DESIGN OF SWAGING MACHINE New

UNIVERSITY OF DAR ES SALAAM

COLLAGE OF ENGINEERING AND TECHNOLOGY (COET) DEPARTMENT OF INDUSTRIAL AND MECHANICAL ENGINEERING (MIE) TASK: DESIGN REPORT

TITLE:

DESIGN OF A SHEET METAL SWAGING MACHINE

PROGRAMME:

MECHANICAL ENGINEERING

NAME:

PETER, BENJAMIN

REGISTRATION NUMBER:

2017-04-08426

COURSE:

ME 309 : DESIGN PROJECT

COURSE LECTURER:

DR. ELIAS

NAME OF SUPERVISOR:

MR EVARSTO NYANGA

DURATION:

FROM 18/06/2020 TO 14/08/2020

DECLARATION I, PETER, BENJAMIN declare that this project is my own original work and that it has not been presented. Signature………………………………….

06/09/2020

Date: ……………………………………………………………..

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ACKNOWLEDGMENT

The success and final outcome of this design project in at University of Dar es salaam required a lot of guidance and assistance from many people and I am extremely privileged to have got this all along the completion of my Schedule. All that I have done is only due to such supervision and assistance and I would not forget to thank them. I owe my deep gratitude to my design project supervisor Mr. Evarasto Nyanga, who took keen interest on my design project work and guided me all along, till the completion of my study work by providing all the necessary information for developing and well done study. I would not forget to remember Dr.Elias my lecturer in charge in ME 309 DESIGN PROJECT for his encouragement and more over for their timely support and guidance till the completion of my work. I am thankful and fortunate enough to get constant encouragement, support from all Teaching staffs of Mechanical and Industrial engineering department which helped me more to reach line of success. My last gratitude goes to my fellow mechanical engineering students and others for the cooperation that we showed to each other during design exercise period.

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ABSTRACT This report is about design of a sheet metal swaging machine. A swage machine is a metal forming machine that is used to reduce the rod, wire or tube and can transform a piece of metal into desired form through pressure, it results in taking a material and giving it a ridge, groove or some shaped depending on the forming tool. In our case, observation has shown that many metal working SMEs require a swaging machine to facilitate their daily operations on such items as charcoal stoves, metal cooking pots and many other domestic appliances. The aim was to design a simple hand swaging machine for use in metal working SMEs. In this document I have shown step by step procedures toward successful design of the swaging machine. Starting from information collection, product design specifications (PDS) writing and observing several samples of swaging machine from different sources. Different design concepts were generated, evaluated using rating and weighting matrix method and controlled convergence method then the best concept was selected and worked with. Therefore, the selected design concept was discussed in this report from the hand draft, necessary strength analysis, design draft, detail drawing and assembly drawing that sum to the fabrication of the swaging machine.

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Table of Contents DECLARATION ..................................................................................................................................................... i ACKNOWLEDGMENT ........................................................................................................................................ ii ABSTRACT .......................................................................................................................................................... iii LIST OF ABBREVIATION .................................................................................................................................. vi CHAPTER ONE ..................................................................................................................................................... 1

1.0 INTRODUCTION ............................................................................................................ 1 1.1 Background ................................................................................................................... 1 1.2 Design brief .................................................................................................................. 1 CHAPTER TWO .................................................................................................................................................... 2

2.0 MARKET INVESTIGATION ......................................................................................... 2 2.1 Information collection plan .......................................................................................... 2 2.2 Collected information ................................................................................................... 3 CHAPTER THREE ................................................................................................................................................ 5

3.0 PRODUCT DESIGN SPECIFICATIONS ....................................................................... 5 3.1 Introduction .................................................................................................................. 5 3.2 PDS Checklist ............................................................................................................... 5 CHAPTER FOUR .................................................................................................................................................. 9

4.0 CONCEPTUAL DESIGN ................................................................................................ 9 4.2 Concept generation ....................................................................................................... 9 4.3 Concept evaluation ....................................................................................................... 9 4.4 Summary..................................................................................................................... 11 CHAPTER FIVE .................................................................................................................................................. 15

5.0 EMBODIMENT OF THE SELECTED CONCEPT ...................................................... 15 5.1 Introduction ................................................................................................................ 15 5.2 Strength analysis of swaging machine........................................................................ 15 5.3 Determination of swaging load................................................................................... 15 5.4 Shaft analysis .............................................................................................................. 18 5.5 Strength of the standard Bolts .................................................................................... 22 5.6 Gear analysis............................................................................................................... 22 5.7 Bearing........................................................................................................................ 26 CHAPTER SIX .................................................................................................................................................... 32

DISCUSSION, CONCLUSION AND RECOMMENDATION ......................................... 32 6.1 Discussion ................................................................................................................... 32 6.2 Conclusion .................................................................................................................. 32 iv

6.3 Recommendation ........................................................................................................ 32 REFERENCE ....................................................................................................................................................... 33 APPENDICES ...................................................................................................................................................... 34

