A Project Report on

Modeling and Fabrication of Foot Operated Power

Hammer

Submitted in partial fulfillment of the requirements for the degree of

BACHELOR OF TECHNOLOGY
in
Mechanical Engineering
by
Antony Cyril Varghese 1561310 ME
Arun Shaju 1561374 ME
C Harrison Jose 1561103 ME
Kiran C G 1561371 ME

Under the Guidance of

Mr. Pradeep Kumar

Department of Mechanical and Automobile Engineering

Faculty of Engineering, Christ University,
Kumbalagudu, Bengaluru - 560 074

May-2019
 Faculty of Engineering
Mechanical Engineering

CERTIFICATE

This is to certify that Antony Cyril Varghese(1561310), Arun Shaju(1561374), C

Harrison Jose(1561103), Kiran C G(1561371) has successfully completed the project
work entitled “ Modeling and Fabrication of Foot Operated Power Hammer” in par-
tial fulfillment for the award of Bachelor of Technology in Mechanical Engineering
during the year 2019.

Mr. Pradeep Kumar

Assistant Professor

Dr.Gurumoorthy S.Hebbar Dr. Iven Jose

Head of Department Associate Dean

i
 Faculty of Engineering
Mechanical Engineering

BONAFIDE CERTIFICATE

It is to certify that this project titled ” Modeling and Fabrication of Foot Operated Power
Hammer” is the bonafide work of

Name Register Number

Antony Cyril Varghese 1561310 ME
Arun Shaju 1561374 ME
C Harrison Jose 1561103 ME
Kiran C G 1561371 ME

Examiners [Name and Signature]

1.
2.

ii
IndustryCertificate.pdf
 Acknowledgement
We would like to thank Christ University Vice Chancellor, Dr. Rev. Fr. Thomas C
Mathew, Pro Vice Chancellor,Dr. Rev. Fr. Abraham, Director of Faculty of Engineer-
ing, Fr. Benny Thomas and the Associate Dean Dr. Iven Jose for their kind patronage.

We would like to express my sincere gratitude and appreciation to the Head of Depart-
ment of Mechanical Engineering, Faculty of Engineering Dr.Gurumoorthy S.Hebbar
, for giving me this opportunity to take up this project.

We also extremely grateful to my guide, Mr. Pradeep Kumar , who has supported and
helped to carry out the project. His constant monitoring and encouragement helped me
keep up to the project schedule.

We also extremely grateful to my co-guide, , who has supported and helped to carry
out the project. His constant monitoring and encouragement helped me keep up to the
project schedule.

If outside the college-mention the organisation and the concerned people, like head
of the organisation, guide and any other person you want to thank. All faculty and non-
teaching staff. You may acknowledge your parents or any who supported you.I thank
my parents.

iv
 Declaration
We, Hereby declare that the Project titled “ Modeling and Fabrication of Foot Op-
erated Power Hammer” is a record of original project work undertaken by us for the
award of the degree of Bachelor of Technology in Mechanical Engineering. We have
completed this study under the supervision of Mr. Pradeep Kumar , Department of
Mechanical Engineering and Automobile Engineering and , .

We also declare that this project report has not been submitted for the award of any
degree, diploma, associate ship, fellowship or other title anywhere else. It has not been
sent for any publication or presentation purpose.

Place: Faculty of Engineering, Christ deemed to be University, Bengaluru

Date: 21-04-2019

Name Register Number Signature

Antony Cyril Varghese 1561310 ME

Arun Shaju 1561374 ME

C Harrison Jose 1561103 ME

Kiran C G 1561371 ME

v
 Abstract

In present scenario, all the production based industries are basically meant for produc-
tion of their components at low production cost. Manufacturing process has made an
enormous progress with the help of science and technology. New machines along with
high performance forging tools and with sophisticated manufacturing techniques have
taken machining process to greater heights. Hammering plays a vital role in any of
the manufacturing process. Hammering is an operation in which a powerful stroke is
delivered repeatedly by means of a hammer onto the work piece. Manual hammering
requires more man power and consumes large amount of time.This lead to the idea of
“Design and Fabrication of Foot Operated Power Hammer”, which can be used for small
scale applications like punching; sheet metal works in the foundry shop. The purpose of
this work is achieved by using a drive motor of 0.5 HP mounted on the frame. Initially
a supporting frame has been fabricated as per the design, which houses provisions for
different components to be mounted on it. The cam operated power hammer is used to
achieve the hammering process to increase the production rate with minimum time.

