design Objective Simulation Type Last Modification Date Single Point Static Analysis 09-07-2012, 02:19
Advanced settings:
Avg. Element Size (fraction of model diameter) 0.1 Min. Element Size (fraction of avg. size) Grading Factor Max. Turn Angle Create Curved Mesh Elements 0.2 1.5 60 deg Yes
Material(s)
Name General Steel, High Strength Low Alloy Mass Density Yield Strength Young's Modulus Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Fabricated plate.ipt 7.84 g/cm^3 275.8 MPa 200 GPa 0.287 ul 77.7001 GPa 0.000012 ul/c 47 W/( m K ) 420 J/( kg c )
PHASE II
Operating conditions
Force: 1
Load Type Force Vector X Vector Y Vector Z -16.021 N -11.972 N 0.000 N
Selected Face(s)
Force: 2
Load Type Force Vector X Vector Y Vector Z -14.328 N -13.954 N 0.000 N
Selected Face(s)
PHASE II
Force: 3
Load Type Force Vector X Vector Y Vector Z -7.193 N -18.662 N 0.000 N
Selected Face(s)
Force: 4
Load Type Force Vector X Vector Y Vector Z -1.198 N -19.964 N 0.000 N
Selected Face(s)
PHASE II
Force: 5
Load Type Force Vector X Vector Y Vector Z 8.654 N -18.031 N 0.000 N
Selected Face(s)
Force: 6
Load Type Force Vector X Vector Y Vector Z 9.605 N -17.542 N 0.000 N
Selected Face(s)
PHASE II
Force: 7
Load Type Force Vector X Vector Y Vector Z 15.752 N -12.323 N 0.000 N
Selected Face(s)
Force: 8
Load Type Force Vector X Vector Y Vector Z 19.239 N 5.464 N 0.000 N
Selected Face(s)
PHASE II
Force: 9
Load Type Force Vector X Vector Y Vector Z 17.974 N 8.770 N 0.000 N
Selected Face(s)
Force: 10
Load Type Force Vector X Vector Y Vector Z -5.451 N 19.243 N 0.000 N
Selected Face(s)
PHASE II
Force: 11
Load Type Force Vector X Vector Y Vector Z -15.771 N 12.300 N 0.000 N
Selected Face(s)
Force: 12
Load Type Force Vector X Vector Y Vector Z -10.801 N 16.833 N 0.000 N
Selected Face(s)
PHASE II
Force: 13
Load Type Force Vector X Vector Y Vector Z -14.701 N 13.561 N 0.000 N
Selected Face(s)
Fixed Constraint: 1
Constraint Type Fixed Constraint
Selected Face(s)
10
PHASE II
Results
Reaction Force and Moment on Constraints
Constraint Name Reaction Force 14.2375 N Fixed Constraint:1 38.9716 N 36.2777 N 0N Reaction Moment 0Nm 44.845 N m 0 N m -44.845 N m Magnitude Component (X,Y,Z) Magnitude Component (X,Y,Z)
Result Summary
Name Volume Mass Von Mises Stress Minimum 3173200 mm^3 24.8779 kg 0.00000000504795 MPa 0.115715 MPa 0.0937576 MPa 0.0250434 MPa 0.00000297303 mm 15 ul Maximum
1st Principal Stress -0.0238676 MPa 3rd Principal Stress -0.0834569 MPa Displacement Safety Factor 0 mm 15 ul
Figures
Von Mises Stress
11
PHASE II
1st Principal Stress
12
PHASE II
Displacement
Safety Factor
13
PHASE II
STRESS ANALYSIS- ECCENTRIC BLOCK Stress Analysis Report
Analyzed File: Autodesk Inventor Version: Creation Date: Simulation Author: Summary: Eccentric block.ipt 2011 (Build 150239000, 239) 09-07-2012, 16:34 Somnath Bhattacharjee
Simulation: 1
General objective and settings:
Design Objective Simulation Type Last Modification Date Number of Modes Frequency Range Enhanced Accuracy Single Point Modal Analysis 09-07-2012, 16:33 8 0 - 180 No
Advanced settings:
Avg. Element Size (fraction of model diameter) 0.08 Min. Element Size (fraction of avg. size) Grading Factor Max. Turn Angle Create Curved Mesh Elements 0.2 1.5 60 deg Yes
Material(s)
Name General Steel, High Strength Low Alloy Mass Density Yield Strength Young's Modulus Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Eccentric block.ipt 7.84 g/cm^3 275.8 MPa 200 GPa 0.287 ul 77.7001 GPa 0.000012 ul/c 47 W/( m K ) 420 J/( kg c )
14
PHASE II