I. II.

Pictures from literature review...................................................................................... 34 Drawings ................................................................................................................... 34

v

LIST OF ABBREVIATION UDSM-University of Dar es Salaam TDTC- Technology Development for Transfer Centre TBS- Tanzania Bureau of Standards CoET-College of Engineering and Technology SF-factor of safety

vi

CHAPTER ONE 1.0 INTRODUCTION 1.1 Background Swaging process is applied in metalwork field to serve a variety purpose. It can transform a piece of metal into desired form through pressure; Swaging results in taking an object and giving it a ridge, groove or some shape of mold. The process can alter the diameter of rods, hoses and/or tubes. Swaging is used in items all around you. Typical areas include car design, keyed musical instruments and repairs, circuit boards, hose fittings, pipe fittings, lock bolts, sawing blade teeth, ammunition and decorative metal items. Swaging is a specialized field. Understanding the global definitions of this field can enhance our overall respect for this craft. It required designing a swaging machine for use in metal working SMEs. The swaging machine shall work under the principle of two shafts carrying swaging tools that can be changed depend on work in hand. The machine should be hand driven through a crank handle. The motion link between two shafts shall be through gearing system, belt drive, chain drive or any other system that is convenient. 1.2 Design brief The following is the design brief towards the solution of the need/problem; a) The Centre distance between the two shafts (i.e. in figure 1) should be around 65mm b) The capacity of machine shall be to swage up to 1.5mm thick mild steel sheet to a dent of depth 3mm c) Assume the depth of the dent is reached in three equal feeds d) It should be possible to raise the upper shaft relative to the lower one to a height ( H in figure 1) not exceeding 20mm from it horizontal position to allow tool change and adjustment and feed during swaging e) The swaging machine should be mountable (bolted) on a work table, which is not part of this design project f) Bush bearing should be used were required and should be lubricated appropriately g) The work guide (apron) is not part of this project work, so should not be included h) A simple and cheap construction, using available appropriate materials, is require 1

CHAPTER TWO 2.0 MARKET INVESTIGATION 2.1 Information collection plan S/N

Source of

Places

Expected

Methodology

information 1

Users

(Hrs.) CoET bench

 Price,

 Questionnaire,

workshop

 characteristic

 Interview,

(UDSM),

of machine,  problem facing

TDTC

during operation 2

Time

Literature

Books,

 Properties of

review

Report,

materials,  existing

Standards, Internet

design,

3

 Visual inspection,  Taking measurement  Reading,

5

 Observing  Google advance search

 standard,  price,  Photos/video of swaging materials 3

Tanzania

 Standards and

TBS-Ubungo

Bureau of

regulation

Standard

regardless

(TBS)

Swaging machine in Tanzania  What registered companies that they done their production by

2

 Questionnaire

6

using Swaging machine 4

Manufactures

 Availability of

TDTC-COET Production

the machine

workshop

used for

 Questionnaire

manufacturing of swaging machine. Such as gear, handle, shafts

 Availability of material that will be used for manufacturing of the machine components

2.2 Collected information a) From user Information collected from CoET BENCH WORKSHOP, TDTC and design brief also involved meeting of various experienced experts to gain some useful information and documents that would make easy of design to cruise forward with efficiency. Information obtained  Raising and lowering upper shafts. Using bolt and nuts only/bolt, nuts and return spring. Modifying of the top shaft tensioner bolt which is square headed, by making it a T- handle shape which will save you looking for a spanner every time  Power transmission between shafts is done by gear  Product coast will range between 650,000 to 900,000 Tsh 3

 Material cost, specification/dimensions and their different shapes viewed with consideration of ability to withstand expected load. Documents from SITA STEEL Company Limited were perused  The machine should be greased on bush bearings and gear after 90 operating hours b) From literature review Swaging machine are also known as swagers, are low cost way to efficiently point, reduce and form rod, tube, or wire. Swaging can be performed either hot or cold, although cold is popular because of its hardening effect on the most material. The process also improves grain structures, giving the part greater strength and unusually fine finish.  Types of swager -

Rotary swager

-

Stationary swager

-

Hydro former swager

-

Long die swager

 Application -

Used to produce rectangular shapes, square and hexagon

-

Create fluted shapes and cross circular sections

 Size -

2 die swagers for smaller part and better surface finish

-

4 die swagers for pointing and large initial reduction on larger part

 Different type of link between the two shafts that could be used like chain drive, belt drive, gearing system.  Method of lubrication and techniques for smooth operation, in which different form of bush bearing viewed and their suitable lubrication medium (square housing bush and cylindrical housing)  Swager can be used with stand mounted on bench by a vice or bolted  Adjusting system to raise the upper shaft relative to the lower one can be done by using bolt and nuts only or by using bolt, nut and spring as return and adjusting support to ensure stability of working operation.  Types of material to used cast iron for the frame and mild-steel for a round solid shaft and gear.

