Design Analysis of a Nail Production Machine

Transcription

1 IOSR Joural of Mechaical ad Civil Egieerig (IOSR-JMCE) e-issn: ,p-ISSN: X, Volume 15, Issue 4 Ver. V (Jul. - Aug. 2018), PP Desig Aalysis of a Nail Productio Machie Kotigo W.K, Jumbo E.E ad Tuaweri T.J Departmet of mechaical Egieerig, Niger Delta Uiversity,BayelsaState, Nigeria Correspodig Author:Kotigo W.K Abstract: This paper describes the desig aalysis of a ail makig machie which ca be used to ehace ail productiofor the cottage idustry. It is also desiged to maufacture special shaped ails such as lioleum ails, roofig ails, double cap ails, shaped ails, cocrete ails, etc.. with low oise geeratio ad vibratio. Galvaized steel is used i the moutig of L-sectio beams ad frame sectios due to its compositio. The desiged equipmet also cosists of lubricatig system ad drivig system With over all dimesio of1588mm legth x635mm width x 804mm height ad a weight of 200kg icludig shear force ad bedig momet calculatios. The desiged machie uses a motor of 1.5kw ad with a productio output of 351pieces of ails/mi. Also the cost of the desiged equipmet is cheaper whe compared to other existig machies i the ailmarket.the desig implemetatio will boost local productio of ails for cottage idustry ad our local ecoomy sice the cash iflow from the ail sales is also calculated through the tabulatio ofoperatioal cost ad iitial ivestmet which was foud to yield a payback period of ivestmet divideds withi three moths of operatios, Keywords: Bedigmomet, Shear force, Nail productio machie, cuttig die lever, bedig stress Date of Submissio: Date of acceptace: I. Itroductio Nails are pi-shaped. Sharp objects of hard metals or alloy used as fasteers, typically made of steel, ofte dipped ad coated to prevet corrosio i high coditios or improve adhesio. Nails are drive ito wood by a hammer, ail gum or a explosive charge ad it holds material together by frictio i the axial directio, ad shear stregth but mostly used i the idustry ragig from buildig ad costructio to carpetry. I Nigeria ail productio has ot bee embraced fully as the ail productio machie is ot affordable due its cost ad high exchage rate i terms of purchase from other foreig coutries but with the demad for housig amid risig populatio; the productio of locally made ail productio machie caot be ipped i the bud. The ail makig process cosist of wire drawig through a series of dies to reduce it to a required diameter. The ed of the wire is gripped ad puched i a die with the shape of the ail head. It forms a head which is kurled for easy hittig while drivig it ito the work piece to be fasteed. After this, depedig o the legth of the required ail i iches; the wire is severed with a die that is formed with the shape of the sharp poit. The complete ail at this stage goes through a collectig tray ad other coatig processes to improve hardess ad corrosio resistace. The desiged ail makig machie has the power drivig system, wire feedig system, head formig system, ail cuttig system, machie fixture system ad ail exit system. The total iitial ivestmet, cost of operatio ad cash flow per moth for the ail makig machie are preseted i table 4.1, 4.2 ad 4.3 respectively. Also the detailed desig of the ail makig machie ad its parts are preseted i the appedix. II. Materials ad Method Desig Cosideratios The desig of the ail productio machie must be i compliace with stadard specificatios. Machie dimesios are 1588mm legth by 635mm width by 804mm legth. Machie speed is 1400rpm, Weight is 200kg ad a motor of 1.5kw ad frame. Desig Compoets Compoets used for the desig are frame, slidigroller, cuttig die lever, wiregripper, rail guide, ail head puch cover, dieblock, ail feeder support, cam,rollers,coectig rod,bearigs,crakshaft,pulleys,flywheel, motor,ail collector, fasteer material,etc DOI: / Page