Keywords : Motor, Cam Operation, Shaping, Hammering, Frame.

vi
Contents

CERTIFICATE i

BONAFIDE CERTIFICATE ii

INDUSTRY CERTIFICATE ii

ACKNOWLEDGEMENT iv

DECLARATION v

ABSTRACT vi

LIST OF FIGURES ix

LIST OF TABLES x

GLOSSARY xi

1 INTRODUCTION 1
1.1 Problem Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.2 Problem Identification . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1.3 Problem Statement & Objectives . . . . . . . . . . . . . . . . . . . . . 2

2 RESEARCH METHODOLOGY 4

3 LITERATURE SURVEY AND REVIEW 5

3.1 Literature Collection & Segregation . . . . . . . . . . . . . . . . . . . 5
3.2 Critical Review of Literature . . . . . . . . . . . . . . . . . . . . . . . 8

4 MODELING AND FABRICATION 9

4.1 Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.1.1 Selection of Components and Specification . . . . . . . . . . . 9
4.1.2 Design and modelling . . . . . . . . . . . . . . . . . . . . . . 22
4.1.3 Fabrication of frame . . . . . . . . . . . . . . . . . . . . . . . 25

vii
5 RESULTS, DISCUSSIONS AND CONCLUSIONS 32
5.1 Results & Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.2 Comparative Study . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.3 Discussions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
5.4 Conclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
5.5 Scope for Future Work . . . . . . . . . . . . . . . . . . . . . . . . . . 34

BIBLIOGRAPHY 35

Index 37
LIST OF FIGURES

2.1 Flow chart of methodology . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 AC Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.2 Top view of hammer (dimensions are in cm) . . . . . . . . . . . . . . . 11
4.3 Side view of hammer (dimensions are in cm) . . . . . . . . . . . . . . 12
4.4 Isometric view of hammer (dimensions are in cm) . . . . . . . . . . . . 13
4.5 Side of the frame (dimensions are in cm) . . . . . . . . . . . . . . . . . 14
4.6 Isometric view of frame (dimensions are in cm) . . . . . . . . . . . . . 15
4.7 Plummer Block . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.8 Open Belt Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4.9 Mechanical Spring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.10 Cam Disc and Flywheel . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.11 Hammering base made of Forged Steel . . . . . . . . . . . . . . . . . . 20
4.12 Connecting rod . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4.13 Mechanical Pulley . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
4.14 Isometric view of 3D model (Labeled diagram) . . . . . . . . . . . . . 23
4.15 Front view of 3D model . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.16 Left view of 3D model . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.17 Top view of 3D model . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.18 Front view of frame (dimensions are in cm) . . . . . . . . . . . . . . . 26
4.19 Isometric view of frame (dimensions are in cm) . . . . . . . . . . . . . 26
4.20 Top view of frame (dimensions are in cm) . . . . . . . . . . . . . . . . 27
4.21 Complete Fabricated frame . . . . . . . . . . . . . . . . . . . . . . . . 27
4.22 Welding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.23 Drilling Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.24 Metal cutting Operation . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.25 Grinding Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

ix
LIST OF TABLES

4.1 Specifications of 1018 Mild Steel . . . . . . . . . . . . . . . . . . . . . 16

x
GLOSSARY
.

