ODISHA HOBBY CENTER AND RESEARCH LAB CHANDI CHHACK, MASIKPATNA COLONY, CUTTACK, 753001 ‘CONTACT NO- 8480802781, 8917654554 MINI WORK SHOP CRANE Abstract : In general the forklift can be defined as the machine capable of lifting heavy weights that is difficult for an ordinary human being to lift . It is similar to vehicle but a addition of two forks to lift the weight makes the difference . The operator using these forks can lift any heavy weight material on a click of button without any effort . The forklift operator just pushes the fork below the weights and upto certain distance the weights are lifted above in air so that they can be moved accordingly as per the requirement . Keywords : Forklift, machine, lift, weights, forks . CHAPTER | : INTRODUCTION A Forklift ruck is one of the most used machines employed for several types of tasks. They range from warehouse use 10 large scale industry with multiple locations. They make lifting of heavy objects fast and a whole lot easier than manual lifting, There is a wide range of forklifts to select from going well with your particular requirements and necessities. Rough Terrain forklift trucks are used primarily in new construction work locations and areas where you may >be on dirt or loose gravel Forklift trucks are either powered by propane, electricity, gasoline or diesel, Blectric forklift tucks rely on the batteries to operate, Propane or gasoline forklifts are faster ot stronger than clectric forklifts, but they're more difficult in maintenance, & fuel can be costly. The electric forklift tucks are great for the warehouse use as they don’t give-off noxious fumes like the gas-powered machines do, Forklifts are often used in the warchouses; however, some of | them are meant to be used outdoors. Vast majority of rough- terrain forklift’ trucks operate on propane or gasoline, but some of them are powered by natural gas or diesel. Rough terrain forklifts have the greatest lifting capacity of the entire forklifts & heavy duty tires, making it likely to drive on uneven surfaces outdoors. Forklifts have revolutionized the warehouse work. Well-maintained & safely operated forklift trucks make lifting & transporting cargo infinitely easier. The most popular forklift types on the market today are: Warehouse forklift Side Loader Counterbalance Forklift Telehandler Industrial Forklift, Rough Terrain Forklift Pallet Jack Walkie Stacker Order Picker Reach Fork Truck (CHAPTER 2: LITERATURE SURVEY A} SURVEY : The first contribution toward scientific material handling instrumentality seems to possess been the 2-wheel go-cart During this we tend to square measure move the fabric however not carry it. In 1906, a political candidate of thePennsylvania Railroad at Altoona, — supplementary accumulator power to a baggage wagon, it absolutely was the primary power truck . The primary transportable elevator on record within the Patent and Trademark Office Database was engineered of wood in 1867, with upright, cantilever platform, and a hoist. One of the first efforts to mix horizontal and vertical motion was in 1887, once a erude truck capable of lifting its platform some inches was build This was most likely the primary application of the unit load principle with skids. Thenin 1909, once the primary all steel any truck appeared, In advantage of combined vertical and horizontal handling ability. It took a kind of tiny crane ‘mounted on a platform truck. The introduction of hydraulic power and therefore the development of the primary electrical power self-propelled vehicle, beside the utilization of standardized pallets within the late Nineteen Thirties. In 1954, a British company named state capital Bagnall, currently a part of KION cluster, developed what was claimed to be the primary slim aisle electrical reach truck Throughout Fifties to Nineteen. Sixties, operator safety became a priority because of the increasing lifting heights and capacities. In our project, we tend to square measure exploitation the battery power for the horizontal movement the vehicle and therefore the human power to carry the fabriclk from the bottom . Its same because the 1* self-propelled vehicle beside the battery power that was use in 1913 truck ‘the easy mechanical mechanism for the lifting the fabri. BY SCOPE : Project