DESIGN AND ANALYSIS OF AUTOMATED HYDRAULIC SWARF COMPACTOR

1R. Prakash, 2V. Kailashkumar, 3S. Kartheepan, 4S.K. Rajkumar, 5M.M. Karthi,

1Assistant Professor, 2,3,4,5 Students of Mechanical Engineering1, 2,3,4,5 Department of Mechanical Engineering

1, 2,3,4,5 Sri Shakthi Institute of Engineering and Technology, Coimbatore-62, Tamil Nadu, India

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Abstract: Foundry is one of the major industries where casting is produced. 70% of automobile components are produced with casting process. To produce such intricate shape hollow components core are required, which are produced in core shop. And also swarf compactor machine is used in machining industries for producing briquettes. In manual hydraulic compacting process, briquettes are produced manually and the man power requirement is required. So, the automatic swarf compactor process is needed on its behalf. In this study, the system evolves through development of design and analysis. In automatic swarf compacting process, hydraulic and pneumatic systems are used for movements which are controlled by programmable logical controller (PLC). In this process, fixture box is used for making briquettes. The briquette size can be changed according to the specification of the fixture box. The fixture box size is specified according to the requirement of the industry. Here, the swarf compactor machine was analyzed and studied about the old swarf compactor machine which is available and was redesigned for the use of small industries and hereby they become the beneficiary. A large amount of metal chips at industries and workshop will result in untidy and a hazardous environment, which causes unwanted accidents. In order to prevent such accidents, the industries must clean and transport those swarf. The cleaning and transporting of these chips are not easy, to make this process easier the hydraulic swarf compactors are used, in which the powdered chips and waste materials are inserted and the output will be in briquette form which is easy to handle. Although the price of the chip briquettes can be directly used in furnace. The project includes analyzing and testing of the hydraulic swarf compactor.

Index Terms – Design, analyzing, development,swarp compactor,chips and scrab________________________________________________________________________________________________________

I. INTRODUCTION

Almost all industrial production processes include machining of metal parts by means of turning, milling and drilling by both conventional and CNC producing large quantities of chips on the daily basis. These chips are collected in the industrial plant without any use, occupying valuable floor area of the industrial plant. In a regular interval the industry sells the metal chips to a third-party consumer for a low price with an unseen loss to the industry. In addition to minimize waste and adding value to which includes also the reuse and recycling of waste chips in foundries, which consumes high energy for melting. Instead of melting the chips directly in the furnace, with the help of this swarf compactor we can make the chips in briquette which adds the value to the chips as the foundry can directly use the briquette for the melting purposes because it consumes less energy for the melting pur-pose. The issue of briquette of metal wastes is studied from different points of view in the industrial plants. Also with an addi -tional usage in this swarf compactor is that, coolant oil can be separated from the chips which is taken directly after machining which is highly valuable for the industry. The cutting fluid which is separated in the swarf compactor can be reused again for ma-chining. And the swarf compactor uses less space in the plant which can be mainly used in almost all small scale industries.

1.1 Present scenarioPresently the industries are using storage bins or a specified area for storing the chip in the shop floor. Currently the

small-scale industries don’t do any operation on the waste chips were they directly sell to any third party buyers, were they are losing a certain amount in their profit. And the compactor which is available in the market is not affordable by all the industries.

An idea of designing and fabricating an automated hydraulic swarf compactor was developed to perform the operation of turning the chips into briquette within an affordable cost for increasing the ROI of the industries.

1.2 Scope of the project

In this project, a automated hydraulic swarf compactor is designed and fabricated to covert the chip to briquette. The main advantage of this project is to reduce the cost of the chip compactor and make it affordable to all the small scale industries. With the help of this chip compactor, the value of the scrap is increased and the coolant can be separated and reused.

By converting the chip to briquette, the foundry is also profitable because the power consumption is less in furnace. By this the small scale mechanical industries is benefited and their standard is increased.

1.3 Objective of the project

To design and analysis the components of an automated hydraulic swarf compactor suitable to compact any type of chip material within high production rate.

