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DESIGN AND FABRICATION OF

MULTI PROCESS MACHINING


USING SCOTCH YOKE MECHANISM

A PROJECT REPORT

Submitted by

GOWTHAM M (720816114030)
KAVIYARASU T (720816114044)

BHARATH R (720816114304)

In partial fulfillment for the award of the degree

of

BACHELOR OF ENGINEERING
in

MECHANICAL ENGINEERING

HINDUSTHAN COLLEGE OF ENGINEERING AND TECHNOLOGY

COIMBATORE- 641 032.

ANNA UNIVERSITY: CHENNAI 600 025


APRIL 2019

I
ANNA UNIVERSITY: CHENNAI 600025

BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION OF


MULTI PROCESS MACHINING USING SCOTCH YOKE
MECHANISM” by the help the guide prof.K.V.Ganesh Kumar M.E., at
hindusthan institute of technology by his guidance to held by GOWTHAM M
(720816114030) KAVIYARASU T (720816114304) BARATH R
(720816114304)

SIGNATURE SIGNATURE
Dr. K.R.RAJA BALAYANAN., M.E., Ph.D. DrK.V.GANESH KUMAR.,ME.,
HEAD OF THE DEPARTMENT SUPERVISOR
Assistant Professor,
Department of Mechanical Engineering Department of Mechanical Engineering
Hindusthan institute of technology, Hindusthan institute of Technology,
Coimbatore–641 032. Coimbatore – 641 032.

Submitted for the Anna University Project Viva–Voce conducted on …………..

INTERNAL EXAMINER EXTERNAL EXAMINER


II
ACKNOWLEDGEMENT
It is a great opportunity to express our sincere thanks to all those people who have
contributed to the successful completion of our Mini Project Work through their support,
encouragement and guidance.

At this pleasing moment of having successfully completed our project, we wish to


acknowledge with thanks, to significant contribution given by management of our college.
We also shoulder our endeavor to Our Managing Trustee Mr.T.S.R.Khannaiyyan and
Mrs.Saraswathi Khannaiyyan who hauled us to meritorious heights.

We are deeply indebted express our profound gratitude to Dr.C.Natarajan


M.Tech.,Ph.D., Our Principal, for providing us all the facilities necessary to finish this
project.
It is a great privilege to express our sincere thanks to Dr.K.R.Raja balayanan
M.E., Ph.D., Head of Department, Department of Mechanical Engineering, for his
valuable guidance and co-operation.
We are extremely obliged to Our Guide Mr.K.V.Ganesh Kumar,M.E.,
Assistant Professor, Department of Mechanical Engineering for his valuable guidance and
support throughout out endeavour.

We owe debt of gratitude to All Faculty and Staff Members and Students of
Mechanical Engineering from Hindusthan institute of Technology, Coimbatore for helping
throughout the course of project work

III
ABSTRACT
“Multi Operational Mechanical Machine “This work was mainly carried for
manufacturing and fabrication industries. The machine which is used to produce
the product with high accuracy and quality and produce the goods in an
economical manner. It makes the inventory cost less. The multipurpose machine
has performed different operations simultaneously with high possibility. The
scotch yoke mechanism which is attached with the main drive shaft directly
attached then it is used for different operation. Number of operations has been
performed by a single drive system. The main focus of the work is to reduce power
usage and increase the productivity reduced floor space. Portability is an important
quality in any machine in today’s world; every field of science and engineering has
got portability as one of its most important advancements. Therefore, the machine
we have designed satisfies this principle with respect to the manufacturing
industry.

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Content
PAGE NO.
CHAPTER 1. Introduction about the Project
1.1 Scotch yoke mechanism
1
1.2 History
2

CHAPTER 2. Mechanism
2.1 Principle
3
2.2 Simple Harmonic Motion
4

CHAPTER 3. Construction
3.1 Construction 6
3.2 AC Motor 6
3.2.1 Principle of AC motor 7
3.3 Pulley 8
3.4 Bearing 9
3.5 Shaft 10
3.6 Hacksaw 11
3.7 V-belt 12
3.8 Shaping 13
3.9 Drilling 14
4.0 Bevel gear 15