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CHAPTER THREE 3.0 PRODUCT DESIGN SPECIFICATIONS 3.1 Introduction Part of the PDS must include measurable elements of the design. These elements are indicators of performance. (PDS) is a very important part in the design process as it contains all the information necessary for a design designer to successfully produce a solution to the design problem. 3.2 PDS Checklist 3.2.1 Performance  Ability to change the die for different operations  Manual operated  3mm indentation depth  Swage up to 1.5mm thick mild steel to a dent of depth 3mm  Centre distance between the two shafts should be around 65mm  To raise the upper shaft relative to the lower one to a height not exceeding 20mm  Machine can provide rotary motion on both direction 3.2.2 Ergonomics Ergonomics is the process of designing or arranging workplaces, products and systems so that they fit the people who use them. It aims to improve workspaces and environments to minimize risk of injury or harm. So as technologies change, so too does the need to ensure that the tools we access for work, rest and play are designed for our body’s requirements. Ergonomics is about designing for people Swaging machine will be designed as the following for the people comfort ability  Ergonomic portability, the machine should be portable it can be moved from one bench to another according to the people use.  Swaging machine should be mounted one the table, to obtain the certain height approximately for user comfort  Swaging machine with the rubber handle  Lubrication systems to avoid excess noise

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3.2.3 Safety  Sharp edges and corner points have to be chamfered and filleted to ensure the smooth surfaces  Good lubrication to prevent noise pollution 3.2.4 Disposal  The product consists of steel material which are non-toxic materials and does not need special disposal methods because it’s easy to re-use/recycle steel products to a new one

3.2.5 Size  The length of the shafts should be 450mm  The diameter could be 30mm (diameter of both upper and lower)  Height of the machine should be 300  The size of handle should be accessible to handle by one hand 3.2.6 Installation  The product should be fixed/mountable on a worktable since it comprises of 4 holes bolted so as to ensure its stability during operation with consideration of easy removal from site when needed

3.2.7 Testing  The manufactured product must be tested within the company/ or with a designer itself to verify its functionality; also, the product might be tested for its performance by the customer, i.e. outside the company 3.2.8 Standards  The standards used are within the company/designer/manufacture, ISOStandard 3.2.9 Maintenance  Should be able to be relatively easy to disassembled and assembled in order to do maintenance  The product should be inspected and greased once a month, maintenance tools and spare parts are available  Lubrication using grease nipple 6

3.2.10 Manufacturing facility  It should be possible to manufacture the swaging machine in local workshops, with traditional machine tools and welding facilities.  Standard parts should be purchased from local suppliers 3.2.11 Aesthetics  Colored (i.e. green, blue, red) 3.2.12 Quality reliability  Quality assurance plan proposed shall be followed 3.2.13 Targeted product cost  Product/ machine price, cost estimation and quantity of materials needed, this Influenced the use of minimum materials as possible (ie; machine price can range from 312,675.01 to 800,000 Tsh) 3.2.14 Environment  Working environment should be free from dust.  During operation should be mounted (clamped/bolted) on flat surface especially table  The working temperature should be 30±100C  Relative humidity of the working environment shall be 40-60%  Preventing rusting from machine by painted with rust-proof primer and paint to prevent rusting and be able to operate on different places. 3.2.15 Life in service  The swaging machine shall be operated on 9 hours per day.  The product last for 10 years 3.2.16 Shipping  The swaging machine will be transported by bicycle, motorcycle or small tracks by using roads within Tanzania and by using plane or ships for larger distances outside the country. 3.2.17 Packaging  The machine will be protected by packaging containers such as wooden boxes, crates and millboard structures. 7

 Due to extreme variations in temperature which may occur in transport and bring about sweating in the package. The metal surface should be isolated from moisture by using temporary corrosion protective methods such as dipping waxes or using corrosion protective oils. 3.2.18 Weight  The weight of the machine will range from 15 kg to 25 kg.

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CHAPTER FOUR 4.0 CONCEPTUAL DESIGN 4.1 Introduction Conceptual design is the early phase of the design process, which aim evaluating the best design variable and operating condition in order to maximize the profit. Conceptual Design phase consists of two major activities;  Generation of solutions to meet the stated needs (concept generation)  Evaluation of these solutions to select the best one. 4.2 Concept generation Concept generation, which is when a product development designer comes up with the ideas, is the most critical step in the engineering design process – without it, there is no design. Concept generation method used;  Deep thinking  Literature review  Analysis of existing similar products 4.3 Concept evaluation  Method used, Rating and weighting Matrix; As the follows 

Placing the criteria in order of merit by giving a weight factor to each, usually based on a 1-5 or 1-10 scale, or in percentage such that the total of individual weights add up to 100% or simply to 1. This is done by feeling or judgment.



Rating the Concepts in turn against the criteria, usually by locating a value of 1-10 scale by judgement. The concepts that appear to satisfy the criteria best are given highest numbers out of 10. Two or more concepts may score the same out of 10 if the evaluator feels that they satisfy the criterion equally.



Multiplying the criteria weight values by the concept rating values to give a score for each concept for a given criterion. Add the points for every concept to obtain the overall value of points.



