Power Hammering Using Cam Follower Mechanism

Group Members:

Sooryadas Sudhakaran - B180494PE

Karthik BC - B180814PE

Pradeesh Karun PK - B180367PE

Amrutha Sai K - B180444PE

Gayathri Sandeep - B181025PE

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Problem statement

To reduce the manual effort in hammering and thereby increasing the productivity of manufacturing processes like Forging.

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Project Plan

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Flow chart 1

SCHEDULE 1

• Selection of problem statement
• Literature survey
• Analysis of some existing designs
• Selection of a suitable mechanism
• Division of work.
• Identifying the subassemblies and individual parts by preparing BOM.
• Identifying the manufacturing processes involved and materials to be used.
• Calculations for design purpose.
• Design using SOLIDWORKS.

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SCHEDULE 1

• Analysis of the design using ANSYS.
• Feasibility check based on analysis data
• If feasible : proceed
• If not feasible : back to design stage and correction measures
• Cost estimation

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SCHEDULE 2

• Fabrication
• Testing
• Final report preparation.

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Cam and follower

A cam and follower mechanism is a profiled

shape mounted on a shaft that causes a lever

or follower to move. Cams are used to convert rotary to linear (reciprocating) motion. As the cam rotates, the follower rises and falls in a process known as reciprocating motion.

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MECHANISM IINVOLVED

Fig 1:Cam and Follower Mechanism

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About the mechanism

• The motion of the follower is restricted to a pre-determined pattern by a guide.
• The follower maintains contact with the cam through the force of gravity or by a spring
• The total range of movement produced by the cam is called the stroke.
• The range of movement of the follower will depend on the distance from the shaft supporting the cam to the upper and lower points of the rotation circle.
• Cams are commonly used in engines to control valves (in which the valve is the follower), sewing machines, children's toys and many other mechanical applications

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Cams - Lift, fall and dwell

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Cams can provide

• Lift - when the follower is moving up
• Fall - when the follower is moving downward
• Dwell - when the follower is not moving

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The shape of the cam is altered to give the movement that is required in the mechanism

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Advantages and disadvantages of cam mechanism

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1. Advantages of the cam mechanism
2. By designing the appropriate cam profile, the follower can be arbitrarily expected to move, and the structure is simple, compact and convenient to design, so in automatic machine tools, light industrial machinery, textile machinery, printing machinery, food machinery, packaging machinery and Widely used in mechatronic products.�
3. Disadvantages of the cam mechanism
1. 1. The point between the cam and the follower is in contact with the line, which is easy to wear and should only be used in occasions where the transmission force is not large.
1. 2. The accuracy of cam profile is high, and it needs to be processed by CNC machine tool.
2. 3. The stroke of the follower should not be too large, otherwise the cam will become bulky.

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CAM AND FOLLWER NOMENCLATURE

• Cam Profile: The contour of the working surface of the cam.

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• Tracer Point: The point at the knife edge of a follower, or the center of a roller, or the center of a spherical face.

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• Pitch Curve: The path of the tracer point.

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• Base Circle: The smallest circle drawn, tangential to the cam profile, with its center on the axis of the camshaft. The size of the base circle determines the size of the cam.

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• Prime Circle: The smallest circle drawn, tangential to the pitch curve, with its center on the axis of the camshaft.

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• Pressure Angle: The angle between the normal to the pitch curve and of motion of the follower at the point of contact.

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• the direction

Fig 2:Cam Nomenclature

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Bill of materials

Flow chart 2

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Cam

• The usual disc shape of cam is been changed so as to form Snail Cam thus obtaining the required behavior of hammer.
• A Snail drop cam is used where the drop or fall of the follower must be sudden.
• Spiral Curve profile .
• Designed to be unidirectional.

Follower

• The type of follower that has been planned to use is a roller type follower.
• Roller type is used as rolling produces least amount of friction.

COMPONENTS

Fig 3:Cam

Fig 4: Roller Follower

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Hammer

• To get highest force the design has considered to make the hammer with material of which has got a higher hardness and strength. Materials under design consideration is High Carbon heat Treated Steel
• Wooden handle ~ 55cm in length

Pulley

• Bigger pulley is used to transmit power from driving pulley / motor to rotation of snail cam.
• Here the radius of bigger pulley controls speed to cam.
• Driving pulley is connected to motor so as to transfer motion from motor to bigger pulley.

Fig 5:Hammer

Fig 6:Pulley

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Body framework

• Design of Body framework - Aluminum/ mild steel - as it is strong, hard, durable, corrosion resistant, cheap, easily available, provide rigid support to overall integration of components.

Motor

• Power rating:3hp
• RPM:1000 rpm
• motor capable of providing enough torque and rotation for required hammer motion

V belt

• V belt is used to connect driving pulley and bigger pulley.
• Width in accordance to the width of pulley used.

Fig 7:Motor

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Shaft

• Transmits rotation from pulley to snail cam.
• material: mild steel(as per preliminary design )
• diameter: 3- 5 cm diameter

Anvil

• High strength material to resist force impact.
• cast iron with hard steel face to resist the large impact.

Additional Handle

• Manually Operated

Fig 8:Shaft

Fig 9: Anvil

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Numerical calculation

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Initial data collected for design purpose are as follows :

�1. Total weight of hammer = 6 kg

�2. Hammer head weight = 4 kg

�3. Hammer Length = 420 mm

�4. Hammer stroke height = 200 mm�

5. Motor : 3Hp, 1000 rpm, 224 V Ac motor�

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Fig 10:Base length Calculation

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3. Estimate of pulley diameters

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• Let diameter of bigger pulley be D
• The expected rpm in shaft containing cam, N = 125 rpm
• Let the diameter of small pulley be d
• The input rpm, n = 1000 rpm

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D x N = d x n

D x 125 =d x 1000

D = 8 d

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So the bigger pulley should be 8 times as big as the smaller one.

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PROCEDURE

MANUFACTURING PROCESS

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CONFIRMATION AND SELECTION OF MATERIAL IS SUBJECTED TO AVAILABILITY AND MACHINABILITY

Table : Material and manufacturing of the components

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Procurement list

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• Shaft bearings
• Follower (roller)
• Trolley wheels(optional)
• Belt and pulleys
• Motor
• Nuts and bolts

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Welding

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• The framework of the machine is welded with available electrodes.

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Assembly

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• Bearings for supporting shaft
• Nuts and bolts for fixing motor ,wheels and bearings to frame work.

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Joining process

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REFERENCES

[1] Power Hammer | Automatic Hammering Machine | New Mechanical Project

YouTube video, 7:00, November 13, 2017, https://youtu.be/qKsp4L6m8cs

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[2]Modification and fabrication of simple power hammer, Volume : 6, Issue : 2�01/05/2018

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[3] Experimental testing of low-power hammer techniques in a variety of rock materials

November 2006 Conference: The 9th ESA Workshop on Technologies

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[4]“Design, cad modeling & fabrication of automatic hammering machine” Abhijeet Dhulekar1, Suyash Shirbhate2, Rizwan Shaikh3, M V ingalkar4 1,2,3 student department of mechanical engineering, P.R.Patil institute of polytechnic, amravati, maharashtra, india

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Thanks!

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