V
CHAPTER 4. Parts Required

4.1 List of Parts using in the machine 19

CHAPTER 5. Prototype Building


5.1 Framework 20

5.2 Scotch yoke Mechanism 20

CHAPTER 6. Cost Estimation

6.1 Introduction 22
6.2 What is project cost estimation? 22
6.3 Purpose of cost estimating 23
6.4 Cost element 24
6.5 Type of Cost estimation 25
6.5.1 Material cost estimation 25
6.5.2 Machining cost estimation 26
6.6 Calculation of material cost 26
6.7 Cost table Estimation 27
6.8 Total cost estimation 28

REFERENCES 29

VI
LIST OF FIGURES

FIG.
NO DESCRIPTION OF FIGURE PAGE NO

1 SCOTCH YOKE MECHANISM 3


2 AC MOTOR 6
3 PULLEY 8
4 BEARING 9
5 HACKSAW 13
6 BEVEL GEAR 15
7 PHOTOGRAPHY 30

VII
CHAPTER 1
CHAPTER 1

INTRODUCTION
1.1 GENERAL

In a multipurpose machine has a fine-toothed hacksaw for cutting the


metals with high speed of operations. There are hand saws and power
hacksaws. The hacksaws are adjustable and can hold a number of blades within
a specified limit under tension. The blade is mounted on the frame with either
the teeth facing towards or away from a point on the frame, finally cutting
action takes place either by means of push or pull the cutting teeth. Suppose a
work piece requires many operations to be done at the same time but the tools
are situated in various locations in the plant layout, a multi operational machine
can be devised that does the job effectively and efficiently.

1.2 SCOTCH YOKE MECHANISM

The Scotch yoke mechanism is a reciprocating motion mechanism,


converting the linear motion of a slider into rotational motion, or vice versa.
The piston or other reciprocating part is directly coupled to a sliding yoke with
a slot that engages a pin on the rotating part. In many internal combustion
engines, linear motion is converted into rotational motion by means of a
crankshaft, a piston and a rod that connects them. The Scotch yoke is
considered to be a more efficient means of producing the rotational motion as it
spends more time at the high point of its rotation than a piston and it has fewer
part
1.3 HISTORY

This linkage was called by Scotsman in 1869 “a crank and a lot headed rod” but
now it is known as Scotch yoke mechanism because, in America at least, a scotch was
slotted bar that was slipped under a collar on a string of well drilling tools to support them
while a section was being added.

In 1940, Russell Bourke applied this mechanism to internal combustion engine


called Bourke 30 Engine.

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CHAPTER 2
CHAPTER 2

2.1MECHANISM

This Mechanism is an inversion of Double Slider Crank Mechanism. The inversion


is obtained by fixing either the link 1 or link 3.In figure, link 1 is fixed. In this mechanism
when the link 2 (which corresponds to crank) rotates about B as centre, the link 4(which
corresponds to the frame) reciprocates. The fixed link 1 guides the frame.

Figure.2.1 scotch yoke mechanism


2.2 SIMPLE HARMONIC MOTION

This mechanism converts the rotary motion into the transulatory motion which is
simple harmonic in nature.

From the mechanism, we have the following relations-

Component of tangential velocity in Y-direction is given by,

U=Reciprocating velocity of U-slot.

If ‘a’ is the angle made by the tangential velocity with X-axis at any point of time,
Component of tangential velocity in Y-direction is

U=rw sin (a)

U=v sin (a)

As a result, Velocity of U-slot is a function of sine function of a.

Now, as we know that a is directly proportional to the time. This implies that the
velocity of u-slot is a sine function of a so the motion of U-slot is a simple harmonic
motion.

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CHAPTER 3

.
CHAPTER 3

3.1 CONSTRUCTION
Machine has the prime mover at the bottom of the machine. The pulley is attached
to the body at the top and end of the side portion. Pulley is connected with disc type plate.
The pulley and disc has separate connection with one small metal rod through the
bearings.

Motor and pulley is connected with one V type belt. The clamp is fixed with the
disc and at the end of two shafts. Hack saw connected to the each shaft at the end.

Construction of double acting hacksaw using scotch yoke mechanism consist


the following components.

1. AC Motor

2. Pulleys

3. Bearings

4. Shaft

5. Hack saw

6. V belt

7. Shaping

8. Drilling

9. Bevel gear

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3.2 AC motors :
An AC motor is an electric motor driven by an alternating current (AC). The AC
motor commonly consists of two basic parts, an outside stator having coils supplied
with alternating current to produce a rotating magnetic field, and an inside rotor
attached to the output shaft producing a second rotating magnetic field. The rotor
magnetic field may be produced by permanent magnets, reluctance saliency, or DC or
AC electrical windings.