work “3 WHEEL DRIVE FORKLIFT FOR INDUSTRIAL WAREHOUSE" is aimed to Elevate the load with the assistance of chain drive . The most blessings of exploitation this ean be to simply handle significant load by solely switching on the motor. It will increase the productivity. The system is meant & developed with success, for the demonstration purpose — paradigm model (mini model) would be builtin future ‘After collection the go back numerous journal we tend still as analysis paper there's great deal of fuel is wasted by elevating a load or significant material thus we eame to conelusion that manual motor lift is that the solely thanks to stop such industrial issue like ability operator solely will operate don't seem to be needed, significant load handling and therefore ‘the main advantage of this self-propelled vehicle is most effective, low cost & inerease productivity. Most of all the fossil fuel saving could be a major concern by exploitation hydraulic jack self-propelled vehicle, We will use human brain similarly as hands & legs & operate a self-propelled vehicle and thereby nullifying the possibilities of accident, Our project options « simple electrical heart and a simple mechanical body. As this could be the sole one, we have straightforward quick the speed of the vehicle for manual ‘operational. Its typically become any elegant application Considering the project time and everybody the specified steps, we tend to tend to terminate this project is that the proper one. Since merely a simple modification in its mechanical arm and movement suggests that, welll convert into any golem which can perform a special style of work We'll use our human brain additional as body and legs to chop back external offer and wire. AS this could be the sole one. It's typically become any elegant application. We tend to tend to retum to conclusion that operated by hand the vehicle is cut back the worth of skilled worker & any worker can have used our vehicle additional because of i's safe, cheap and straightforward to use and increase the productive. ©) MARKET ANALYSIS ‘The market survey lets the firm to understand and realize the real demand and potential for the product under consideration. First and foremost, it is necessary to establish that the proposed product will fulfill a demand in the market or not, what is supposed to do, and the service it can offer to the consumers. So, we take the survey for our prototype in ‘SAFAR AGENCY ’, Vasai Virar Virar East . There requirement of miniature forklift that can lift the component up to S00 Ke economically After we surveyed in our institute we can found that the educational engineering apparatus up to 50 Kg is not easy to move from one place to another place. So the miniature forklift is requited to design that can utilized for lifting load up to 50Kg, The material required for the frame was selected according to the low in cost , availablity and strength . A square tube is the best as it will provide adequate strength and less in weight Selecting any section of I or C type would give strength more but it will be an over design structure according to the capacity ‘The warning lights and sound is compiled in a small circuit system that includes small system and the PCB would be bought at VISHA AND VEGA KIT , in Grant Road , Mumbai, The wheels of electric vehicle would be available as Tyre Stores 4 SEASON , in MAHALAKSHML They have an inventory of recycling old tyres and would be available in cheaper rates and according to the requirement wheel height Chain drive system is available at the sakinaka PATEL, Workshop, sakinaka. The best economical manufacturer in the budget Steel plate for the frame above support system would be available easily at best workshop at SANATACRUZ. D} MANUFACTURING SCENARIO : The manufacturing process of the project would be done at the workshop .The availabilty of the workshop is at fone of our group members in MAZGAON . All. the equipments required for manufacturing like cutter , grinder , welding equipments , and other safety equipments are available. CHAPTER 3: PROPOSED SYSTEM A} METHODOLOGY The industrial forklift are huge in size. Though they have several advantages, there is a need for better forklift model for small scale pupases, Concern is to be given to improve the