Item Description
3D 3 Dimension
2D 2 Dimension

xi
Chapter 1

INTRODUCTION

Metal forming is the process by which a metal piece having some indefinite shape and
geometry is transformed into some useful part without any change in mass or mate-
rial composition with minimum wastage of material.Hot forging and cold forging both
comes under the branch of metal forming processes.It has been more than 4000 years,
that significance of forging is present in manufacturing industry. The first raw hammer
that early man used before the discovery of fire was hard and heavy rocks and stones.
Hammers use impact strain to deform the material. The word “smith” was derived from
an old teutonic word- “smeithan” which means to forge. The process takes place by
heating the work metal in high temperatures under the effect of a hot furnace, thus its
shape can be easily changed upon pounding a hammer over it. Now when the work
metal is cooled it will have improved metal properties like more strength and durability.
Smiths then initially started forging process by forging work metal into ornaments and
jewelery. Periodically properties of tools like spears and hunting objects were enhanced
by forging. Smiths also found various other applications like creating strong helmets,
defense armour, nails, strong metal doors etc. Weapons like swords, knives, and other
sharp tools were mended with other tools after being forged. Since those olden times,
forging always had numerous applications.

The principle of forging is also the same throughout its evolution as pressure is used to
knead and shape hot metal into strongest material possible with good impact strength
and fatigue resistance and shear toughness. In early days hand forged metal works pos-
sessed superior metal properties so it had good significance. Later with combination of
skilled hammer men, die makers and other forging laboratory workmen, new kinds of
forging machines were created with good impact strength that even hand hammering

1
could never have achieved. Closed die forging was introduced and these could easily
apply more than 50,000 pounds of driving pressure, hydraulic presses and power ham-
mers could now produce custom forgings. During first and second world war forging
had numerous applications such as pneumatic tools, valves, and also material handling
such as lift trucks. This is how application of forging started to expand in the metal and
manufacturing industry. Forging industry is hence reliable and dependable.

1.1 Problem Formulation

Advanced manufacturing mainly aims to reduce human effort and at the same time
increase productivity. Most of the manufacturing for production industries are facing
problems in regulating employees health care, skill gap and causes monetary issues
aswell. Ultimately the capital cost and running cost increases. Mechanization in this
field enhances the foundry environment and precision of the forged parts. Imperfections
happening in forging post an extraordinary issue in foundry. Thus, our ”Power Ham-
mer” might be the solution to increase productivity and bridge the skill gap. The power
hammer used in our project is cam operated with foot assistance and can be widely used
in foundry application, replacing the original manual hammer.

1.2 Problem Identification

At present situation, numerous small scale industries face issue in machining. Laborers
still have the habit of utilizing hand hammers for forming the metals. This prompts
wastage of time and increase in human effort. The hammer can be taken care of by
a person without felling any kind of uneasiness. No different skill set is required to
operate it. The operation is quick and thus saves a lot of time. The operation is simple
and expends less cost. Because of the above reasons it discovers its broad application
in manufacturing industries especially in forging.

1.3 Problem Statement & Objectives

Hammering is the most essential act to carry out forging operations. Power hammers are
commonly used in machine shop to punch the work piece. In light of above, the present
2
work deals with the fabrication of foot operated power hammer for forging operations
like punching, sheet metal works in workshop; with following objectives:

• 3D modeling of Foot operated CAM assisted power hammer.

• To create electrically operated forging machine for the department.

• Fabrication of Main frame and assembly of components.

• To make the hammering process governable with a foot pedal.

3
Chapter 2

RESEARCH METHODOLOGY

The research methodology for the study of this project includes various processes. This
includes the use of different features of engineering and technology to obtain the re-
quired results. It required a more detailed study of the different concepts and segrega-
tion of literature to achieve the desired results.