Less common, AC linear motors operate on similar principles as rotating motors but
have their stationary and moving parts arranged in a straight line configuration,
producing linear motion instead of rotation.

Figure 3.1 AC Motor

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3.1.1. Principles of Operation of AC Motor

The induction motor (or asynchronous motor) always relies on a small difference in
speed between the stator rotating magnetic field and the rotor shaft speed called slip to
induce rotor current in the rotor AC winding. As a result, the induction motor cannot
produce torque near synchronous speed where induction (or slip) is irrelevant or ceases to
exist. In contrast, the synchronous motor does not rely on slip-induction for operation and
uses either permanent magnets, salient poles The two main types of AC motors are
induction motors and synchronous motors. (having projecting magnetic poles), or an
independently excited rotor winding. The synchronous motor produces its rated torque at
exactly synchronous speed. The brushless wound-rotor doubly fed synchronous motor
system has an independently excited rotor winding that does not rely on the principles of
slip-induction of current. The brushless wound-rotor doubly fed motor is a synchronous
motor that can function exactly at the supply frequency or sub to super multiple of the
supply frequency.

Other types of motors include eddy current motors, and AC and DC mechanically
commutated machines in which speed is dependent on voltage and winding connection

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3.2 PULLEY

A pulley is a basic device or machine made of a wheel with a rim that a cord or
rope fits around. The wheel and axle of a pulley make it easier to lift heavy objects
with the rope.

V belts 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 solution, needing less width and tension than flat belts
.

Figure.3.2 pulley

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3.3 BEARING

A Bearing is a machine element that constrains relative motion to only the desired
motion, and reduces friction between moving parts. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation around a
fixed axis; or it may prevent a motion by controlling the vectors of normal forces that bear
on the moving parts.

Figure.3.3 bearing

3.4 SHAFT
The term shaft usually refers to a rotating element, circular in cross-section, which
supports transmission element like gears, pulleys and sprockets and transmits power. The
shaft is always stepped with maximum diameter in the middle portion and minimum
diameter at two ends, where bearings are mounted.

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3.5 HACKSAW
A hacksaw is a fine-toothed saw, originally and principally for cutting metal. They
can also cut various other materials, such as plastic and wood; for example, plumbers and
electricians often cut plastic pipe and plastic conduit with them. There are hand saw
versions and powered versions (power hacksaws). Most hacksaws are hand saws with a
C-shaped frame that holds a blade under tension. Such hacksaws have a handle, usually a
pistol grip, with pins for attaching a narrow disposable blade. The frames may also be
adjustable to accommodate blades of different sizes. A screw or other mechanism is used
to put the thin blade under tension.

Figure.3.4 hacksaw

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3.6. V BELT

V belts (also style V-belts, vee belts, or, less commonly, 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— improving torque transmission and making the V-
belt an effective solution, needing less width and tension than flat belts.

V-belts trump flat belts with their small center distances and high reduction ratios.
The preferred center distance is larger than the largest pulley diameter, but less than three
times the sum of both pulleys. Optimal speed range is 1,000–7,000 ft/min (300– 2,130
m/min). V-belts need larger pulleys for their thicker cross-section than flat belts.

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3.7 SHAPING
The cutting stroke takes more time than the return stroke by means of mechanisms.
Due to the result of quick return mechanism a more powerful cutting takes in forward
stroke and tool rubbing action eliminated by return stroke. In the shaper machine the work
piece is in idle condition, the cutting tools only moves on the work piece. The tool is
mounted on a reciprocating ram. Sometimes the motion of the table has controlled by
manually, but typically it can be automated, it is known as feed mechanism. The
mechanism has been operated by lead screw. At end of the ram has the tool post and
clapper box. The function of the tool post is to clamp the tool at a different angles. The
tool-slide enables the feeding of the tool downwards to make the cut deepen. The versatile
nature of a machine gives a path to the operator to cut the gear teeth, splines, keyways etc.
Due to linkage geometry, the return stroke is faster and hence this is known widely as the
quick return mechanism. This is possible via a Whitworth link or slotted link.

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3.8.Uses :

Shafts have keyways that can be machined without being subjected to any complex
machining setup like broaching. This also includes external, internal splines and gear teeth.