following aspects inthe existing forklift, The frame should have high load taking capability The frame should provide a better stability 10 the whole system, Reducing the size for small space constraint. sale industrial purposes having ‘The manufacturing cost should be minimized by minimizing components used and making it efficient in workingB} DESIGN DETAILS Forklift Description A forklift is a machine which helps in moving a heavy load from place to place as per the requitement. It provides an industry to work efficiently and its much time saving in optimization of a working cycle. Functions of forklift: Its function is to transport the goods over short distance as when the requirement occurs . It must control the load and goods in the correct alignment to meet the conflicting requirements of stable running on straight track and good curving performance with low track wear. At same time, it must also provide acceptable ride levels in the vehicle to which itis fitted, under a wide range of track conditions ‘© Support the goods being lifted, ‘© Rum stably on both straight and curved trac © Ensure good ride comfort by absorbing vibration ‘generated by track irregularities and minimizing impact © Minimize energy or manpower requited to lift a weight ‘© Forklift have forks to lift the weight easily and manually, brake arrangement, axle box guide and many other parts which are welded to the frame. + The main purpose of the forklift is to transfer the load from a manufacturing area to the inventory area of the industry efficiently and it would be time saving approach, ‘© These wheels support the load tranfering the force of the load to the rear part hence tranfering the overall CG point ofthe forklift Working Principle ‘The wheel shaft is connccted with arrangement of a motor. This motor is used to run the vehicle Battery is connected to the motor. The motor is connected to the chain drive to increase the torque and is directly coupled to the wheel by means of a bearing block which runs the vehicle. Motor is controlled by the control unit This vehicle causes no pollution. In front of the Segway the forklift arrangement is mounted. The sprocket is used lift the fork and used to move up and down, The most important consideration of designing a fork lifts is the safety , while the forklifts is during the loading and moving stability system consists of 3 point of contacts , 2 front wheel drives and supporting the real wheel contact axle aranged on safely mounted . Contr of ray THREEPOINT ON CONTACT FRAME FIGURE 1 : THREE POINT CONTACT Forklift Components Forklifis are very important in safe and industrial operations and in performing some functions. The forklift are the undercarriage which supports the goods, In mechanical terms, a forklift consists of is a chassis or framework with wheels, thus serving as a modular subassembly of wheels and axles. The forklift has following components a) Forklift Frame ‘The forklift frameis known as the main supporting system, The bogie frame is either casted or fabricated. The forklift frames are manufectured based on its working conditions. It i the main component which takes the stresses. The forklift frame is designed in such a way that it can take the load of the goods , operator as well as the components attached to it with proper body weights balance. >) Forks The forks are the main element which are made to take up the load of the goods being lifted . These are the most stressed elements as it involves variable loading condition during lifting and loading These components are generally low in cost and made up of cast iron, Hence such elements need 10 be analysed properly and a proper maintenance should be done by removing the rust scales, polishing or others. FIGURE 2 : FORK@lic Brake A pair of Drum brake is provided on driving wheel. The brake actuating mechanism would be underlying the frame next to the connected with the link mechanism such that the it would lock the axle when required d Motor The driving axle would be connected to the motor with the help of chain drive . It drives the axle through chain drive The sprocket is mounted on the axle and will be connected to the driving axle connected with two front wheels FIGURE 4: HIGH GEARED MOTOR ) Chain drive in drive will be used in the system