II. LITERATURE SURVEY

Tarun S.V. (1996) described about the Metal Chips, especially of ferrous metals, are widely recycled and substitutes metal ores in steel making. The collection, storage and transportation of metal chips is an important aspect in the process of recycling. This project focuses on the compaction and creation of metal chips briquette for ease of storage as well handling and transportation of metal chips as a whole. The project is carried out mainly in two parts. First, the compactor machine is designed keeping the size as compact as possible and ease of availability of materials required to build it.

Sinha et al., (2003) has conducted a study on hydraulic presses. It represents a 3- D complex structure. It is found that an exact analytical method of stress and deformation analysis is cumbersome and time-consuming. In order to reduce core memory requirement and the cost of computation, a simplified plane stress (PS) FEM model for a hydraulic press structure (welded frame) has been identified for its analysis. On the basis of this investigation, certain significant guidelines have been obtained for the design of press frames. Such a model has resulted in savings in computational time, core memory requirement and cost of analysis.

Tarun et al., (2015) developed a chip compactor machine using drop hammer mechanism. The advantage of this mechanism is it will provide more impact force which makes the chips into high density briquettes. This is a manual process and it can only be used for small quantity of chip compaction. But here we are making the whole process automation and we are going to use hydraulic drive, because we can avoid lubrication purpose, heavy force can be generated, and long line transmission can also take place. So, we are moving with hydraulic drive.

Milan Brozek et al., (2016) presented pieces of knowledge obtained at chip briquetting by metal cutting. Experiments were carried out using eight chips types obtained at three different cutting methods and five different nonferrous metal alloys. By the evaluation of the measured values the relations between the briquettes volume density and the briquetting pressure and between the force needed for the briquette destruction and the briquetting pressure were obtained. It was proved that the briquettes volume density depends very much on the material which the briquettes are made from. Next influences (cutting method, chips size) are less meaningful. From the point of view of the relation between the destruction force and the briquetting pressure it was found that the resistance to crushing of briquettes made from copper alloys was minimal, the resistance to crushing of briquettes made from aluminum alloys was major and the resistance to crushing of briquettes made from zinc alloys was the highest.

Ramya k. et al.,(2016) describes about how mild steel possess excellent ductility because of carbon contain, which is essential for the deep drawing of sheet but their strength is low. As the percentage is increased (0.2%) the strength steel rises into range required. Reduction the carbon percentage and addition small amount of other alloying elements can achieve this, mild steel possess the desirable properties as good tensile strength. With the above properties along with relative cheapness has made mild steel a desirable material for the use in industry for many mechanical and structural engineering purpose of bridge work, reactors, boiler plates, parts of various components and engines. A great deal of study has been devoted to corrosion in the multidiscipline area of different. With the help of certain materials, including eco-friendly extract a number of organic compounds have been used as potent corrosion inhibitor.

Saravanakumar D. et al., (2018) discussed about the pneumatic cylinders. Pneumatic cylinders are employed extensively in industries for automatic operations. The advantages of pneumatic drives are low cost, high speed linear motion, high efficiency, long working life and a broad working temperature range. Pneumatic drives use only compressed air energy for it operation making it a safer from many hazards such as environment (presence of wetness, dust and chemicals) and radiations. Servo pneumatics is the technology of using a feedback system which enables the pneumatic cylinders to be positioned in any position within its stroke length. This servo pneumatic system has the potential to replace electrical systems which need additional mechanical arrangements for linear motion and expensive hydraulic systems in many applications. During high pressure air supply the accuracy of the servo pneumatic system is much lower than during low pressure supply.

III. DESIGN AND WORKING

3.1 IntroductionIn this chapter a brief view of the materials designed and methods used for the testing and fabrication of automated hydraulic

swarf compactor is discussed. And the project is planned and executed in a well manner.

3.2 Conceptual design

The various models of the project were designed using the software solid works version 2019. The design of automated hydraulic swarf compactor involves the design of various components shown in Table 4.1 below.

Fig. 3.1 Conceptual design

3.3 Components involvedThe conceptual design consists of following parts,

1. Base frame2. Hydraulic cylinder3. Hopper4. Pneumatic cylinder5. Fixture box6. PLC

3.3.1 Base frame

Base frame is the primary part of hydraulic swarf compactor, it is the main body made of I section in order to withstand heavy loads and to avoid failure or breakage. It is made of mild steel material. It is the base for the swarf compactor which holds all the parts of the swarf compactor. The hydraulic cylinder is mounted on the main frame only where the chip compaction takes place within the main frame only. The base frame is shown in Fig.3.2.