Selection: The concept with highest points is normally selected for further development. However, before the selection decision is made, careful consideration and interpretation of numbers in the matrix should be made 9

The following grading scale can be used as a guideline when assigning the marks to concepts for a given criterion Marks

Meaning

0

Useless (concept is useless based on the criterion)

1

Close to useless

2

Very poor

3

Poor

4

Satisfactory

5

Average

6

Good

7

Very good

8

Excellent

9

Close to perfect

10

Perfect

Weight factor is assigned to each criterion (objective) out of 5 points. Weight converted to relative weights (Peter 1997) Priority factor number

Relative Weight = total number of factors Example; for ease to manufacturing 9th priority out of 11 therefore relative weight will 9

=0.82

11

10

S/N

Criteria

Relative

Relative Weight importance (W)

Concept 1

Concept 2

M

P=M*W M

P=M*W

01.

Ease of manufacturing

9

0.136

6

0.816

8

1.088

02.

Performance

11

0.167

6

1.002

8

1.336

03.

Low production cost

10

0.152

7

1.064

6

0.912

04.

Design simplicity

8

0.121

7

0.847

5

0.605

05.

Reliability

2

0.030

5

0.150

8

0.240

06.

Ergonomics

4

0.061

6

0.305

7

0.427

07.

Aesthetics

3

0.045

5

0.225

5

0.225

08.

Light weight

7

0.106

6

0.636

5

0.530

09.

Small machine size

1

0.015

8

0.120

6

0.090

10.

Material availability

6

0.091

7

0.637

7

0.637

11.

Machine service time

5

0.076

5

0.380

7

0.532

TOTAL

6.243

6.622

Concept selected

2

1

4.4 Summary 4.4.1 Determining Criteria  Customer/need related  Based on related example. Aesthetics  often qualitative  Technical/performance related  Often quantitative  Process/enterprise related  Low manufacturing cost 11

 Short time to market  Time/cost of development  Material availability 4.4.2 Decision making. The purpose of decision-making is to choose the concept(s) to develop further i.

Ease of manufacturing

Design for Manufacturing (DFM) is the process of designing parts, components or products for ease of manufacturing with an end goal of making a better product at a lower cost. This is done by simplifying, optimizing and refining the product design Concept 2, determined to be simple to manufacture since other parts involves only cylindrical pipes lather than machining as Concept 1 that need more machining process. Example in manufacturing blocks as the bush bearing housing. ii.

Performance

The act of performing; execution, operation or functioning, accomplishment, fulfillment, etc. usually with regard to effectiveness, as of a machine. Concept 2, The effectiveness in performance is high compare to the concept 1 due the stability it surrounded by the housing both side, also the concept 2 have adjustable work piece guide to ensure the better performance and good job. iii.

Low production cost

Any design the need the low cost at best performance , Concept 1 seem to have the low production costs even if it involves the machining process but involves small number of components compare to the number of components in concept 2.

iv.

Design simplicity

Technically, the word simple means “not complex”, “easily understood”, or “easily done”. Simplicity is the opposite of “Complexity”. 12

Concept 1, its simple due to the fact they have the small number of components compare to the Concept 2. v.

Reliability

Machine reliability, measures the failure rate of a machine to perform its intended task, High equipment reliability is a choice and not an accident of fortune. To a great extent you can choose how long you want between equipment failures. The Concept 2, it more reliable compare to the concept 1 due to the reasons have different guide example housing of bush bearing to come into contact with dusts and also the shaft alignment at the center of the frame for reduction of stress effects. vi.

Ergonomics

Ergonomics is the process of designing or arranging workplaces, products and systems so that they fit the people who use them. It aims to improve workspaces and environments to minimize risk of injury or harm. The housing, Adjustable and rubber handle keeps the machine of concept 2 to be very friendly with the user than concept 1 vii.

Aesthetics

Aesthetics is a branch of philosophy that deals with the nature of beauty and taste, the comparison concept 1 and 2 seems to have same characteristics example in terms of colors. viii.

Light weight

The concept 1, consider to be less weight compare to the concept 2 but in very small quantity since it comparative due to the blocks machined for bearing holding. ix.

Small machine size

Both concept are comparative small in size, but concept 1 it small more than concept 2

x.

Material availability

The availability of the material weighted the same due to the fact the both concepts designed with nearly comparative the same materials. 13

xi.

Machine service time

The reliability of the concept 2, therefore come and yield the huge time before the next service time compare to the concept 1. 2.4.4 Results Concept selected is concept 2, as weighted 6.622 compare concept 1 6.243.