to increase the i ratio’ or increase torque transmitting capability to the Griving wheels as would require hi starting torque due to its ‘own weight and che extemal load (goods) The larger sprocket would be mounted on the driving axle shaft and it would be connected via key and sprocket and the smaller gear would bbe mounted on the motor.The material for chain is medium carbon steel blank form cold rolled sheet hardened to 50 HRC. The pin , bushes and rollers are made up of case carburizing alloy steel and hardened to 50 HRC as well FIGURE 5 CHAIN AND SPROCKET DRIVE D Shaft ‘A shaft is for mounting the wheels , gears . It is designed based on the ASME code approach as itis very convenient and conservative approach to get an accurate dimension of the shaft, The most popularly used shaft material would be medium carben steel due to its properties of , low in cost , readily availaible , high toughness, good strength and high load taking capability ee FIGURE 6; SHAET @ Square tubes The square tubes form support structure to the body of the forklift . This structure is always under a repeated loading condition as the requirement vary according the load or application .These ate made of Mild Steel material with appropriate strength and having the property of good weldabilityFIGURE 7: SQUARE TUBE hy Actuators ‘The actuators like accelerator would be use to control the speed , brake mechanism , switches to turn on the motor Wheels ‘The wheels of two different type would be used . The front wheels would of same type and would vary from rear. The front wheels have their centre at good height so that a good amount of ground clearance would be achieved and it also help the goods to at proper and safe height from the ground so that it doesn’t cause any harm while moving the object. ‘This also propose an important cause of getting the shift of ‘centre of gravity of the Forklift at rear which would avoid its, ‘toppling . The front wheel used would be of Activa bike. FIGURE &: FRONT WHEEL FIGURE 9: REAR WHEEL i) Steel plate ‘These plates would be mounted as a platform above the frame and will carry the load of the operator . These plate are of steel having grids to provide a good frictional grip. These can be popularly observed in the BEST buses, 0 Gn tn unos RON NON NO SOO NAN ARINERENGN N LN NASA A YA A ee WALA Ay NNN NY FIGURE 10: STEEL BASE PLATE:k) Waring lights ‘These are provided to show that the forklift is engaged FIGURE 11: WARNING LIGHT 1 Warning indicator eireuit ‘These are provided to indicate the forklift is in performing its operation, CHAPTER 4: DESIGN OF FORKLIFT A} DESIGN OF FORKS MOMENT OF INERTIA OF FORK T=125 —_— Be40mm FIGURE 12: CROSSECTION OF FORK © L+800mm + MOMENT OF INERTIA OF FORK bebe 22 66666.66 mm* FIGURE 13 : LOADING ON FORK NOW CONSIDERING UNIFORMLY DISTRIBUTED LOAD 1. Moment of inertia of two fork T= +k = 133333.33 mm* 2 ind Wim Wim = W/L. 3. Bending moment (M) we ea) = 100000 Nem 4. Deflection (Yan) You = 3.125 mm B) ANALYSIS FINITE ELEMENT ANALYSIS OF FORK . Mesh Size Selection For Analysis Mesh sizes calculated by plotting a graph between deformation and mesh size from Imm to 1Smm for various iterations. Hence a mesh size of 7mm is selected as the deformation becomes constant. It means that there will be negligible changes in the accuracy of the results on the further reduction in the mesh size,C} DESIGN OF ERGONOMICS FIGURE 14: MESH SIZE GRAPH FIGURE 17: AVERAGE WAIST HEIGHT 1, Determine Height of Handle from Base Female ~ 997.9mm Mean 1185.0mm Maximum 856.0mm Minimum Male— 1072.5 mm Mean 1261.0 mm Meximum 888.0 mm Minimum a) Taking average of male & female mean- (997,9+1072,5)2=1035.2 mm As we know in workplaces workers always wears shoos or any kind of footwear so the thickness of footwear is also to bbe taken info account, So considering normal shoe sole is approximately 25.4mm. FIGURE 18: STRESS ON FORK1) Adding this extra height in average 1035.2 + 25.4 = 1060.6mm, So the height of handle from base is 1060mm, 2. Determine ‘idth of Handle — Female- 468.5 mm Mean 609.0 mm Maximum 373.0 mm Minimum Male- ‘946.1 mm Mean 725.2. mm Maximum 399,0 mm Minimum 1) Taking average of male female mean (468.51546.1)/2-507.3mm ‘We have to provide extra length as allowance So providing allowance of 45mm ) Adding extra