Fig.3.2 Base frame3.3.2 Hydraulic press

Hydraulic press is used to compress the chips and to reduce its area. It is illustrated in the Fig.3.3. It consists of hydraulic fuel which produces high pressure inside the cylinder and moves the piston up and down. The hydraulic cylinders with the specification of 90mm bore diameter with the stoke length of 550mm. In this machine the hydraulic cylinder is helps to move the press to compress the chips in fixture box. The hydraulic press is shown in Fig.3.3.

Fig.3.3 Hydraulic cylinder

Calculation of Force

Hydraulic cylinder force is defined by the applied air pressure and the area of the cylinder

For single acting piston,

F = P * A

A = π4

* d2

For double acting piston,

F = P * A

A = π4

* (d12 – d2

2)

Symbols

F = Force

P = Pressure

A = Area of cylinder

π = pi = 3.14159....

d = bore diameter (single acting piston)

d1 = full bore piston diameter

d2 = piston rod diameter

Actual calculation

Diameter of the cylinder (d) = 90mm

Applied pressure (P) = 550 bar = 55 N/mm2

Area of the cylinder (A) = π4

* (90)2 = 6362mm2

Force obtained from = P * A = 55 * 6362 = 350KN

the applied pressure

Force F = 350KN

3.3.3 HopperHopper is a funnel shaped chamber or reservoir form which solid materials can be discharged under gravity into a

receptacle below, especially for feeding the swarf towards the base of the press in order to compress it. Normally hopper can be made by carbon steels, aluminium and stainless steel. But aluminium cannot be used here because it has less strength and it will get failure easily. If the hopper is made of stainless steel means it will result in high cost. So, mild steel is preferred for manufacturing hopper. It can withstand 10-15Kg load. The hopper is shown in the Fig.3.4.

Fig.3.4 Hopper3.3.4 Pneumatic cylinder

Pneumatic cylinder is the part of compactor, which pushes the compressed briquettes out of the fixture box. It is running with the help of compressor and the PLC circuit. The pneumatic cylinder is manufacture with the ABS pipe through. Which is less in cost when compared with metallic parts. The pneumatic cylinder is illustrated in the Fig.3.5. It is same as hydraulic press manufacturing process. The oil tank is replaced by air reservoir and it can be controlled by solenoidal valve.

Fig.3.5 Pneumatic cylinderCalculation of Force

Pneumatic cylinder force is defined by the applied air pressure and the area of the cylinder

For single acting piston,

F = P * A

A = π4

* d2

For double acting piston,

F = P * A

A = π4

* (d12 – d2

2)

Symbols

F = Force

P = Pressure

A = Area of cylinder

π = pi = 3.14159....

d = bore diameter (single acting piston)

d1 = full bore piston diameter

d2 = piston rod diameter

Actual calculation

Diameter of the cylinder (d) = 56mm

Applied pressure (P) = 150 bar = 15 N/mm2

Area of the cylinder (A) = π4

* (56)2 = 2463mm2

Force obtained from = P * A = 15 * 2463 = 36945N

the applied pressure

Force F = 36945N

4.2.5 Fixture boxThe fixture box comprises the briquette die for the formation of the square briquette with the dimensions of 20x20x10

cm (Length x Breath x Height). The fixture box is connected to the main frame where the base plate is connected to a hydraulic cylinder for the output of the briquette. The die can be changed for the change of shape of the briquette. The fixture box movement is controlled with the help of PLC unit. It is shown in the figure 3.7. Thus it is fixed at the bottom of the press

Fig.4.6 Fixture box

4.2.6 Programmable logic controller (PLC)PLC is short for programmable logic controller and it’s basically a computer designed to work in an industrial

environment. It is shown in the Fig.3.8. It controls and monitor a number of inputs and outputs through an aligned program. In PLC, the sensors are the input signal to initiate the program and when the first sensor detects the output signal is sent to the relay first to increase its voltage and then the signal goes to the solenoid valve to accelerate the hydraulic cylinder. This PLC works on the command that was already feed in the program like once the sensor detection is over, after that the next work starts and finish. This PLC controls the sensors, relay, solenoid valves and hydraulic cylinders. The power supply given to the PLC is 24V and output from it is only 5V this enough to run the metal sensors but for solenoid control the relay is used to increase the output voltage to 24V. The timing controller is also attached for manual control.