Figure.3.5 shaping tool


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3.9.Drilling :

Drill bits are cutting tools used to remove material to create holes, almost always of
circular cross-section. Drill bits come in many sizes and shapes and can create different
kinds of holes in many different materials. In order to create holes drill bits are usually
attached to a drill, which powers them to cut through the workpiece, typically by rotation.
The drill will grasp the upper end of a bit called the shank in the chuck.

Drill bits come in standard sizes, described in the drill bit sizes article. A
comprehensive drill bit and tap size chart lists metric and imperial sized drill bits alongside
the required screw tap sizes. There are also certain specialized drill bits that can create
holes with a non-circular cross-section.

While the term drill may refer to either a drilling machine or a drill bit while in use
in a drilling machine, in this article, for clarity, drill bit or bit is used throughout to refer to
a bit for use in a drilling machine, and drill refers always to a drilling machine.

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3.10.Bevel gear:

Figure:3.6 bevel gear

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CONSTRUCTION OF SCOTCH YOKE MECHANISM
The scotch yoke mechanism is constructed with iron bars. Here the crank is made in
some length and the yoke is also made using the same material. It is noted that the
minimum length of the yoke should be double the length of the crank. The crank and yoke
is connected with a pin.

Figure:3.7 Scotch yoke mechanism

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Iron bars are welded to both sides of the yoke to get the reciprocating motion. The
yoke with the iron bars is fixed on the display board with the help of c clamp. Now the
crank is welded to the end of the shaft of the motor. Now the pin on the crank is connected
to the yoke. The pin used to connect yoke and crank is a bolt.

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CHAPTER 4

18
CHAPTER 4

4.1 PARTS REQUIRED


Following parts are needed for construction of the construction of multi purpose
machine using scotch yoke mechanism.
4.1.1 Listes of parts using in the mechanism

1. A.C. Motor

2. Bevel gear

3. Power supply

4. Square tubes

5. Hacksaw

6. Nut-bolts

7. Switches

8. Shaper tool

9. Slots and guides

10. Pulley and belts

11. Drill bit

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CHAPTER 5
CHAPTER 5

5.1 PROTOTYPE BUILDING:

A sample prototype was constructed with the following specification and governing
parameter were calculated.:

5.1Work frame

Length 68.5 cm

Breadth: 18.5 cm

Height: 71 cm

5.2 Scotch Yoke mechanism

Tube length: 85.5cm


Tube diameter: 2.5cm
Disc: 14cm
Slider height: 13cm
Slider width: 5cm

Rectangular frame length: 68.5cm

Rectangular frame height: 36cm

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5.3. Work Table

Table diameter: 7.5cm

Supporting link length: 18cm

Supporting link height: 13cm

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CHAPTER 6
CHAPTER 6
6.1 COST ESTIMATION:

6.1 INTRODUCTION:

Cost estimation may be defined as the process of forecasting the expenses that
must be incurred to manufacture a product. These expenses take into a consideration all
expenditure involved in a design and manufacturing with all related services facilities
such as pattern making, tool, making as well as a portion of the general administrative
and selling costs.

6.2 What is a Project Cost Estimate?


A “project cost estimate” is a prediction of the most likely total cost of the identified
scope of work for a project. Cost estimates should reflect an overall accuracy indicative of
the level of information available at the time the estimate is prepared.

Project cost estimates are based on identifying, quantifying and


estimating the cost of consuming all the resources (e.g. people,

machines, materials, services, property) required to complete all activities (e.g.


planning, engineering, property acquisition, construction, etc.) including appropriate
allowances for associated risks and uncertainty (contingency), using prices prevailing at
the time the estimate is prepared.

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Each project is unique. To accurately develop an estimate of costs for a project an
estimator must be capable of mentally constructing the project, accounting for all the
activities necessary to complete it, and then estimating the costs using prices prevailing at
the time the estimate is prepared. Many of the best cost estimators are knowledgeable in
both transportation design and construction.

6.3PURPOSE OF COST ESTIMATING:

The primary purpose of a project cost estimate is to provide a basis for


developing, amending, or reviewing a project budget.

A cost estimate is a key component of the project business cases, as it is the


foremost document to justify/support the funding allocation. Cost estimates are also used
in value analysis/value engineering, and program

planning in the Ministry’s capital investment plans.

1. To determine the selling price of a product for a quotation or contract so as to ensure a


reasonable profit to the company.