2 Shear force ad bedig momet calculatios. M mac h ie = 200kg M load =200kg 9.81 =1962N 1962 F+ W = R A + R B... (3.1) M= R B 2 R B = =529.74N 2 W=R A +R B R A =W-R B... (3.2) R A = R A = N Fig 3.1 F.B.D of bottom frame SHEAR FORCE SF A =R A = N SF B =R A = W SF B = SF B = N SF C =R A -W+R B SF C = SF C =0 BENDING MOMENT BM A =0 BM B =R A 0.54 BM B = BM B = BM C =R A 2-W 1.46 BM C = BM C =0 Nail head puch The fuctio of this is to hit the wire tip hece makig it coform to the required shape of the ail head. Its tip is kurled to form the surface ecessary for providig frictio while usig the ail. It is made of high carbo, heattreated steel for stregth ad durability. The heat treatmet helps prevet chippig or crackig caused by repeated blows o the cut wire. It eeds to be strog ad sturdy. It should be hard to prevet crackig ad chippig durig hittig. It is coected to a support which trasfers motio from the crakshaft through the coectig rod. Figure 3.2 Nail head puch DOI: / Page

3 The auxiliary compoets which support ad guide the ail head puch iclude; die block, wire gripper, ail guide ad the ail head puch cover. Force required to forge the ail head ca be calculated as below:- Stress, σ is give by σ = Force Area Makig force the subject of the formula, Force=Stress Area Area of wire acted upo by the force of the ail head puch is give by: Area = πd², where d is the diameter of the wire=2x2.54x Area = π(2x2.54x10 2 )² = m² 4 The yield stregth of mild steel is, σ = 248 MPa Therefore, the force P = = N The desity of the ail head puch material is 7.85g/cm 3 The liear speed of the ail head puch ca be calculated as follows: - The motor speed is 1400 rpm From ω = 2πN 60 N = 1400 r.p.m The ω = 2 π = rad/sec From v = ωr r = 1.5 x 2.54 x 10-2 = m The liear speed of the ail head puch is v =146.6x = 5.585m/s The mometum of the ail head puch is give by Mometum = mv, where m = mass v = liear velocity The mass of the ail head puch ca be estimated as follows. Mass = ρv, where ρ = desity V = volume The miimum force required to forge the ail is N as determied above. Puttig a safety factor of 2, the actual force imparted o the ail wire is X2 = N Cuttig die lever This is to drive the ail cuttig dies. They push the cuttig dies to the cuttig positio ad are themselves pushed back by the retur sprig. Fig3.3 Cuttig die lever The Stress due to the Bedig Momet that the cuttig die levers must overcome is calculated as follows: The bedig stress is give by σ bedig = M d I 2 Where M=the maximum bedig momet, I= the momet of iertia Ad d=the thickess of the beam The momet of iertia I is give by, I = bd³ = ² ( ²)³ = Computig the stress due to the bedig momet: The cuttig die lever ca be modeled as a simply supported beam as illustrated i the diagram below: DOI: / Page

4 Figure 3.4: Cuttig die lever aalysis This ca be represeted i a free body diagram as follows Figure 3.5: Cuttig die free body diagram R1 ad R2 are the reactios at the eds due to the cetral load P From the balace of clockwise ad ati-clockwise momets, R1 ad R2 are foud to be: R 1 = R 2 = N The resultig bedig momet will be maximum at the ceter where P acts ad is give by: M max = x 8 x 2.54 x 10-2 = Nm The stress due to the maximum bedig momet experieced at the cetre of the cuttig die levers is give by, σ bedig max = M d = ² = MPa I ⁷ 2 The cuttig die levers should be desiged to overcome this stress i.e. the levers should have higher bedig stress stregth so that the ail machie does otfail. III. Results ad Discussios With the objective of desigig a ail makig machie suitable for the cottage idustry i Nigeria, it is of paramout importace to get a machie which ca be fabricated locally. Havig made a ivestmet for the ail makig machie, the payback period ca be computed as below. 1 The followig equatio ca be used i the calculatio:- = 1 Where R p is the icome durig the period p; D p is the operatig cost durig the period p; is the payback period; ad Iis the iitial ivestmet made i period 0. Total iitial ivestmet (I) is give by: p =0 R P D P Table 4.1: Total Iitial ivestmet COST ITEM Nail makig machie 288,950 Lad ad buildigs 575,900 Vibratio isolators 38,300 Wire coil stad 10,600 Weighig scale 12,200 Istallatio 75,800 TOTAL 1,001,750 Operatig costs (D p ) ca be computed as follows: Table 4.2: Operatio costs ITEM COST Nail wire Packagig material Operator 60,700 Labour 62,000 Mechaic Security Trasport costs 90,900 Electricity Water 2000 TOTAL 541,500 Cash iflow ca be calculated as show below as follows: DOI: / Page