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CHAPTER FIVE 5.0 EMBODIMENT OF THE SELECTED CONCEPT 5.1 Introduction Swages are formed on cylindrical objects to serve as stiffeners, reinforcement or ornamentation. The swaging machine is a rotary machine equipped with special swaging rolls. The swaging tools must be stiffer than the work piece materials. It’s necessary for the designer of the swaging machine to possess a thorough basic knowledge of the properties of the materials which he has to use. This enables him to understand, and forecast the behavior of materials under applied forces, and be in control of the direction of their flow during a particular forming process. Failure to understand these points will result in material, time, and effort being spent producing faulty shapes, stressed areas, splitting and other undesirable features. The methods employed for shaping work by hand are similar for most materials, the main difference being concerned with such factors as: a) The Force with which the blow strikes the metal. b) The Direction in which the Force or blow is applied. 5.2 Strength analysis of swaging machine The following are the important parts to be analyzed in swaging machine to be designed; a. Diameters of the shafts b. Spring (s) and screw c. Gears (trans system) d. Handle e. Bush bearings f. Bolts 5.3 Determination of swaging load The swaged metal is mild steel with the following description properties,  Dent of depth 3mm reached in three equal feeds  Low carbon steel  Young’s modulus of elasticity E=204000N/mm2 (from data book)  Ultimate tensile strength σult=370 N/mm2 (From data book)  Swage up to 1.5 mm thick mild steel.  Assumption: The swaging load is equal to the bending load as in v-bending. S

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Consider the figure below,

(a)

(b) Figure 1: Swaging force

(a) swaging force arrangement (b) air bending

By assuming this U-bending is approximately equal to the V-bending force therefore by three feed to 3mm each feed will bend to 1mm and two first feed will be considered as air bending but the last will be normal bending. In V-bending air bending force it is less compare to the normal bending therefore the calculation of force will be considered of the last feed which have the maximum bending force. 16

Recall maximum bending force kbf x Ts x w x t⌃2 …………………………………………. (i) 𝐷

Fsw=

Where Fsw=Swaging load Ts=Tensile strength (σuts) =370N/mm2 w=width of bending =4.5 mm D=Die opening diameter = 9mm Kbf= bending factor for the u-bending =1.33 t- Thickness of the sheet metal =1.5mm Then Fsw=

𝑁 𝑚𝑚2

1.33 𝑥 370

𝑥 4.5 𝑚𝑚 𝑥 (1.5𝑚𝑚)2 9𝑚𝑚

Fsw= 553.6 N The working load will be normal to the work piece, and due to motion there are static and dynamic frictional forces between die-work piece interface acting tangentially, and taking average value of coefficient of friction between steels surface of 𝜇 = 0.2 (databook, page 249). μ=

Fr R

Fr= 0.2 x 553.6 N= 110.72N This friction force produces a frictional torque T or twisting moment Mt on the shaft. This subject the shaft to torsion. Taking the swaging tool diameter of 40mm Torque produced, T =Fr x r (radius of the tool) T= 110.72N x 32.5 mm = 3598.4 N mm The force which will be applied on the crank handle will be obtained by T = F × R (Radius of the crank handle rotation curvature) ∴F=

T 3598.4N = = 24N R 150

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Figure 2.Torque at the handle The human torque is 40lb.inch (4521Nmm) in wheel diameter 115-200mm, therefore it can be operated by hand only of the radius of curvature of 150mm 5.4 Shaft analysis The material used for shafts should have the following properties: 1. it should have high strength. 2. It should have good machinability 3. It should have high wear resistant properties. 5.4.1 Forces act on the shaft; 

Reaction forces



Forces act through gears



Swaging force

Consider the force acts on the spur gear, Consider each tooth as a cantilever beam loaded by a normal load (FN) as shown in Figure below. It is resolved into two components i.e. tangential component (Ft) and radial component (Fr) acting perpendicular and parallel to the Centre line of the tooth respectively. The tangential component (Ft) induces a bending stress which tends to break the tooth. The 18

radial component (Fr) induces a compressive stress of relatively small magnitude; therefore its effect on the tooth may be neglected. Two figures below show the action of force to the tooth of the gears

Figure 3 Distribution of force on the gear If efficiency is 100% then

2𝑇1 2𝑇2 𝐷1

= 𝐷2

Since D1=D2, Then T1=T2. Tangential force Ft Ft=

2𝑇 𝐷

…………………………………….…………………………………. (ii)

D-Centre distance of the gears Ft=

2𝑋3598.5 65

N

Ft=110.72 N Assumed is full depth system large tooth size, α=20 ͦ 110.72N

Then FN= 𝐶𝑂𝑆 20 =117.83 N Fr= 110.72 N x tan 20 ͦ = 40.3 N Consider FBD representation of forces

19

Figure 4: Forces Representation 1 Where; R1 and R2 are the reaction forces on the shaft, Fr radial force act on the spur gear, Ft Tangential force act on the spur gear and FSW is the swaging force

Consider the moment at point A +ve sum of the clockwise moment at point A is equal to zero +ve ƩMA=0 160R2 – 40.3x290 - 420R1 + 3598.4 =0…………………………………………….. (iii) 160R2 - 420R1=8096.6 N ƩFy=0 at equilibrium position -R1+R2 =40.3N + 553.6N………………………………………………………… (iv) -R1+R2 = 593.9 N R2=928.24 N and R1=334.34N Also R2 is considered to be the force require to raise up and the lower down the upper shaft.

5.4.2 Bending moment of the shafts Consider the FBD and BMD below

20

Figure 5: FBDs and BMDs Moment equations Bending moment at B Mb=160 x 553.6 N mm Mb=88576 N mm Bending moment at C Mb at C = -334.34 N x 130mm Mb at C = 43464.2 N mm

The shaft are normally acted upon by gradual and the modified equation in ASME code by suitable factors will be; 16

τall=𝜋𝑑3 (1−𝑘 4 ) √𝑀𝑏 2 + 𝑇 2 …………………………………………………………..(v) k=0, for solid shaft.