F IGURE 2.1: Flow chart of methodology

4
Chapter 3

LITERATURE SURVEY AND

REVIEW

3.1 Literature Collection & Segregation

Automated portable hammering machines, which can be customized to suit various

needs, help achieve instant repeated hammering and impacting. The machine can be
used for hammering operations in mass production units. Punching, filling, riveting,
smithy and forging are certain common operations performed by hammering machines.
A prototype portable automatic hammering machine designed by Dhulekar et al [1]
used slider crank mechanism in order to transform rotatory motion into linear. The ob-
jective of their project was to develop an automatic hammer machine that required min-
imum manpower for operation. The approach of CAD modeling along with graphical
analysis technique enabled them visualize the end result in advance. Some of the fea-
tures of the machine they planned to design were: instant and fast hammering, portable
system requiring less manual efforts and user-friendliness. The design involved a motor
fixed on a stand with its shaft connected to a disc which in turn was connected to the
hammer rod through a linking rod. A 96-watt DC motor fitted with a wiper gear so as
to have a speed of 30 rpm powered the 1.5 kg hammer. For designing the hammering
machine, the designers calculated the torque and impact velocity with respect to the
specifications of other spare parts and power requirement to run the machine. Finally,
they verified if the shear stress of the bolted joints was within the permissible limit. The
designers also suggested improvements in terms of technology and enhanced speed to
improve the effectiveness of the machine to cope up with future demands.

5
Gontarz et al [2] conducted theoretical as well as experimental analysis of the pro-
cess of hammer forging of rim part using AZ31 magnesium alloy and found that the
alloy went well with the process of hammer forging. The rim finds application in light
planes. Energy required for forging each unit was also calculated using simulation. The
strokes required for various operations as found in the study were: one stroke for upset-
ting, two strokes each for preliminary operation and final operation. Interestingly, the
study found a positive correlation between the hammer size and operations that required
two to four strokes. This technology of using die forging hammers finds application in
forging units that are not equipped with presses with required load. The chief advan-
tages of this technology include low cost and increased output when compared with
forging presses that make use of presses under isothermal conditions.

Makvana et al [3] designed a simple power hammer machine with the intention of
simplifying, reducing cost and economizing on power consumption. Computer software
was used to design the layout of the machine as per forging requirements. The design-
ers were hard-pressed to lookout for any forging machine with a simple and compact
design. As they could not find one, they modeled a simple power hammer machine that
effectively performed forging operations. This simple forging machine comprises of
three components: the frame, ram and anvil. The frame supports the reciprocating ram
through nuts and bolts. The shaft of the electric motor is connected to the ram which in
turn operates the hammer up and down. The machine, after all, is compact and easy to
operate even though it cannot be used for heavy works.

An attempt was made by Siddiqui et al [4] to simplify and economize the power ham-
mer. Other objectives of this invention were to make the power hammer multi functional
through adjusting the stroke to suit the work piece and to make the hammer perform em-
bossing operations. A 1,400 rpm motor supplied power to the hammer through pulleys.
This power hammer was capable of performing operations like hammering, forging, em-
bossing, piercing, blanking by changing tools mounted on a leaf spring. A leaf spring
in place of iron bar was found to absorb damping forces that originated due to the effect
of hammering.

While using hammering machines industrial units are challenged with different prob-
lems specific to workplaces like less power supply, labor shortage, labor intensiveness
in getting tasks accomplished and safety. A flexible multipurpose hammering machine

6
that can be operated manually and through electricity to address workplace difficulties
was designed by Thakre et al [5]. The objective of this project was also to reduce the
cost of construction by avoiding complicated mechanisms, and instead using a snail cam
to make the hammering impact. Some of the advantages of the Cam Operated Hammer,
according to the designers, are: compact size and easiness to operate, simple construc-
tion and low maintenance cost. The best part of this study was that the designers arrived
at this design after thorough literature review that helped them choose a machine with
simple design that could be operated both manually and mechanically using electricity.

