FACTORY MECHANICAL MAINTENANCE & SERVICES

 MECHANICAL MAINTENANCE: Mechanical maintenance is the work that keeps

mechanical assets running with minimal down time.
Machine maintenance can include regularly scheduled and emergency repairs. It also
includes replacement of realignment of damaged, or misaligned. Machine maintenance
can be done either in advance of failures or after failure across.

Machine maintenance is critical at any plant or facility that uses mechanical assets. It
helps organization meet production schedules, minimize costly, downtime, and lower
the risk of workplace accidents and injuries.

TYPES OF MECHANICAL MAINTENANCE

There are nine type of machine/mechanical maintenance. Each one has its pros and cons
(expect reactive maintenance, which is all cons), and can be mixed and matched with
assets to create a balanced maintenance program.

 Reactive maintenance
 Run to fail maintenance
 Routine maintenance
 Corrective maintenance
 Preventive maintenance
 Condition based maintenance
 Predictive maintenance
 Perspective maintenance

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 REACTIVE MAINTENANCE: - Refers to repairs done when a machine has already done
when a machine has already reached failure. Since it’s unexpected, unplanned, and
usually leads to rushed, emergency repairs, it’s often called “fighting fires”.

 RUN TO FAIL MAINTENANCE:- Is very similar to reactive maintenance. It involves

letting a piece of equipment run until it break down however, run to fail is a deliberate
choice, whereas reactive maintenance is not. A plan is in place to ensure parts and
labour are available to get the asset up and running, or replaced, as soon as possible.

 CORRECTIVE MAINTENANCE:- Is any work that gets assets back into proper working
order, although it’s most commonly associated with smaller, non – invasive tasks that
fix a problem before a complete failure occurs. For example, realigning a part during a
routine inspection.

 PREVENTIVE MAINTENANCE:- Refers to any regulation is scheduled machine

maintenance intended to identify problems and repair them before failure occurs.
Preventive maintenance can be split up into two predominant types: Time based
preventive maintenance and usage- based preventive maintenance. Time based
preventive maintenance are tasks scheduled at a certain time interval, such as the last
day of every month or every 10 days. Usage based preventive maintenance is when
work is scheduled based on the operation of equipment, such as after 500 miles or 15
production cycles.

 PREDICTIVE MAINTENANCE:- Builds on condition based maintenance, using tools and

sensors to track machinery performanance in real time. This enables the identification
of potential problems so they can be corrected before failure occurs

 CONDITION BASED MAINTENANCE:- Depends on monitoring the actual condition of

assets in order to perform maintenance when there is evidence of decreased
performance or upcoming failure. This evidence can be obtained through inspection,

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performance data, or scheduled tests, and it can be gathered either on a regular basis
or continuously, though the use of internal sensor.

 PERSPECTIVE MAINTENANCE:- Perspective maintenance automates the

maintenance process even further through the use of machine learning and artificial
intelligence (AI). With strategy in place, sensor track machinery performanance in real
time and uses AI to let you know what maintenance work needs to be done and when.

FUNCTION OF MECHANICAL MAINTENANCE

 Maintenance of existing machines and equipment

 Inspection and lubrication of machine and equipment
 Installation of new machines and equipment
 Modification of existing machines, equipment
 Disposal of used items
 Maintaining the physical condition of equipment by performing routine
inspection and repairs
 Repairing or replacing defective components

NEED FOR MAINTENANCE:- Once of the factors that can ensure availability of installed
facilities for efficient use is an effective and efficient maintenance engineering system.
Gone were the days when maintenance was not given adequate attention. For any
company with mechanized and automated systems, more attention is now given to
maintenance function. Therefore, the need for maintenance increases with
technological advancement in production facilities. Others factor which seem to
emphasize the need for effective maintenance system are,

 Strong competition

 Tight production schedule

 Increased machine utilization

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  Increased production level

Inadequate or lack of effective and efficient maintenance system especially in a

manufacturing enterprise gives rise to several undesirable consequences. These
consequences include,

 Excessive machine break down

 Frequent emergency maintenance work
 Shortened life span of the facility
 Poor use of maintenance staff
 Loss in production output
 Inability to meet delivery date
 Excessive overtime
 Loss of lives

Industrial mechanical maintenance refers to the routine maintenance and repair of

mechanical equipment and machinery used industrial settings.

This includes large industrial machine such as conveyor belts and cranes and small
equipment such as pumps and motors.