2. Check the quotation supplied by vendors.

3. Determine the most economical process or material to manufacture the product.

4. To determine standards of production performance that may be used to control the


cost
“...a project manager is only as good as the cost estimate...”

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6.4 COST ELEMENTS:

The Cost Elements are the major categories of work that make up the project.
The vast majority of MOTI capital and rehabilitation projects generally entail the same
fundamental cost elements regardless of delivery method.

6.5 Types of Cost Elements:

1. Project Management

2. Planning

3. Engineering

4. Environment

5. Property Acquisition

6. Construction (including site supervision)

7. Contingency

TYPES OF COST ESTIMATION:-

1. Material cost

2. Machining cost
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6.5.1 MATERIAL COST ESTIMATION:

Material cost estimation gives the total amount required to collect the raw material
which has to be processed or fabricated to desired size and functioning of the
components.

These materials are divided into two categories-

1. Material for fabrication:

In this the material in obtained in raw condition and is manufactured or processed to


finished size for proper functioning of the component.

Standard purchased parts:

This includes the parts which was readily available in the market like Allen screws
etc. A list in orchard by the estimation stating the quality, size and standard parts, the
weight of raw material and cost per kg. For the fabricated parts.

6.5.2 MACHINING COST ESTIMATION:

This cost estimation is an attempt to forecast the total expenses that may include to
manufacture apart from material cost. Cost estimation of manufactured parts can be
considered as judgment on and after careful consideration which includes lab our,
material and factory services required to produce the required.

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6.6 CALCULATION OF MATERIAL COST:
The general procedure for calculation of material cost estimation is

1. After designing a project a bill of material is prepared which is divided into


two categories.

a. Fabricated components
Standard purchased components

2. The rates of all standard items are taken and added up.

3. Cost of raw material purchased taken and added up.


Cost estimation is done as under:

Cost of project = (A) material cost + (B) Machining cost

Material cost is calculated as under:-i) Raw


material cost

ii) Finished product cost i) Raw


material cost:-

It includes the material in the form of the Material supplied by the Steel authority of
India limited as the round bars Channels, angles, square rods, plates along with the strip
material form. We have to search for the

suitable available material as per the requirement of designed safe values.

ii) Finished product cost:-

Following the components which we have directly purchased from the Market, being
easily available and cheaply availably available as compared to their manufacturing cost
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6.7 COST TABLE ESTIMATE

S.NO COMPONENTS COST IN RUPEES


1 AC Motor ₹1500.00
2 Material ₹500.00
3 Drill bit ₹300.00
4 Hack-Saw (1) ₹100.00
5 Bearing(2) ₹200.00
5 Bevel gear(2) ₹200.00
6 Switches ₹50.00
7 Pulley & Disc plate ₹400.00
8 Belt ₹150.00
9 Other stuffs ₹300.00
Total ₹3700.00

6.8 TOTAL COST ESTIMATION:


1. Labour Cost:

Lathe, drilling, welding and power hacksaw cost Labour cost –


Rs.500
2. Overhead charges:

The overhead charges are arrived by “manufacturing cost”

Manufacturing cost = Material cost + Labour cost

= Rs.3700 + Rs.500

=Rs.4200

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Total Cost:

Total cost = Material cost + Labour Cost

=Rs.3700 + Rs.500 =Rs.4200

Total cost of the project = Rs.4200

ADVANTAGE:

It gives a high torque output with small cylinder size and few moving parts that
enable smoother operation. There is no necessity for piston skirt in Combustion engines
since side loading due to sine of connecting rod is nil. Also scuffing is eliminated.

APPLICATIONS

It is used in IC engines namely Bourke and SyTech engine also in valve actuator
mechanisms in high pressure applications. It was used in crude shapers

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References

1) http://www.mechengg.net/2015/08/double-acting-hack-saw-machine-
operated.html

2) https://www.youtube.com/watch?v=hsaoTo1vuY4

3) https://www.scribd.com/doc/91644590/Project-Report

4) http://topicideas.org/ppt/scotch-yoke-mechanism-report-in-mini-project-in-pdf

5) https://www.nmri.go.jp/eng/khirata/stirling/scotch/scotch00_e.html

6)
Theory of Machines and Mechanisms-Ghosh & Mallik

7)
Theory of Machines – Khurmi & Gupta

8)
Theory of Machines-S.S. Rattan

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7.PHOTOGRAPHY:
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