Mahendra Rathi et al [6] analyzed on ‘An overview of forging processes with their
defects to determine the various forging defects and their causes. During forging pro-
cess, because of the defects rejection rates are increased. So in order to avoid this it
is important to move any process in the direction of eliminating all imperfections as
part of an effective continuous improvement. With the aim of removing the defects and
its causes, He concluded that incomplete forging penetration occurs by using light raid
hammers and can be avoided by using forging press. Surface cracking can be avoided
by increasing the temperature.

Guoqiang Wang et al [7] has analyzed on “Design optimization of low impact trans-
mission foundation for forging hammers”, and has presented a new method for defining
the key design constraints of a forging hammer foundation system. Optimization prob-
lem is then articulated using the dynamic model and system retort of the foundation
system with the minimization of the maximum impact force transmissibility is com-
pleted. A consideration study on the impact isolation proficiency of the foundation
system, with respect to given design variables, is being carried out to verify the design
optimal. This work adds to the application of SA optimization technique to engineering
design and fabrication.

In the journal ’Closed Die Hammer Forging of Inconel 718’ S. Chenna Krishna et
al[8] has investigated and has completed closed die hammer forging. Defect-matrix was
engaged to overcome the free surface cracking observed in the forged dome. Stakeso-
lution annealing temperature for the domes was carefully chosen. Solution annealed
dome exhibited non uniform microstructure. Grain size of the semi-circular dome at
all locations was finer than ASTM No. 4. The tensile properties of forged dome were
better than the feedstock used for forging.

7
3.2 Critical Review of Literature

[1]The idea of designing CAD model and graphical analysis will help in predicting the
results well in advance. The design we have modeled has a basic frame and then a 0.5hp
motor fixed to it which rotates at 1440 rpm, powering a hammer of 6.35 kg. [2]Cost ef-
fective model was proposed to be created using scrap material. Primary objective of the
paper is low cost and maximum impact energy. [3]The main aim was that the machine
should be capable of handling heavier working metal with proper ease of use.[4]If a
leaf spring is attached to the hammer hand, instead of the metal piece kept currently, it
can absorb all damping forces produced.[5] A cam operated Powerhammering machine
with motor and a further flywheel. [6]Forging cracks can occur on using light hammers,
which can be minimised by using a forging press or a power hammer.[7]Maximum
impact force ensured.[8]The tensile properties of forged dome were found better than
feedstock used for forging.

8
Chapter 4

MODELING AND FABRICATION

4.1 Modeling

4.1.1 Selection of Components and Specification

1. AC Motor

A motor to which the drive is given by an Alternating Current as an AC motor. The AC

motor usually incorporates two essential parts, an exterior settled stator having rings
supplied with alternating current to deliver a turning attractive field and one interior ro-
tor attached to yield shaft to create an optional rotating magnetic field. The magnetic
field of the rotor is produced by fixed magnets or by DC or AC electric windings. Less
commonly, linear AC motors function on similar concepts as rotary motors but have
their fixed and moving parts organized in a straight line setting, generating straight line
movement instead of rotation.An AC motor is shown in figure 4.1

9
 F IGURE 4.1: AC Motor

Specifications

• Power : 0.5 hp

• Shaft speed : 1440 rpm

• Current : 3.5 amps

• Voltage : 240 volts

2. Hammer

Hammer is one of the main components of this model it is fixed to the one end of con-
necting rod which is attached to the cam mechanism. Hammer material is made harder
and stronger than the workpiece material in order to avoid deformation of hammer af-
ter several hitting. Hammer shape and size is obtained from a block of Cast mild steel
material.

10
F IGURE 4.2: Top view of hammer (dimensions are in cm)

11
 12
F IGURE 4.3: Side view of hammer (dimensions are in cm)
2D drawings of the hammer is shown in figure 4.2 and 4.3 . The height and width of the
hammer is

F IGURE 4.4: Isometric view of hammer (dimensions are in cm)

3D model of hammer is created using CREO PARAMETRIC modeling software with

required dimensions, criteria’s and conditions as shown in figure 4.4. It is then subjected
to fabrication process.