The main goal of industrial mechanical maintenance is to keep the asset in good
working condition, prevent breakdowns and extend its life.

Industrial mechanical maintenance involves tasks such as:

 Equipment inspection for wear and tear

 Moving parts lubrication

 Replacing worn parts

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  Aligning and adjusting equipment& Equipment cleaning and maintenance

SERVICES & WORKSHOP

A mechanical service work shop is a specialized facility equipped with tools, machinery,
and equipment for carrying out various tasks related to mechanical engineering,
fabrication, maintenance, and repairs. These workshops play a crucial role in supporting
engineering activities, allowing professionals to design, construct, and maintain
mechanical systems and components

Here are some key aspects of mechanical workshop and its importance in engineering:

Fabrication and manufacturing:- mechanical workshop are equipped with machine

machinery such as lathes, drilling machine, boring machine, grinding machine. These
tools allow engineers and technicians to fabricate and manufacturing of mechanical
components, parts and prototypes.
Assembly and Testing:- Workshop are essential for assembling and testing
mechanical systems. Engineering can integrate individual components into largest
systems, ensuring that they function correctly and meet design specification.
Maintenance and repair: - Mechanical workshops are crucial for the maintenance
and repair of machinery, equipment, and mechanical systems. This include routine
maintenance to prevent break down and unplanned down time, as well as repairing
or replacing components that have experienced wear or damage.
In summary. Mechanical service workshop are vital hubs of hands-on engineering
activities, offering the infrastructure and tools needed for fabrication, testing,
maintenance, and skill development. They as a bridge between theoretical
knowledge and practical application, contributing significantly to advancement in
mechanical engineering.

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 MACHINES IN WORKSHOP & TOOL ENGINEERING SECTION

NOTE ON MACHINE TOOLS :- A Machine tool is a machine for handling or

machining metal or other rigid materials, usually by cutting, boring, grinding,
shearing, or other forms of deformations, machine tools employ some sort of tool
that does the cutting or shaping. All machine tools have some means of
constraining the work piece and providing a guided movement’s of the part of the
machine. Thus, the relative movements between the work piece and cutting tool
(which called the tool path) is controlled or constrained by the machine to at least
some extent, rather than being entirely “offhand” or “freehand” It is a power-
driven metal cutting machine which assists in managing the needed relative motion
between cutting tool and the job that changes the size and shape of the job
material. The precise definition of the term machine tool varies among users, as
discussed below. While all machine tools are "machines that help people to make
things", not all factory machines are machine tools.

 INDOFAB Pedestal grinding machine

 Champion planer machine
 HMT Radial drilling machine
 HMT LB Type Lathe
 TATA “H” Type Lathe
 HMT LT Type Lathe
 Takisawa Lathe
 Tool & cutter grinder
 Diamond face grinding
 Kirloskar Lathe
 Mysore kirloskar Lathe
 Manual fly press
 Burde TT – slotting machine
 HMT Universal milling machine
 VEB vertical milling
 Horizontal cutting machine
 Vertical cutting band saw
 Rolling machine
 Hand shearing machine

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 CONCEPT 01: - BEARINGS

A bearing is a machine element that constrains relative motion to only the desired
motion and reduces friction between moving parts. The design of the bearing may, for
example, provide for free linear movement of the moving part or for free rotation
around a fixed axis; or, it may prevent a motion by controlling the vectors of normal
forces that bear on the moving parts. Most bearings facilitate the desired motion by
minimizing friction. Bearings are classified broadly according to the type of operation,
the motions allowed, or the directions of the loads (forces) applied to the parts.

The term "bearing" is derived from the verb "to bear"; a bearing being a machine
element that allows one part to bear (i.e., to support) another. The simplest bearings
are bearing surfaces, cut or formed into a part, with varying degrees of control over the
form, size, roughness, and location of the surface. Other bearings are separate devices
installed into a machine or machine part. The most sophisticated bearings for the most
demanding applications are very precise components; their manufacture requires some
of the highest standards of current technology.

Bearings are divided into two basic categories they are;

 Rolling element or Antifriction bearings

 Sliding surface or plain bearings

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 Anti friction bearings
Bearings are classified as plain journal or antifriction bearings. An antifriction bearing is
a bearing that contains moving elements to provide a low friction support surface for
rotating or sliding surfaces. Antifriction bearings are commonly made with hardened
rolling elements (balls and rollers) and races.

Anti friction bearings consist of the following basic elements.