16

τall=𝜋𝑑3 √𝑀𝑏 2 + 𝑇 2 …………………………………………………………………(vi) Where Mb=88576N mm, T=3598.4 N mm 21

Also ASME Code for commercial steel shafting 40Mpa (40N/mm2) for shaft with keyway τall=40N/mm2 assume the factor of safety (FS) is 1.2, therefore working stress is 33.33 N/mm2 16

Then, 33.33 N/mm2 = 𝜋𝑑3 √(88576 𝑁𝑚𝑚)2 + (3598.4 𝑁𝑚𝑚)2 d= 23.83 we say 25mm Diameter of the shaft is 25mm

5.5 Strength of the standard Bolts For my application I have selected entire range of the bolts based on the proof strength as defined by ISO specification (ISO 4017-Hexagon head). Proof strength can be defined as the stress at which bolt begins to take permanent set. 5.6 Gear analysis Gears are used to transmit torque and angular velocity in wide variety of application. There is also a wide variety of gear types to choose from. The simplest type, the spur gear, designed to operate on parallel shaft and having teeth parallel to the shaft axis. Other gear types such as helical, bevel, and worm can accommodate non parallel shaft. In this design gear will be of the same size i.e. gear train ration is 1 𝐷1

Gear train ratio =𝐷2 =1 Consider the sketch;

Figure 6: Centre distance of gears Torque produced on the handle of the handle is equal to the torque transmitted on the gear. Therefore as calculate the force acting on the spur gear. FN=117.83N, Ft=110.72N and Fr=40.3N 5.6.1 Components of Gear -Module -Number of teeth 22

-Pitch cycle diameter -Circular pitch -Addendum circle diameter -Dedendum circle diameter -Face width a. Number of teeth Let Z1 = Number of teeth on gear 1, D1 = Pitch circle radius of gear 1, and Similarly, Z2, = Number of teeth on gear 2 Since the distance between the centers of the shafts of gears 1 and 2 is 65mm, therefore the pitch cycle diameter of the gears D1=D2=65mm D

-Number of teeth, Z1=Z2= 𝑚 where m is module 65

Z= 2.5 =26 teeth Z1=Z2=26 teeth. b. Face width Face width (b) = 9 m ≤ b ≤ 12.5m generally, face width is assumed as ten times module b=10m where m is the module, b=12x2.5 =30mm c. Circular pitch Circular pitch= πm =π x 2.5 =7.85 mm d. Addendum circle diameter From Da=d+2m, Da=65+2x2.5 =70mm e. Dedendum circle diameter Dd- dedendum circle diameter

23

From Dd=D-2x1.25m…………………….……………………………….. (vii) Dd=65-2x1.25m =58.75mm 5.6.1 Strength analysis of the gear From Lazarev and Mosha (1985), the allowable bending stress is calculated from 𝐹𝑡

𝜎𝐹 = 𝑏𝑚𝑌𝐹𝑆𝑌𝜀𝐾𝐴𝐾𝑉𝐾𝐹𝛽𝐾𝐹𝛼 ≤ 𝜎𝐹𝑃…......................................................... (ix) Where; 𝜎𝐹=tooth root strength 𝜎𝐹𝑃=permissible tooth root strength Ft=tangential load -b=face width =30mm -m=module= 2.5mm -YFS=combined form factor Depending on number of teeth for gear For Z=26; YFS≈ 4.47 -For Y𝜀, Y𝜀=0.25 +

0.75 εα 1

1

From, 𝜀𝛼=1.88-3.2(𝑍3+𝑍4)……………………………………………..(x) (Mr. Nyanga 2020) 1

1

𝜀𝛼=1.88-3.2(26+26) 0.75

Y𝜀=0.25 + εα , since εα=1.554 Y𝜀=0.733 -KA= Application factors= 1.0 (based on working characteristics of the machine) -Kv=Dynamic factor, it depend on the pitch line velocity v1, 2 and the number teeth V1,2=

ωd 2

, which is the same for both gear d=0.65m and N3=20rpm

24

V1,2=

πx20x0.065 60

, V1,2=0.1m/s therefore Kv=1

-KFβ longitudinal load distribution It depends on the material of the gear and the ratio of the face width to the pitch diameter b/d. Solving of b/d and find the corresponding value of KFβ. Therefore, b/d=30/65= 0.46; KFβ=1.02 -KFα=transverse load distribution factor This value depend on the accuracy grade ISO For ISO-8 the value of KFα=1.2 Substituting the values into equation (x) 𝐹𝑡

𝜎𝐹 = 𝑏𝑚𝑌𝐹𝑆𝑌𝜀𝐾𝐴𝐾𝑉𝐾𝐹𝛽𝐾𝐹𝛼 ≤ 𝜎𝐹𝑃 For pinion 3 110.72

𝜎𝐹=30𝑥2.5x4.47x0.733x1x1x1.02x1.2 σF = 6 Mpa Therefore it’s safe to use any material for gear, (selected grey cast iron (ISO/R 185)-DIN GG-20 for both since its 𝜎𝐹≤ 𝜎𝐹P ≤ 80Mpa Properties  Surface hardness 180 HB  σHlim=300N/mm2, σFElim=80 N/mm2  Good machinability  Low cost

25

5.7 Bearing We use the term bearing here in its most general sense. Whenever two parts have relative motion, constitute a bearing by definition, regardless of their shape or configuration. Usually, lubrication is needed in any bearing to reduce friction and remove heat. Bearing may roll or slide or do both simultaneously. Type of bearing used bush bearing.