Specifications

• Material : Cast Mild Steel

• Height : 200 mm

• Width : 60 mm

• Mass : 6.35 Kg

13
3. Frame

Frame is the skeletal structure that holds and supports the complete model it was fab-
ricated with the help of Welding, Grinding and Cutting operations. Mild steel material
has been used for making the frame. A 3D model of frame is depicted in figure 4.5 and
4.6 . The 3D model of the frame was created using CREO PARAMETRIC modeling
software. After creating 3D model it was subjected to further fabrication process.

F IGURE 4.5: Side of the frame (dimensions are in cm)

14
 F IGURE 4.6: Isometric view of frame (dimensions are in cm)

Specifications

• Material : Mild Steel

• Total Height (fro the ground) : 1015 mm

• Base Height : 60 mm

• Base Length : 1010 mm

• Base Breadth : 800 mm

Table 4.1 shows the specifications of 1018 Mild Steel used for the fabrication of frame.
All the minimum properties and chemical compositions that are required by the mate-
rial are depicted in the table.

15
 TABLE 4.1: Specifications of 1018 Mild Steel

Minimum properties Ultimate Tensile strength 63,800 psi

Yield strength 53,700 psi
Elongation 15.00 %
Rockwell hardness B71
Chemistry Iron (Fe) 98.81 - 99.26 %
Carbon (C) 0.18 %
Managanese (Mn) 0.6 - 0.9 %
Phosphorous (P) 0.04 % (max)
Sulphur (S) 0.05 %

4. Plummer Block

Plummer block is a stand that is used to hold a spinning base with the help of suitable
bearings and various other components . It is also known as bearing housing or pillow
blocks. Cast steel or cast iron is generally used in manufacture of plummer blocks. A
bearing is enclosed inside the pillow block, which helps in smooth rotation of the shaft,
thus another bearings need not be purchased by the consumer. Pillow blocks are mainly
intended for smaller loads of common market and they are generally installed in better
surroundings. A typical plummer block is shown in figure 4.7.

16
 F IGURE 4.7: Plummer Block

Specifications

• Manufacturer : Ashoka Bearing Company pvt. ltd.

• Inner diameter : 25 mm

• Closures : Casing present

• Length : 140 mm

• Breadth : 70 mm

5. Belt Drive

Belt drive is a looped strip of elastic material used to link either tw or more rotating
shafts or pulleys for the transmission of power. This drive is used as source of motion
to transfer power efficiently and to track relative motion. There are mainly two types of
belt drives as follows :

17
* Open Belt Drive :- An open belt drive is used to rotate the driven pulley in the same
direction as that of driving pulley. In the motion of belt drive, power transmission re-
sults make one side of the belt is tight and the other as slag side. An open Belt Drive is
shown in figure 4.8.

F IGURE 4.8: Open Belt Drive

* Crossed Belt Drive :- A cross belt is used to rotate driven pulley in the inverse direc-
ton of driving pulley. However, bending and wear of the belt drive are major concerns.

6. Spring

A spring is an elastic material which stores mechanical energy within it. When a con-
ventional spring, without stiffness variability features, is compressed or stretched from
its actual position it shows retarding force which is approximately proportional to its
change in length. Springs are made different types of elastic materials, the most com-
monly used material is spring steel. It can be seen as a device that stores potential
specifically elastic potential energy. one of the springs are shown in figure 4.9 .

18
 F IGURE 4.9: Mechanical Spring

7. Cam Disc & Flywheel

The rotational motion of the motor is transmitted to the flywheel through the belt drive,
which is further connected to the cam using a shaft, which is passed through two bear-
ings. A connecting rod is the next transmiting device that converts the rotating motion
to reciprocating motion of the hammmer. The connection that we have used is as Shown
in figure 4.10.

19
 F IGURE 4.10: Cam Disc and Flywheel

8. Hammering Base

figure 4.11.