5 Productio ratig of the ail makig machie iovatio = 350 ails per miute. Total umber of ails produced per moth assumig 7 workig hours per day ad 20 workig days per moth = 350x60x7x20 = 2,940,000 ails. Number of ails i kilograms per moth assumig a kg is approximately 481 ails = 6,112.3kg. Icome from sale of ails produced per moth assumig NGN. 250 per kilogram = NGN. 1,528,075. Cash flow is tabulated as follows: Table 4.3: Cash flow per moth Moth 1 Moth 2 Moth 3 Moth 4 Moth 5 Moth 6 Cash iflow (Rp) 697,140 1,060,860 1,389,500 1,389,500 1,389,500 1,389,500 Cash outflow (Dp) 515, , , , , ,650 Net cash iflow 181, , , , , ,890 Cumulative cash 181, ,510 1,554,400 2,405,270 3,256,150 4,107,050 flow From the formula above, I = p=0 R P D P, whe =1 moth, I=337,940 R P D P = 59,800 < I therefore 1, whe =2 moths, I=337,900 p=0 p=0 R P D P = 232,100 < I therefore 2, whe = 3 moths, I = p=0 R P D P = 512,823 > I therefore = 3 This shows that the payback period for the ivestmet will be achieved i the third moth of operatio. IV. Coclusio The curret desig of the ail makig machie has overall dimesios of 1588mm legth, 635mm width ad 804mm height with a output of 351Pcs/mi ad a weight of 200kg. Desiged to yield a payback period of ivestmet withi three moths of operatio. Motio of ail cuttig machie is coveyed from the crakshaft to the ail head puch via a coectig rod ad the ail head puch i tur drives the rest of the compoets. Sufficiet lubricatio makes it air-cooled without a coolig system. The ail makig machie requires a traied operator. The cottage idustry stads to experiece gais as jobs will be created to boost the Nigeria ecoomy ad also reduce the overall cost of ails i the market. Refereces [1]. Khurmi, R. S. (2004). A Textbook of Machie Desig (14th ed., pp ). Eurasia Publishig House (PVT) LTD. [2]. Darbyshire, A. (2008). Mechaical Egieerig (2d ed., pp ). Macmilla Publishers. [3]. Kempster, M. H. A. (1984). Egieerig Desig III (1st ed., chap. 2 9). Macmilla Idia Ltd. [4]. Sigal, R. K. (2008). Fudametals of Machiig ad Machie Tools (3rd ed., chap. 11). Iteratioal Publishig House Pvt. Ltd [5]. Khurmi R. S. (2004). Egieerig Mechaics (19th ed., chap. 11). RajedraRavidra Priters (Pvt) Ltd. [6]. Madara, M. O. (2004). Egieerig Desig (1st ed., pp ). Togo Press Ltd. [7]. S., L. M. (2012). Advameg Ic. Retrieved from [8]. Mauree, K. P. ( ). Glasglow Steel Nail Co. Ltd. Retrieved from [9]. Ashley Alliso (2011), Properties of Galvaized Steel [10]. [11]. Bechtel, R., Certified Rehabilitatio Techology Supplier: Uiversity of Michiga Health Systems. (734) [12]. Chakrobarti, D. (1997), Idia Athropometric dimesios for Ergoomic desig Practice, Natioal Istitute of Desig, [13]. Chitale, A.C., Gupta, R.C. (2002), Product desig ad maufacturig Pretice-hall [14]. Galvaizers associatio of Australia (April, 2012), Atmospheric Corrosio Resistace of HDG coatig, [15]. Gerald Austi, (2012). Shielded Metal Arc Weldig: Advatages ad Disadvatages [16]. Hobart Istitute of Weldig Techology, (July, 2005).Guidelies for Shielded Metal Arc Weldig (SMAW). DOI: / Page

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8 Kotigo W.K Desig Aalysis of a Nail Productio Machie. IOSR Joural of Mechaical ad Civil Egieerig (IOSR-JMCE), vol. 15, o. 4, 2018, pp DOI: / Page