length of allowance- 507.3 +45 = 560 mm So total length of handle bar is $60 mm D} FRAME : FIGURE 18: BASE FRAME Frame is being made using square tube made up of mild steel having good properties and it can be way better to make using these material as itis less in cost , readily available and sufficient material property for the purpose it is used in Al Frame Analysis: Stress (von mises ) FIGURE 19: STRESS ON BASE FRAME Factor of safety : FIGURE 20 : FOS OF FRAME Deformation : FIGURE 21 TOTAL DEFORMATION OF FRAMEE} HANDLE: The handle has been added and many holes are provided such ‘that the driver can adjust the handle accordingly to his comfort . The selected handle is of hollow type as it would ‘be in low in cost, less in weight and the throtile wires ean be incorporated through it janer handle : FIGURE 22: INNER HANDLE 2, Outer handle : FIGURE 23: OUTER HANDLE FIGURE 24: ASSEMBLY OF HANDLE. F} MOTOR SELECTION AND LOAD CALCULATIONS + Selecting , PMDC (Permanent Magnet Direct Current ) reversible motor and we have following options. 2 volt non geared 12volt_ geared 24 yolt non geared 2A volt geared As we ate lifting heavy load and our application is forklift And we are not just lifting but also we have to stop weight at different height and again have to come down for this we are going with PMDC 24V reversible geared motor and going with 1440 rpm as compromise between cost and performance, We ate doing two different operations with the help of motor. Lifting(using 1 motor) Driving (using two motor on front tire with throtle) Lifting + For Lifting in which we ae using motor with pulley ané motor having power rating of 125W Which is giving approximately 170 Nm torque which can lift casily upto 45, ig. Hence we ate going with this PMDC reversible motor having this much of torgue and uiput speed of 30 rpm.ole Load calculations : Total load that has to lifted by motor = weight which has to lift +f ork weight + some extra 204743 30 kg < loading capacity Our motor can easly take load therefore safe for capacity, Velocity of iting = x pulley dia x output speed = 7 x0.07%30 6.59 mimin Since recommended maximum velocity of lifting is 8 to 10 ‘m/min such that no accident takes place because of inertia, Velocity = 6.59 m/min < 8 m/min , hence safe Driving : For driving we are using 2 motor on front tire separately of PMDC type because manufacturer are using same motor can easily take 80 kg load as we are using two such motor can easily take 150kg_ with throttle system and motors are reversible and having output speed is 500 such we can use in reverse mode, It has to carry lifting mechanism weight in addition to that body, motor and battery weights and drive it maximum up to $ miles per hour but in risky area it should operate at 3 miles per hour without load and in loaded condition speed should not exceed 3 miles per hour as recommended for safety as we know steering and braking of forklift are not so responsive so it suggest take safety as government and industry norms. Load calculations : Total load = total load lied driver weight + battery and body weight 30150+20-100kg < loading capacity (Our motor can easily take load therefore safe capacity Velocity of vehicle=n x tire dia x output speed onx03 x 20:28 11 kmph 6.83 <8mileshr Which is within the range recommended hence safe Gy BATTERY CALCULATIONS : Battery Size in AH = W= Total oad 300 watt (assuming the ‘maximum of 50 kg load can be lifted and drive the motor for the wheel as well) = Backup time in hours = 6 hours (assumption for 4 hrs testing and 2 hrs for presentation) v attery voltage = 12 volt Load Assumption = 300 watt = 150 AH (standard size availeble ) Since, the motor is of 24 V , hence 2 batteries of 12 V each ‘would be connected in series FIGURE 25: BATTERY ‘Hj BRAKE CALCULATIONS Brakes are very important system of any vehicle or machine ,ILis used to control Vehicle ie to make vehicle stop or slowing down the speed It docs this by converting ‘mechanical energy into heat energy by means of friction In our case our brake force boost by means of lever, spring and other parts. And we are going with drum as ‘matter of cost and accessibility in loaded vehicle The normal man ean generate maximum 45 Newton force with one hand because of mechanical linkage it ‘maximises by three