F IGURE 4.11: Hammering base made of Forged Steel

20
9. Connecting rod

Connecting rod is a link between two moving parts in which one end is connected to
cam disc and the other end to the one end of hammer hand. It changes a rotary motion to
reciprocating motion it has a wide range of mechanical application.As shown in figure
4.12.

F IGURE 4.12: Connecting rod

Specifications

• Material : Mild Steel

• Diameter : 20 mm

• Length : 760 mm

10. Pulley

21
A pulley- belt mechanism is classified by two or more pulley in accordance to belt.
This provides for mechanical energy,torque and rate to be passed on across axles. If
the pulley’s are of varrying diameters, a mechanical benefit is obtained. A belt drive is
comparable to that of a chain mechanism as shown in figure 4.13.

F IGURE 4.13: Mechanical Pulley

4.1.2 Design and modelling

2D and 3D model of foot operated power hammer has been created using CREO PARA-
METRIC modeling software with required dimensions, criteria’s and conditions. After
creating the 3D model it was further analysed and was subjected to fabrication of pro-
totype model.

(1) 3D Drawing of foot operated power hammer

Figure 4.14 shows the isometric view of 3D model of foot operated power hammer
with all major components labelled.

22
F IGURE 4.14: Isometric view of 3D model (Labeled diagram)

F IGURE 4.15: Front view of 3D model

23
F IGURE 4.16: Left view of 3D model

F IGURE 4.17: Top view of 3D model

24
Front view, Left view and Top view of 3D model are shown in figure 4.15 , 4.16 and
4.17 respectively.

4.1.3 Fabrication of frame

Steps involved in fabrication of frame

• 2D and 3D model of frame was created using creo parametric modeling software
with required dimensions as shown in figure 4.18 and 4.19.

• After creating the 3D model it was further analysed and was subjected to fabrica-
tion.

• Mild steel was selected for the frame and it was subjected to cutting, grinding and
welding operations.

• Two base frames are constructed first of 60x120x800 by cutting it into C shape
channel as shown in figure 4.20. These two frames are for supporting other metal
frames on top.

• Two cylindrical pipes of dimension (diameter 70mm and length 800mm) is con-
nected between square blocks attached to the base C- Channel.

• Finishing of the frame is carried by the application and paint coatings to pro-
tect the metal from corrosion. Red oxide is coated as a base layer above which
painting is done.

• Figure 4.21 shows complete fabricated model obtained by carrying out cutting
and welding operations on mild steel material.

• Following are the proceses involved in fabrication of the frame:

25
 F IGURE 4.18: Front view of frame (dimensions are in cm)

F IGURE 4.19: Isometric view of frame (dimensions are in cm)

26
F IGURE 4.20: Top view of frame (dimensions are in cm)

F IGURE 4.21: Complete Fabricated frame

27
1. Welding:

Welding is the main fabrication process which was carried out for constructing the
frame. Welding is a fabrication process that joins materials, usually metals by caus-
ing coalescence. It is often done by melting work piece and adding a filler material
to form a pool of molten material that cools to become a strong joint, with pressure
sometimes used in conjunction with heat or by itself, to produce the weld. welding
is distinct from other operations like soldering and brazing which are low temperature
applications in which the base metal does not get melted. Normal welding process is
shown in figure 4.22.

F IGURE 4.22: Welding Operation

28
2.Drilling :

Drilling, as shown in figure 4.23, is a process in which circular contours are cutting
solid materials with the help of a drill bit. The cutting tool used is mostly multi point,
which is made to rotate at speeds depending on the work requirements. The rotating
speed can varry upto 1000(rpm). As the rotating drill bit is pressed against the work
piece, metal is removed in the form of metal chips, thus forming the hole of required
diameter. Drilled gaps are recognized by presence of distinct sharp sides on the entry
part and the existence of rough metal particles on the tool departure part. Drilling leads
to change in properties of material.