 Outer race or ring
 Inner race or ring
 Rolling element
 Cage or retainer
 Bearing seals

The races or rings

In the case of ball bearings, the bearing has inner and outer races and a set of balls.
Each race is a ring with a groove where the balls rest. The groove is usually shaped
so the ball is a slightly loose fit in the groove. Thus, in principle, the ball contacts
each race at a single point.

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In the case of roller bearings, the bearing has inner and outer races and a set of
rollers. Each race is a ring with a groove where the rollers rest. The groove is usually
shaped so the roller is a slightly loose fit in the groove. Thus, in principle, the roller
contacts each race at a line contact point.

The rolling element

The rolling element is determined by the magnitude of the load and direction of the
load (axial or radial).

Ball
Balls are point contact. Most commonly used rolling element. Relative large radial
loads with some axial

Roller
Rollers are line contact and thus can carry very large radial loads with minimal axial
loads.

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 Taper roller
Taper rollers are line contact and will run in taper races. They can carry both radial
and axial loads.

Needle roller
Needle rollers is similar to rollers, their length is longer in relation to their
diameter. They can be used with races or without. Normally used where radial
space is limited

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 Spherical roller (Barrel)
A spherical roller bearing is a rolling-element bearing that permits rotation with low
friction, and permits angular misalignment. Typically these bearings support a
rotating shaft in the bore of the inner ring that may be misaligned in respect to the
outer ring

Cage or retainer
The ball bearing cage (also known as a ball bearing retainer or ball separator – these
are used interchangeably), is the component in a ball bearing that separates the
balls, maintains the balls and rollers symmetrical radial spacing, and in most cases,
holds the bearings together.

Solid cages consist of brass, steel, light metal, sinter iron and phenolic. Manufacture
process for metal and phenolic cages is consisting of turning and milling. Cages
made out of plastic materials are manufactured by injection moulding.

Press metal cage Machined cage Nylon cage

Bearing seals
The primary functions of a bearing seal are to keep lubricant in the bearing and
bearing chamber contaminants out. Bearings are pre-pact with grease in the
factory and will stay lubricated for the life of the bearing. Some seals are integral to
the bearing; others aren’t. The focus here is on what to consider when selecting
external bearing seals. Key factors in making the right choice for an application
typically include:

 Bearing type (rolling or sleeve)

 Lubricant (oil or grease)
 Seal friction and consequent heating
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  Shaft surface speed and finish
 Physical space available

Nylon seal Metal seal Rubber seal

Type of anti friction bearings

 Single row deep groove ball bearing
 Double row deep groove ball bearing
 Angular ball contact bearing
 Roller bearings
 Taper roller Bearings
 Spherical roller bearings
 Thrust ball bearings
 Roller thrust bearings
 Needle bearings

TYPES OF LOAD ON BEARINGS

AXIAL LOAD: - A bearing axial load is a force that acts parallel to the axis of
the shaft, sometimes referred to as a thrust load.

RADIAL LOAD: - Bearing radial loads are forces that are perpendicular to the
axis of the shaft, parallel to the bearing's radius.

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TASK 01:- LOAD CELL & MANUFACTURE OF LOAD CELL FIXTURE

Manufacturing of new load cell fixture for insulator bend testing machine

Model of load cell fixture:-

1.1Material used to manufacturing of new load cell fixture:-

1.1.1 Mild steel (MS):-

Mild steel is a type of carbon steel that has low carbon content, typically around
0.05% to 0.25% by weight. Contrast this with high-carbon steel containing up to
2.5% carbon by weight. It is prized for being weldable, machinable, and ductile. It is
utilized in many applications, including fences, signs, and the automotive and
construction industries.
Properties of Mild Steel
 High tensile strength.
 High impact strength.
 Good ductility and weld ability.
 A magnetic metal due to its ferrite content.

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 Good malleability with cold-forming possibilities.
 Suitable for various heat treatment options to improve properties.
MANUFACTURING PROCESS

 TURNING
 BOARING
 STEP TURNING
 INNER THREADING
 CUTTING
 DRILLING
 MILLING

USED MACHINES

HMT LB TYPE LATHE:-

Machine type: LB-20

HMT LB-20 LATHE 500mm SWING x 2000mm BETWEEN CENTRES. 18 SPEEDS 32-
1600 RPM. 52mm SPINDLE BORE WITH 3 JAW CHUCK, 4 JAW CHUCK, FACE PLATE,
MULTIFIX QUICK CHANGE TOOLPOST. Programmable Z axis control, manually
operated x and y

A lathe machine is a machine tool that is used to remove unwanted material from a
rotating workpiece in the form of chips. This is accomplished with the use of a tool that
traverses across the workpiece and feeds into it.