Operating conditions
Force: 1
Load Type Force Vector X Vector Y Vector Z -25.363 N -493.348 N 0.000 N
Selected Face(s)
15
PHASE II
Fixed Constraint: 1
Constraint Type Fixed Constraint
Selected Face(s)
Results
Result Summary
Name Result Value Volume 164852 mm^3 Mass 1.29244 kg
16
PHASE II
STRESS ANALYSIS- SHAFT ASSEMBLY Stress Analysis Report
Analyzed File: Creation Date: Simulation Author: Summary: Shaft assembly_new.iam 09-07-2012, 23:45 SomnathB Autodesk Inventor Version: 2011 (Build 150239000, 239)
Simulation: 1
General objective and settings:
Design Objective Simulation Type Last Modification Date Number of Modes Frequency Range Enhanced Accuracy Single Point Modal Analysis 09-07-2012, 23:35 8 0 - 700 Yes
Advanced settings:
Avg. Element Size (fraction of model diameter) 0.08 Min. Element Size (fraction of avg. size) Grading Factor Max. Turn Angle Create Curved Mesh Elements Use part based measure for Assembly mesh 0.2 1.5 60 deg No Yes
17
PHASE II
Material(s)
Name General Steel, Mild Mass Density Yield Strength Young's Modulus Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Name General Shaft1.ipt Cast Iron Mass Density Yield Strength Young's Modulus Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Name General 7.25 g/cm^3 200 MPa 120.5 GPa 0.3 ul 0 GPa 0.000012 ul/c 50 W/( m K ) 540 J/( kg c ) 7.86 g/cm^3 207 MPa 220 GPa 0.275 ul 0 GPa 0.000012 ul/c 56 W/( m K ) 460 J/( kg c )
100dia plate.ipt 0420-129-61-332000_Clutch.ipt Flywheel.ipt coupling.ipt Steel, High Strength Low Alloy Mass Density Yield Strength Young's Modulus 7.84 g/cm^3 275.8 MPa 200 GPa 0.287 ul 0 GPa 0.000012 ul/c 47 W/( m K ) 420 J/( kg c ) block.ipt key.ipt key.ipt
Ultimate Tensile Strength 448 MPa Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Name General Eccentric Clutch Clutch Sleeve.ipt Cast Steel Mass Density Yield Strength Young's Modulus Stress Poisson's Ratio Shear Modulus Expansion Coefficient Stress Thermal Thermal Conductivity Specific Heat Part Name(s) Spacer.ipt 7.85 g/cm^3 250 MPa 210 GPa 0.3 ul 0 GPa 0.000012 ul/c 50 W/( m K ) 460 J/( kg c )
18
PHASE II
Operating conditions
Force: 1
Load Type Force Vector X Vector Y Vector Z -80.283 N -487.433 N -0.000 N
Selected Face(s)
19
PHASE II
Fixed Constraint: 1
Constraint Type Fixed Constraint
Selected Face(s)
20
PHASE II
Fixed Constraint: 2
Constraint Type Fixed Constraint
Selected Face(s)
21
PHASE II
Fixed Constraint: 3
Constraint Type Fixed Constraint
Selected Face(s)
22
PHASE II
Fixed Constraint: 4
Constraint Type Fixed Constraint
Selected Face(s)
23
PHASE II
Fixed Constraint: 5
Constraint Type Fixed Constraint
Selected Face(s)
24
PHASE II
Results
Frequency Value
F1 20.54 Hz
Result Summary
Name Result Value Volume 8227430 mm^3 Mass 60.3516 kg
Figures
F1 20.54 Hz Displacement
25
PHASE II
F1 20.54 Hz X Displacement
26
PHASE II
F1 20.54 Hz Y Displacement
27
PHASE II
F1 20.54 Hz Z Displacement
CONCLUSION
The CAD designs of the parts of the modified version of the EC6 Press Machine along with their dimension specifications are:
1. Fabricated Plate 2. Spacer 3. Sleeve 4. Cover Plate 5. Flywheel 6. Shaft 7. Eccentric Block 8. 100 dia plate 9. Clutch key 10. Top Base 11. Machine base 12. Modified EC 6 Press Machine assembly
viii
6
M1 12 nos @ 0x1.5 - 6H PCD 408 ,00
A-A ( .4 )
D A6
A5
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
A4
A3
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
A1 C
A2
n145,00 THRU
HOLE
b 10 A
B
n
f 10 A
N6
24,00 Item 1
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
N6