F IGURE 4.23: Drilling Operation

29
3.Metal Cutting:

Cutting is a type of metal working process were a workpiece is made into a particu-
lar dimension by removing the unwanted material from the workpiece by using cutting
tool to get a product that meets required dimensions. The cutting process produces two
products at the end, the excess or unwanted material and the final product. In the cut-
ting process of metal work pieces the waste materials will be the chips formed and the
excess metal. The process is as shown in figure 4.24.

F IGURE 4.24: Metal cutting Operation

30
4.Grinding :

Grinding is the machining operation that typically makes use of rough grinding rim. It is
a machining operation that upholds production of tools. This ensures smooth finish and
precise measurement. In large scale production it can rule out large quantity of metal. It
is favourable for rough materials than for usual machining process. It is also favourable
for taking surface cuts which can result in reduction of shaft dimensions. Figure 4.25
depicts the process of grinding.

F IGURE 4.25: Grinding Operation

31
Chapter 5

RESULTS, DISCUSSIONS AND

CONCLUSIONS

Here, the results of the project work (literature survey and review along with actual
work) shall be listed and discussed in detail with appropriate arguments (result analysis)
leading to logical conclusions. The list of conclusions should sync with the project
objectives. The scope for future research and development in the field of the current
project work must also be included in this chapter.

5.1 Results & Analysis

5.2 Discussions

32
5.3 Conclusions

Conclusion should be on new page and the same should come here.

33
5.4 Scope for Future Work

Future scope should be on new page and the same should come here.

34
Bibliography

[1] Dhulekar. A, Shirbhate. S, Shaikh. R and Ingalkar, ”Design, Cad Modelling & Fab-
rication of Automatic Hammering Machine”, International Research Journal of En-
gineering and Technology, vol. 05, pp. 949-954, April 2018.

[2] Makvana. S, Lashkari. N and Ram. K, ”Modification and Fabrication of Simple

Power Hammer Machine”. International Journal of Scientific Research and Devel-
opment, vol. 6, pp. 2114-2117, April 2018.

[3] Siddiqui. M, Mashirakhanam. P, Ahmed J S, Meraj S K, ”Fabrication of Power

Hammer for Forging and Embossing Operation”, International Journal of Advance
Research in Engineering, Science & Technology, vol. 4, pp. 2114-2117, April 2017.

[4] Thakre. C, Mandal K, Ghormare C, Biswas. A, Dongre L, ”Advance Cam Operated

Hammer”, International Journal of Engineering Science and Computing, vol. 7, pp.
6003-6004, March 2017.

[5] Gontarz. A, ”Theoretical and Experimental Research of Hammer Forging Process

of Rimfrom AZ31 Magnesium Alloy”, vol. 53, pp. 645-648, March 2014.

[6] Mahendra G. Rathi and Nilesh A. Jakhade, ”An overview of forging processes with
their defects” Internnational Journal Of Scientific and Research Publications, vol.
4, pp. 101-113, June 2014.

[7] Guoqiang Wang and Zuomin Dong, ”Design optimization of low impact transmis-
sion foundation for forging hammers”, International Journal for Computer-Aided
Engineering and Software, vol. 23, pp. 166-186, June 2006.

[8] S. Chenna Krishna, Satish Kumar Singh, S. V. S. NaryanaMurthy, Ganji Venkata

Narayana, Abhay K. Jha, Bhanu Pant, and Koshy M. George, ”Closed die hammer
forging”, International Journal Of Mettalurgy, vol. 13, pp. 1-7, December 2014.

35
[9] Chehab. A and M. H. Shinde, ”Design of efficient base isolation for hammers and
presses”, Soil Dynamics and Earthquake Engineering, vol. 23, pp. 8-12, March
2006.

[10] Taylan Altan, Gracious Ngaile and Gangshu Shen, Cold and Hot forging - Funda-
mentals and Applications, New York: McGraw Hill, 2005.

36
Index

Methodology, 9

37