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The machine is used to accomplish all fundamental operations, including drilling,
sawing, tapping, and turning, among others, with the aid of various tools located in the
work area. Hence, the lathe is also referred to as the “Mother of all machines.”

VERTICAL BAND SAW MACHINE:-

 Machine Type: Metal Cutting Bandsaw.

 Size/Dimension: 175 Mm.
 Automation Grade: Manual.
 Capacity: 200 Mm x 25.
 Square Cutting: 150 Mm x 150 Mm.
 Machine Weight: 400 Kgs.
 Blade Size: 3000 Mm.

Vertical band saws may be dedicated to cutting meat, metal, wood, and plastics,
whereas general purpose machines address multiple materials because of their
variable speed and blade options. The primary features of all vertical band saws are
almost identical, with variations that support their specialties. For example, sanitation
standards usually require that meat saws have components of stainless steel that can
be disassembled without the use of tools. They do not require tilting tables and
welding/grinding accessories for their blades. Metal working band saws are typically
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low speed with band saw blades that use a large number of small teeth per inch that
occasionally require continuous lubrication.

HMT RADIAL DRILLING MACHINE:-

Specifications :

RM 62 RM 63 RM 65

Drilling Capacity mm 50 50 50 dia 100

In Steel In Cast Iron (At 60 rpm with
mm 60 60 60 0.5 mm/rev.

dia.125

(at 60 rpm with 0.62

mm/rev)

Drilling depth mm 325 325 325

Tapping In Steel In Cast Iron M56x2.5 or BSW 1-3/4 dia. 80 dia. 100

M70 or BSW 2-1/2"

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 Boring dia. 250 dia. 300
In Steel
In Cast Iron

Spindle speeds rpm 12:40-1800 32:10-1545

Spindle feeds no:mm/rev 6:0.125-1.25 18:0.075-4

Max. drilling radius mm 1790 2350

1500

Main motor kW 3.6 / 4.5 20

The machine consists of a heavy, round, vertical column mounted on a large base. The
column supports a radial arm which can be raised and lowered to accommodate work
pieces of different height. The arm may be swung around at any position over the work
bed. The drill head containing mechanism for rotating and feeding the drill is mounted
on a radial arm and can be moved horizontally on the guide ways and can be clamped
at any desired position. These three movements in a radial drilling machine can be
combined together to permit the drill to be located at any desired point on the work
piece for drilling the hole. When several holes are drilled on a large work piece, the
position of the arm and drill head is altered so that the drill spindle may be moved
from one position to the other after drilling the hole without altering the setting of the
work. This versatility of the machine allows it to work on large work pieces. The work
may be mounted on the table or when the job is large it may be placed on the floor or
in a pit.

USED MEASURING DEVICES:-

VERNIER CALIPER:- A vernier caliper is defined as a measuring device that is used for
the measurement of linear dimensions. It is also used for the measurement of
diameters of round objects with the help of the measuring jaws. Least count =
0.02mm

DIAL INDICATOR:- They are designed to measure in vertical or horizontal positions

and typically used to measure clearances, tolerance, and variation in tolerance of
machined parts to ensure accuracy. Least count = 0.01mm

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VERNIER HEIGHT GAUGE:- A height gauge is a measuring device used for determining
the height of objects, and for marking of items to be worked on. Least count =
0.02mm
KNOWN ABOUT LOAD CELL:-

A load cell is a transducer which converts force into a measurable electrical output.
Although there are many varieties of load cells, strain gage based load cells are the
most commonly used type.

Except for certain laboratories where precision mechanical balances are still used,
strain gage load cells dominate the weighing industry. Pneumatic load cells are
sometimes used where intrinsic safety and hygiene are desired, and hydraulic load
cells are considered in remote locations, as they do not require a power supply. Strain
gage load cells offer accuracies from within 0.03% to 0.25% full scale and are suitable
for almost all industrial applications.
Load Cell Operating Principles
Load cell designs can be distinguished according to the type of output signal
generated (pneumatic, hydraulic, electric) or according to the way they detect weight
(bending, shear, compression, tension, etc.)

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TYPES OF LOAD CELL
Hydraulic load cells
Pneumatic load cells
Strain-gage load cells

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