HOLE TABLE XDIM YDIM DESCRIPTION n8,20 THRU -105,00 40,00 A1 v n15,00 x 9,00 n8,20 THRU 105,00 40,00 A2 v n15,00 x 9,00 n8,20 THRU 144,00 92,00 A3 v n15,00 x 9,00 B n8,20 THRU 0,00 92,00 A4 v n15,00 x 9,00 n8,20 THRU -144,00 92,00 A5 v n15,00 x 9,00 n8,20 THRU 0,00 167,00 A6 v n15,00 x 9,00 Qty. Part Name Material OHNS 1
Fabricated plate
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
7 43 0 ,0
3 4,00
60 ,0 0
N6
N6
f 10 A
45,00 H7*
A B B
Material OHNS
Qty. 1
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
6
b5A
4
n50,00
D C1
45,00 H7*
B
C2
b5A n6 0, 00
C3
C4
45,00 H7*
N6
N6
f5A
B
0, 2 0X 45
,00
B(5)
Item 3
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
NOTE: *Sliding fit with Shaft Chamfer points: C1, C2, C3 & C4 0,20 X 45 Qty. Part Name Material Sleeve OHNS 1
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
2 2,50
60
, 00
N6
N6
D
2 n1 0 ,0 0
f 10 A
C
80,00
Item 4
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
Material OHNS
Qty. 1
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
5
15,00
00 15,
M12x1.7 5 18 nos
45, 00
n80,00 H7#
80,00 H7#
N6
U cut 18,00 + 10 +0
N6
N6
U cut B
* H7 0 ,0 U 40 THR n
f 10 C
5,00 70,00
A
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
NOTE: # Sliding fit with Bearing outer race * Sliding fit with Shaft Qty. Item Part Name Material 5 Unit Flywheel Cast Iron 1 no
General Tol. Remarks: Part to be given Dim. Tol. Linear Angular Drawn Checked Approved
WATCH DIVISION
mm mm
50
D PC 8,00 40 n
A-A ( .35 )
00 5, 1
f 10 C
27,00 + 10 +0
b 10 C
N6
b 10 C
6
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-6
x1 .
.5
M 10 x1
0, 5
U cut R 0,25
-6 g
M 10
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00
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N6
N6
20,00
A/F 13,00
Item 6
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
Material EN 45
Qty. 18
Unit
Checked Approved
mm mm
50
F:\EC6 conversion\EC 6-Pneumatic clutch conversion\Drawing files\Round pin_Brake & clutch plate.idw
0,50 X 45,00 D
M1 0 x1.5 - 6g
U cut R 0,25 N6
C
74,50
24,00
M10 x1
38,00
.5 6H
50,50 + 20 +0
N6
,0 n20 0
TITAN INDUSTRIES LTD.
Item 7
(MODULE MAINTENANCE)
Material EN 45
Qty. 18
Unit
A/F 15,00
Checked Approved
mm mm
50
C 100dia plate
A-A ( .6 )
Eccentric block
Item 8
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
Material ---
Qty. 1 set
Unit
Checked Approved
mm mm
50
6
+ 10# +5
4 586,50
n40,00
n38,00
87,00
, 00 n8
- 6g x1.5 M45
RU TH
n45,00 h6*
n45,00 h6*
n32,00
n34,00
1,50
15,00
n37,30
A/F 36,00
n40,00 h6*
28,00
C CIRCLIP GROOVE
11,00 2,00
N6
90,00 18,00 9,00 50,00 47,50 161,50 #INTERFERENCE FIT WITH 100Dia PLATE 174,00
2,00 52,50
.5 M24x1
12,50 61,00
n 14 ,0
0
f5A
90,00
7,95
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
NOTE: * Sliding fit with bearing inner race # Intereference fit with Eccentric block & 100dia plate 6 5 4 3
HARDENED & GROUND Qty. Item Part Name Material 8a & Shaft & Key OHNS 1&2 8b Unit General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved
WATCH DIVISION
mm mm
50
44,00
N6
30 M .5 x1 g -6
15,00
3,18
- 6H
4
RU
3 50,00
N6
80 ,0 0
h6
N6
,0 24 n
N6
TH
22,50
15,00
M4 DE x0.7 EP 25 6H ,0 0
N6
25,00
28,50
28,50
B
H
Item 8c
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
NOTE: #Interference fit with shaft HARDENED & GROUND Qty. Part Name Material Eccentric block OHNS 1
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
25,00
x1 M6 -6
# +0 10 0 ,0 U 40 HR n T
5
n 10
0,
D
r 10 A
00
h6
45,00 +0 - 10
n62,00
B
N6
4,00
N6
5,00
B ( 10 )
Item 8d
TITAN INDUSTRIES LTD.