Figure 7: bearing load W= Fr –Radial force subjected d- Inner diameter of the bearing l- Length of the bearing p- Specific bearing load 𝐹𝑟

𝐿𝑂𝐴𝐷

p=𝑑𝑥𝐿 =𝑃𝑅𝑂𝐽𝐸𝐶𝑇𝐸𝐷 𝐴𝑅𝐸𝐴……………………………………………………………….. (xi) From SKF and MBA (METAL BUSHING IN ITALIA) Outside diameter of the bush bearing for 25mm is 40mm Chamfer of 0.5mm From, Fr

p= 𝑑𝑥𝑙 N

p= 25 𝑥 40 p= 0.93 N/mm2 we say 1N/mm2 26

c=0.001d c- Radial clearance of the bearing with the shaft. c=0.001x25mm c=0.025mm From a table 16.2 (Bhandari, Design of Machine element, pg. 625-626) permissible unit bearing pressure is 2 N/mm2, Due to diameter of shaft 25mm For the machine tools bearing pressure permissible is 2N/mm2, therefore the bearing will be safe Due Specific bearing load, the material selected also due to the availability, low cost, and good also friendly to the performance. Material selected is Bronze with pressure greater than 3.5 N/mm2 5.8 Power screw and springs 5.8.1 Power screw

Figure 8: Terminology of power screw A power screw is a device used in machinery to change angular motion into linear motion, and, usually, to transmit power. Familiar applications include the lead screws of lathes, and the screws for vises, presses, and jacks. Load 110.72 N It is important to know the torque required to raise or lower a given load, Let p = pitch of the screw dm =mean diameter of the screw α =Helix angle l =lead of the screw P = Effort applied at circumference of the screw to lift the load W = the load to be lifted or lower μ = coefficient of friction between the screw and nut 27

There are three components of a power screw, which are screw, nut and frame Properties, i.

Sufficient strength

ii.

Good machinability

iii.

High wear resistance

a) Lead and pitch of the power screw Lead is the distance through which the power screw advances axially in one revolution of the nut. Lead =number of starts x pitch Note: In the design, dent given is 3mm must be reached by 3 equal feed therefore each feed will be 1mm. Lead of the power screw will be equal to 1 mm. Assumed, its single start, therefore lead=pitch b) Design of screw The bearing pressure between the contacting surfaces of the screw and the nut is important consideration in design. Bearing area between the screw and the nut for one thread is 𝜋(𝑑2 −𝑑𝑐 2 )

Ab=

…………………………………………………................................... (xii)

4

𝑊

Sb=𝐴𝑏 …………………………………………………………………………………. (xiii) According to (Bhandari, Design of Machine element, pg. 196) for hand press using Screw material: C40 (unhardened) carbon steel screw Nut material: bronze, bearing pressure Sb = (18-24) N/mm2 Therefore; 18N/mm2, assume the safety of factor is 5.3 therefore the working pressure is 3.4N/mm2 Ab=

40.3 N 3.46N/mm2

= 11.85 mm2

Since the my design it simple machine, decided to use outer diameter (d) of the power screw is dc + pitch in mm Where pitch is 1mm d2 - dc2=

11.85x 4 𝜋

-dc =7.04 mm Therefore we say dc = 7mm 28

Inner diameter (dc) of the collar = 7 mm Outer diameter (do) of the screw = 8mm c) Helix angle and pitch Pitch (p) = d - dc …………................................................................................................ (xiv) p= 8mm - 7mm p= 1mm 𝑙

α =tan-(𝜋𝑑𝑚) …………..................................................................................................... (xv) (d+dc)

dm=

2

…………........................................................................................................... (xvi)

dm =7.5 mm Assumed to be single thread therefore l=p =1 mm 1

α =tan-(𝜋 𝑥 7.5) Helix angle (α) =2 .4 ͦ 4.7.2 Spring A spring is defined as an elastic body, whose function is to distort when loaded and to recover its original shape when the load is removed. It may be tension or compression In this swaging machine the spring required is tension spring which will Return the upper shaft to the original horizontal balance. Assumed the length of the spring before extension will 12 mm (free length) The extension of must not exceeding 20 mm as given, therefore to the small diameter of the swage work piece assumed the extension is 15mm The weight needed to be raise up is approximately the weight of the upper shaft, upper tool, and bearing