to four times. Force applied on lever 45 . Calculation of required brake force, Fe = w= 035 « 100= 375 N + Required torque Ty Fox R (drum radius) 375 «0,065 = 2.43 Nm + Calculation of force generated by system , Fy = 45 x mechanical advantage (3 t04 times) 45<3= 135 + Generated brake torque, Ty= Fx drum radius 135 «0.065 = &8.Nm + Stopping distance , A120 kimph Fullload sxmass of (By work energy principle) =5.m Without load , sxmass of vehiclexvetoity? (By work energy principle ) 4m I) EXPECTED WEIGHT. FRAME. MOTOR, FORK, 0 BATTERY DRIVER w LIFTING WEIGHT » ‘WHEELS © J} WHEEL LOADS : ‘The below figure shows the components involved in the forklift load acting on the wheel due to The brake torque would be developed on the wheel while braking and that would be equal to 8.8 Nm The maximum tuming moment on the wheels due to the driven motor would be 170 Nmalc TURNING BRAKE TORQUE TURNING no sANm xe FIGURE 27; WHEEL LOADS K} WEIGHT DISTRIBUTION : The weight distribution would be S0 : $0 in front and back The drivers weight would be accounted in the rear. Lj STEERING SYSTEM : 2400 FIGURE 28; STEERING DIAGRAM. . TURNING MECHANISM : The turning mechanism is the best and a innovative here rather than ordinary four wheeled forklifls The drive o the power would be given to the front two wheels independent of each other and would be driven with a motor Since the wheel would have braking system involved in cach. > Left turn scenario Here the wheel on the right would be given drive while the left front wheel would act as a pivot point . If in cease some slip occurs in the according to floor conditions then the brake could be applied on the left wheel as the brakes of the two front wheel are independent, © FIGURE 29 LEFT TURN SCENARIO > Right turn scenario Now the right wheel would act as a pivot point and and the power would be provided to the left front wheel and in slip conditions the right wheel could be stopped ae O IGURE 30; RIGHT TURN SCENARIO > Onplace turn scenaric ‘These is the innovation added to our project it would require the minimum space to turn as both the front wheel would be rotating in opposite directions and the time also required to perform the operation would be minimum,er nan ie FIGURE 31 : ON PLACE TURN SCENARIO CHAPTER $ ; IMPLEMENTATION PLAN A} COST ESTIMATION 1 | Fork 000 2 | praxeassemacy — | soo 2__| motor 000 «| suarr 200 s | cam prive 100. | square-Tune 00 1 | cue 1000 s__| pasepLare 00 9 | actuator 200 wo _| swarenes: 200 11_| warnine sysrews | 100 12_| artery system | so00 13__[ miscetnansous | 2000 B} PIE CHART COST ESTIMATION a FIGURE 52: PIL CHART CHAPTER 6 : ADVANTAGES AND DISADVANTAGES ADVANTAGES + Longer life Minimum noise level Suitable for indoor use co friendly operation Ttcan be also used in hazardous arces Huge advantage is that it does not have fossil fuel cost, ‘The electric forklift has zero emissions and hence safe and healthy. It can also be called GREEN FORKLIFT © Less maintenance due to minimum mechanical components used ‘+ Small seale industries can also incorporate these forklifts + Minimum turning radius DISADVANTAGES : © Amount of load is limited . Less speed © Trained personnel needed to control = They are usable only indoor purposealc CHAPTER 7 : EXPECTED RESULTS AND MODEL REFERENCES [1]. Seidl M, Dvosk 2 (2011) Inouse transport as apart of business logis. J BpManagCompet (12)15, (2). Maszshre M (2010) Moods for accounting of ancillary ativitis” coats» (Metadyorlcraniakostéwdbiaaaoicipomocnica) TN] Gabrasewier W. (ed) Avdyt w systomickonols Conference Procoodngs, KIBR, Poznan, Poland 28.11.2010 pp. 181-142 ISBN: 97683-61287 45-2 hip praconney se porn pl! ‘mataalerioaiezanieproduke} pomocticz} pa in Polish) uecess: St November 2015, [5] Michaowska K' 2013) Logistiss costs in a company (Cnacrenieiponchyrolirasiakoantogisycznyeh: ZeseyiyNoukowel niversyeuSzerecskieg® nf 76S, Finanse, RynkiFinansowe, Ubczpiecreni® WydawnienwoNsukowsUniwersyetuSzczecfshicgo. 