HARDENED & GROUND Qty. Part Name Material 100 Dia plate SKS 3 1
1,00
(MODULE MAINTENANCE)
General Tol. Remarks: HARDNESS: 550 HV - 600 HV Dim. Tol. Linear Angular Drawn Checked Approved Unit
WATCH DIVISION
mm mm
50
1 48,00
A
D
A-A ( 1/3 )
D
f 10 A
A6 B3 A5 B2 A4 C1 C6 C C2 A3 B1
b 10 A
A1
A2
n85,00
A
N6
C
F:\EC6 conversion\EC 6-Pneumatic clutch conversion\Drawing files\Top base1.idw
C5 C4
C3
b 10 A
A
B
HOLE TABLE HOLE XDIM YDIM DESCRIPTION -105,00 40,00 A1 M8x1.25 - 6H 105,00 40,00 M8x1.25 - 6H A2 144,00 92,00 A3 M8x1.25 - 6H 0,00 92,00 A4 M8x1.25 - 6H -144,00 92,00 A5 M8x1.25 - 6H 0,00 167,00 A6 M8x1.25 - 6H Dowel hole 165,00 120,00 +0 B1 n8,00 10 -15,00 DEEP B2 0,00 120,00 Dowel hole +0 n8,00 10 -15,00 DEEP
TITAN INDUSTRIES LTD.
f 10 A
3,00 + 20 +0
Item 9
(MODULE MAINTENANCE)
Qty. 1
B3 C1 C2 C3 C4 C5 C6 6 5
-165,00120,00 0,00 43,30 43,30 0,00 -43,30 -43,30 4 50,00 25,00 -25,00 -50,00 -25,00 25,00
Dowel hole +0 n8,00 10 -15,00 DEEP M5x0.8 M5x0.8 M5x0.8 M5x0.8 M5x0.8 M5x0.8 6H 6H 6H 6H 6H 6H 3
Unit
Checked Approved
mm mm
100
A-A ( .2 )
D FRONT SIDE 50,00 85dia bearing
Flywheel
108,00
80dia bearing
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
100dia bearing DIN 471 - 40x1.75 Shaft assembly_new Spacer Sleeve B Machine base B
Item X
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
Unit
Material ---
Qty. ---
NOTE: Clutch not visible Top base moves 40mm (from its Original mounting position) 6 5 4 3
Checked Approved
mm mm
100
NOTE: Clutch not visible Top base moves 40mm (from its Original mounting position)
Item X
TITAN INDUSTRIES LTD.
(MODULE MAINTENANCE)
Unit
Material ---
Qty. ---
Checked Approved
mm mm
100
40,00
6 155,00
4 150,00
100,00
50,90
24,84
Weldment
96,00
156,00 140,00
D Weldment
400,00
0 0 ,0 n4 RU TH
PRODUCED BY AN AUTODESK EDUCATIONAL PRODUCT
Weldment
6 ,8
552,00
R5
0, 0 0
07 R1
560,00
19,00
35,00
14,00 8,00
50,00
U 0 THR n11,0 3 no s
26,00
19,00
25,00
64,00
6,00 Item Part Name 10a & Machine base & 10b Projected piece Unit General Tol. Remarks: Dim. Tol. Linear Angular
WATCH DIVISION
Material ---
Qty. ---
(MODULE MAINTENANCE)
25,00
Drawn
Checked Approved
mm mm
100
100,00
100,00
BIBLIOGRAPHY
Papers and Journal:
1. 2. 3. 4. 5. 6. Mechanical Press Types and Nomenclature 1993-2005, David Alkire Smith, pg 10-13. Manufacturing process-III, pg 38-40. Pneumatically actuated clutches and brakes- Ortlinghaus. Metal Forming Practise, Heinz Tschaetsch, pg 300-303. Rolling key clutch- service manual, Bliss clearing. Power transmission design 1997, pg 129, 140-141.
ix
Websites:
1. www.mullermachines.com/es/pdf/machine/15011 2. www.merriam-webster.com/dictionary/rolling%20key%20clutch 3. www.ortlinghaus.at/pdf/tpi/en/TPI_0750_EN.pdf 4. http://books.google.co.in/books?id=W-6SFIX2qp4C