Figure 9: extension spring For shaft, 𝑀𝑠 = 𝑣 × 𝜌 =

𝜋×(25×10−3 )2 ×8050 ×0.42 4

= 1.7kg

29

For bearing Mb = v × 𝜌 =

𝜋 ×( 0.0322 −0.0252 ) 4

× 0.020 ×8050=0.051 kg

For tool 𝜋 × ( 0.052 −0.0252 )

MT= v × 𝜌 =

4

× 0.021 × 7300=0.226 kg

M= 1.7 kg + 0.051 kg + 0.226 kg M= 1.977kg W= 1.977kg x 9.81 N/kg W= 20 N. Forces acting on the spring during restoring is approximately to 20 N Consider for cold drawn steel wire of ultimate tensile strength of 1090 N mm-2 and modulus of rigidity of the spring material is 79300 N mm-2. The permissible shear stress is given as 𝜏 = 0.5 𝑆𝑢𝑡 = 0.5 × 1090 = 545 Nmm−2 The spring index is taken as 𝐶 = 5 Wahl’s factor 4𝐶−1

𝐾 = 4𝐶−4 +

0.615 𝐶

= 1.3105………….................................................................. (xvi)

8𝐹𝐶

𝜏 = 𝐾 (𝜋𝑑2 )…………........................................................................................... (xvii) 8×20×5

545 = 1.3105 × (

𝜋×𝑑2

)…………................................................................... (xviii) 𝑑 = 0.7825 mm

We say d= 0.7825≈1mm Mean coil diameter 𝐷 = 𝐶𝑑 = 5(1) = 5𝑚𝑚 Number of active coils 𝑁 𝛿=

8𝑃𝐷 3 𝑁 𝐺𝑑4

…………........................................................................................... (xix)

30

15 × 79300 × 14 𝑁= = 8 × 20 × 53 𝑁 = 60 Coils Total number of coils 𝑁𝑡 = 𝑁 + 2 = 40 + 2 = Pitch of the screw 𝑝=

Free length 16 = = 0.27mm 𝑁𝑡 − 1 60 − 1

5.9 Keys The key size is dependent to the shaft diameter and hub length. Sunk key is chosen for this application of square type. The selection is made without considering stress analysis and by the thumb rule for square key dimensions:

Figure 10: square gear 𝑑 25 = = 6.25 mm 4 4 𝑑 25 ℎ= = = 6.25mm 4 4

𝑏=

𝑙 = 1.5𝑑 = 1.5 × 25 = 37.5mm The key used is of dimensions 6.25mm x 6.25 mm x 37 mm, with shaft cut depth of 3.5 mm. and it calibrated the same as the key at swaging tool.

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CHAPTER SIX DISCUSSION, CONCLUSION AND RECOMMENDATION 6.1 Discussion AS to compare the manual operated swaging machine and power operated swaging machine, the manual swaging machine is affordable and have low cost to compare that of power operated swaging machine. Also the manual operated machine designed its portable it can shipped from one position to another manually without any other shipment equipment, swaging machine design need very small force to operate which comes less to 20 N. 6.2 Conclusion In this part a summary of the contributions made by the present research work and few suggestions for further research are presented in the present work on Intelligent Design of Progressive Dies, five important problems have been investigated. The first problem is to develop a knowledge-based system module for checking the design features of sheet metal parts from manufacturability point of view. Since the design of strip- layout forms the next stage of progressive die design, investigations have been made to develop an intelligent CAD system for design and modeling of strip-layout the problem of selection of proper types and dimensions of progressive die components has been tackled through the development of a knowledge-based system. For automating the modeling of progressive die components and die assembly, an intelligent modeling system has been designed finally, an intelligent system has been developed for selection of suitable materials for progressive die components. 6.3 Recommendation Having progressed through the entire design process, from data collection to concept generation to final design evaluation, I have several recommendations for both improvements on the current design and future work The greatest consideration of the design on my design is proper working and simplify the swaging purposes but for now days due to the huge technology development, the design must add simple power system to simplify and to add the functionality of the machine. Ultimately, I consider the semester a success and are proud of this project. My final recommendation. I believe that the design project should be considered a large step in the right direction and the frame with the inclinable back support should be given to a future designer tasked with providing other metal swaging either powered or manually 32

REFERENCE 1. April 1983, DRAWING AND DESIGN, Data book for mechanical engineering 2. www.machineseeker.com 3. Swaging machine Wikipedia 4. National swaging machine and die warning, use, maintenance and application installation report by The Crosby Group LLC 5. Swagger Safety Guide by Associated Wire Rope Fabricators (AWRF) 6. Pugh 1991, Total design approach 7. Dr Elias 2018, ME 202-Lecture notes 8. r.s. khurmi j.k. gupta 2005, a textbook of machine design 9. V.B Bhandari design of machine elements (third edition) 10. Prabhu. T.J, 2002. Design of Transmission Elements-edition

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APPENDICES I.

Pictures from literature review

Figure 11 Different type of swaging machine

II. Drawings -Concepts drawings -Hand Draft drawings -Design draft drawing -Detail drawings i. ii. iii. iv.

Shaft Power screw Frame Gear

34