81()325— 334 in Pols, [4] RS Khurm, J Gupta (2005), text book of Machine Design [5]. $ 5 Ratan (2009), Thoory of Machine, Professor of Mectanical gineering, National Iaiute of Technology, Kuma, (6) VB Bhander (2010), Design of Machine Hlemens, Retired Profesor and Head Department of Mechanical Enginesring, Vishwakarna Inst of Technology, ? [7] 38 Gupta 2011), Basic Flecvieal & Elecvonies Engineering, [8] BL Thue, AK Tharea Revised by SG Tamekar (2005), Flccrical Techuology, Former Profesor & Head, Eletica FIGURE M: FORKLIFT MODEL, Engineering Department, ‘The turning radius would be minimum (91. Vievervraya Nena Inetiute of Technology, Nagpur Low in cost [10] Conte M (2010) Super capaci tchnieal requirements for new applcaons Fuel Ces 10: 806-8 : Less hazardous to environment [11] Hyster-Vale Materials Handing, Ine, Retoved 1S December2013. © No fossil fuel required (12) Bendy, James (December 2005). “The History of The Fork Lit . Eco friendly operations ‘Warehouse Logistic News . Archived from the original ot 2009 Cal wrt tow scale ind 0831 Retrieved 2008-01-25, : ‘an be incorporated in low scale industries (13] Clank Material Handling Company. 2008, Reseved 15 December * Small in size compared to regular forklifts 2013, © Good load carrying capacity [14] Radescko (bising equipmens design) © Tough and compatible for small purpose . CONCLUSION ‘The deveploment of Mechanical forklift assures the ergonomically comfort to the operator ot worker and to reduces time required for manual lifting and handling . This increases the productivity & it provide safety of operator while handling of the materialgrinding quantity is discussed. In abrasive belt grinding Titanium alloy blade of aviation ‘engine experiment, through the single factor experiment method, the influence of abrasive belt linear speed and work-piece feeding speed on the grinding quantity is discussed. [1] ‘A. Robert Henry et al. studied Machining processing industries have continuously developed and improved technologies and processes to transform finished product to obtain better super finished product quality and thus increase products. Abrasive machining is one of the most important of these Processes and therefore merits special attention and study. Belt grinding is an abrasive machining process used on metals and other materials itis typically used as a finishing process in industry. The main objective of this project is to design and fabricate an abrasive belt grinding which can be used as versatile grinding machine, the work area can be rotated from 0 degree to 180 degree. The 0 degree work area can be used for bottom grinding of component, the 90 degree work area can be used for vertical grinding of component and The 180 degree work area can be used for top grinding of component. [2] Huang presented the surface finishing and stock removal of complicated geometries is the principal objective for grinding with compliant abrasive tools. To understand and achieve optimum material removal in a tertiary finishing process such as Abrasive Belt Grinding, it is essential to look in more detail at the process parameters/variables that affect the stock removal rate. The process variables involved in a belt grinding process include the grit and abrasive type of grinding belt, belt speed, contact wheel hardness, serration, and grinding forec. Changing these process variables will affect the performance of the process. [3] [4] [5] 2. Design of Belt Grinding Machine Pulley-1 L,_| Aeiustable Column to fitthe belt on pulley Position of belt in Pulley-2 bee ier Agjustable Table to locate the work piece e—] Vertical Column Base Plate Figure 1, Front view of Belt Grinding MachineFigure 2. 3D modelling of Belt Grinding Machine in CATIA. 2.1 Working Principal of Abrasive Belt Grinding Machine: ‘As you know that nowadays wheel grinding machines are mostly used for grinding operation. In most the workshops it is used for grinding, to remove the sharpen edges, sharpen the cutting tools by giving different angles. But in such wheel grinding machines there is one problem that very less area of wheel available to perform the grinding operation. Due to this area of contact in between grinding wheel and workpiece ‘maximum time is required finish the surface or to grand the surface. To avoid this major disadvantage we have developed this vertical abrasive belt grinding machine, The above figure 1 shows the front view of this machine with all important components. Figure 2 represents 3D modelling or 3D views of belt grinding ‘machine which is designed using CATIA vS software. The basic working principal of this ‘machine is too grand or to finish the surface using abrasive belts which to be mounted on this designed machine. Due to this abrasive belts used maximum area of belt is comes in contact with workpiece due to which material removal rate or surface finish rate is more in less time as compared to wheel grinding machine. 