4.3 Fabrication Design The designed components are drafted to manufacture the components accurately. In this drafting, the part design is

detailed in required parameters with this help of the drafted parts only the manufacturers fabricate the components. So only the drafted design is also called as fabrication design. Each manufacturing parts must be drafted and give cut sections, detail views wherever required.

IV. RESULT AND DISCUSSION

4.1 AnalysisThe machine had been design and analyzed, Analysis like stress analysis, load analysis and deformation rate analysis are

carried out and discussed, it is given below.4.2 Stress analysis of main frame

The stress analysis has been conducted in the main frame to find the stress that can withstand by the frame. In that analysis von-misses stress test was conducted and it found that the maximum stress that the main frame can withstand is 87.497 MPa.

Fig.4.1 Stress analysis of main frame

4.3 Load analysis - self weight of frameLoad analysis is done in the frame of the swarf compactor machine. From this analysis it can be find

withstanding capacity. Then to find the deformation in main frame during pressure applied. During the testing the various pressure can be applied. It found that the maximum pressure that the main frame can withstand is 450 bar. Since the deformation is only 1micron it will not affect the core box, so the core box is also safe.

Fig.4.2 Load analysis of main frame

4.4 Analysis of hopperAnalysis is carried in the hopper for checking its safe limit during the pressure applied. From this analysis it can be given

that whether the hopper design is in safe limit. Input pressure given is 450bar and swarf weight is 15kg. The result obtained is max stress developed 158.58mpa and factor of safety is 1.573. Since the materials yield strength is 220mpa, and obtained is more.The factor of safety is 1.573 where it is not much safe so the analysis is conducted again on hopper by giving input pressure as 400bar and sand mass 15kg. The obtained stress is 158.58mpa, it is within the yield strength. The FOS is 5. So the design is safe.

Fig.4.3 Stress analysis of hopper

Fig.4.4 Load analysis of hopper

4.5 Analysis fixture boxAnalysis is carried in the fixture box for checking its safe limit during the pressure applied. From this analysis it can be

given that whether the fixture box design is in safe limit. Input pressure given is 450bar and swarf weight is 15kg. The result obtained is max stress developed 36.572mpa and factor of safety is 6.8358. Since the materials yield strength is 220mpa, and obtained is more. So the design is safe.

Fig.4.5 Stress analysis of fixture box

Fig.4.6 Load analysis of fixture box

4.6 Analysis pneumatic cylinderThe undergone the stress analysis, deformation analysis and FOS analysis. Based on the analysis to found the maximum

pressure to withstand the cylinder is 28.054mpa, deformation of cylinder is under the safe limit and the FOS is 8.9227. So the design is safe.

Fig.4.7 Stress analysis of Pneumatic cylinder

Fig.4.8 Load analysis of pneumatic cylinder

V. RESULT AND CONCLUSION

Thus, the design of automated hydraulic swarf compactor machine was done and for its machine parts are analyzed by using ansys software. Hence, the result of the analysis was positive and it was above the required parameter with all safety con -cerns and all the stated benefits was achieved with high production ability and it can be readily used by any small scale indus -tries. The project was completed within the given amount of time. It can be operated with the help of PLC programming so we have achieved cent percent safety in this project.

1) This project is helpful in determining safe limit of parts in machine.2) Analysis is more helpful for selecting the materials for the components of the hydraulic chip compactor.3) Analysis is used for identify the thermal coefficient and stress limit of the components.

VI. REFERENCE

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3. Mohd Fahrul Hassan et al., (2017). Design and development of a portable metal chip baler using a system design ap-proach, EDP sciences, Vol.135,Pp.1-9.

4. Sinha et al., (2003). Computer-aided design of hydraulic structures, math1 computer modelling, Vol. 10, No. 9, Pp. 637-645.

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