2.2 Construction of Abrasive Belt Grinding Machine: The above figure | represents the construction of abrasive belt grinding machine with all its important components. This machine is constructed on one base plate and is supported through vertical column shown in both figure 1 and figure 2. The motor is also ‘mounted on base plate from which drive is given to grinding belts through pulleys shown in figure 1. One adjustable column is also provided to attach and remove the belts easily. The grinding belt rotates when motor starts and its movement used to grind or finish the surface similar to grinding wheel. The table is also attached to vertical column to put the workpiece while performing the grinding operation shown in above figure 2. Due this vertical rotation of belts its maximum area is utilized for finish the surface due to which less time is required for grinding with maximum material removal rate than wheel grinding operation.23 Abrasive Belts used in Belt Grinding Machine: There are different abrasive materials which are used to manufacture the grinding wheels or belts. Sometimes abrasives materials used in wheel and belts are common sometimes it is different. But nowadays some special abrasives belts are available or manufactured to perform the grinding operation. The basic advantages of belts over wheels we have discussed above. Following figures represents the types of abrasive belts, used in belts grinding machine having different dimensions manufactured for different applications. Figure 3. Abrasive Belt (Ceramic and Nylon) ‘able 2 Specifieations of Ceramic and Nylon Belt Material [ Ceramic and Nylon. | Size 25 mm width ‘Scope of | ‘Metal processing industry, non- Application | ferrous metal, rubber product, stone, black metal etc. Figure 4, Abrasive Belt (Aluminium Oxide) ations of Aluminium Oxide Abrasive Belt Drillpro ] Material | Aluminium Oxide | Size 30 mm width Scope of | Grinding of metal, wood, furniture, Application _| stone, steel other fields ete.8. Conclusions Grinding is an abrasive machining process that uses @ grinding wheel as the cutting tool. A wide variety of machines are used for grinding. Although mini belt grinding abrasive belt have stronger cutting ability than that on the grinding wheel. But as, wheel grinding is having some disadvantages in form of time required to finish the surface, material removal rate, surface finish obtained ete. To over such disadvantages this vertical abrasive belt grinding machine is designed using CATIA v5 software to overcome disadvantages of wheel grinding ‘machine, Also this machine helps too grand or to finish the surface using abrasive belts which to be mounted on this designed machine. Due to this abrasive belts used maximum, area of belt is comes in contact with workpiece due to which material removal rate or surface finish rate is more in less time as compared to wheel grinding machine. REFERENCES: [1] 1. Huanga, Z.M. Gonga, X.Q. Chena, L. Zhoub, “Robotic grinding and polishing for turbine-vane overhaul”, Journal of Materials Processing Technology ,127, 140-145, 2002. [2] Yun Huang, Yun Zhao , and Xindong Zhang, Chongging University, Chongging, PR. China, “Experiment research on the abrasive belt grinding titanium alloy blade of aviation engine”, ISSN 1662-8985, Vol. 565, pp 64-69, China, 2012 [3] Huang Yun, Huang Zhi. Modern belt grinding technology and engineering applications [M]. Chongqing: Chongqing university press, (2003). [4] L. Yi, ¥. Huang, G. H. Liu. Experimental research on the electrochemical abrasive belt grinding 0CrI7Ni4Cu4Nb stainless steel [J]. Advances in Materials Manufacturing Science and Technology, 2009, 626-627: 617-622. [5] XY. Re, K. Bernd. Real time simulation and visualization of robotic belt grinding processes [J]. International Journal of Advanced Manufacturing Technology, 2008, 35:1090-1099, [6] S. Mezghani, M. El Mansori, E. Sura. Wear mechanism maps for the belt finishing of steel and cast iron [J]. Wear, 2009, 267:132-144,