1. AVC COLLEGE OF ENGINEERING Mechanical Engineering DESIGN OF DRILL PCD ADJUSTABLE MECHANISM AND RESPECT MODIFICATION OF MULTI DRILLING MACHINE. Guided By Mr.P.Amith kishore, Asst. Prof/Mech. Industrial Guide Mr.A.Balakrishnan(DGM) AXELS INDIA LTD, Sriperumbudur. Submitted by E.Krishna samy(80107144020) R.Sudhakar(80107144047) V.Vasanthabharathi(80107144052) K.Veerapandian(80107144055)

2. PROBLEM DESCRIPTION In order to drill multi hole of the 60SH and 90SH diff case components in industries used a rigid fixture without any PCD (Pitch Circle Diameter) adjustments in nature. For That reason,we have to work more for replacement of the rigid tool guide setup. But it practically gives more hard and work time delay. The conventional machine used for various type same ratio PCD drill components, but there is a need of adjustable tool guide is essential.

3. OBJECTIVES To simplify the tool position adjustments. To reduce the time of drill PCD adjustments by the movable tool holding set. To avoid replacing of the rigid tool guider. Here we use adjustable clamping of tool holder.

4. DRILLING COMPONENTS 60SHand 90SH they are components used in the differential case in bus and heavy trucks respectively. They have twelve holes in the same angle ratio and slightly differed in the diameter of drill. All aspects of the drilling of that components are same. Simply says, they are same ratio in all.

5. COMPONENT VIEW

6. MULTI DRILLING MACHINE Multi drilling machine is a heavy duty machine type it has high drill force and motor power. in this case drill will be twelve holes at the same time. This machine specification: Speed of drill machine: 1700rpm Torque of the motor: 48 Nm Power of the motor: 11 Kw Feed rate of the machine : 400mm/min Drill bit diameter: 15mm

7. MACHINE VIEW

8. METHODALOGY

9. MACHINE MODIFICATIONS Height variation provider. Plate dimensions changing with permissible limits. Minimum and maximum diameter of the drill PCD determination. Tool holder travel distance in the slot of the adjustable plate.

10. ADJUSTABLE PLATE Adjustable plate consist of C shaped clamp with U bolts. Slots are formed in the plate for required size of the drill diameter. Then C shaped clamp with specified diameter, along with U bolts. This clamp diameter based on the diameter of the PCD of the component. U Bolt dimensions based on the clamp and tool holder diameter and it will be same for any type of C shaped clamp used here.

11. TOP VIEW OF THE PLATE

12. ADJUSTABLE PLATE DIMENSIONS Total length of the plate taken 700mm Travelling distance of the slider in slot simply it as triangle: 111.35 mm Distance travel of the slider with use of universal coupling: ((2*5.17)+111.35)=121.69mm Slot length up to out end: 2*distance travel)+2(slot circle diameter)+minimum diameter of the pcd: ((2*121.69)+(2*25)+164)=457.38mm

13. Contd… Position 1(Minimum) Height =(2*universal joint 1st yoke height )+(2*Universal joint 2 nd yoke height)+Propeller shaft length) =(2*20)+(2*15.32)+222.69 = 292.79mm Horizontal travel initially =0mm

14. Contd…. Position 2(maximum) Height =(2*universal joint 1st yoke height )+(2*Universal joint 2 nd yoke height)+Propeller shaft length) =(2*20)+(2*19.32)+280.12 =358.76mm Horizontal travel length=(2*yoke length )+(travel of shaft without universal joint) = ((2*5.17)+111.35) = 121.69mm

15. Contd… C shaped clamp dimensions: For minimum diameter of drill pcd Inner diameter =164+(2*12.5)=189mm Outer diameter =10+inner diameter U Bolt Dimensions: U bolt wire diameter taken as 10mm U bend diameter=10+slider diameter =10+25 =35mm

16. Recommendation 1 (Hydraulic height variation adjustment) All dimensions are in mm POSITIONANGLE (DEGREE) HARIZONTAL TRAVEL HEIGHT VARIATION STATUSDRILL PCD DIAMETER 1212 140 165 0 121.69 0 (292.79) 66.15(358.9 4) Minimum Maximum 164 386.7

17. Recommendation 2 (Spline shaft adjustment ) All dimensions are in mm PositionDrill PCDAngleTravelling distance Height variationSpline hub Inserting(%) variationSpline in hub 1212 164 386.7 140 165 0 121.69 0 66.15 100% Inserted 33.85% Inserted 100/100= 1*100 66.15/100= 0.3385*100

18. COMPONENTS USED Propeller shafts Universal joints Spline joint Press fit bush U bolts C shaped clamp Linear bearing Stud bolts

19. Propeller shaft and universal joint

20. UNIVERSAL JOINT ANIMATION

22. MODEL AND MACHINE VIEW

23. 3D VIEW OF TOOL GUIDE

24. 3D VIEW

25. ADVANTAGES Easy to handle the adjustment clamps and U bolts while clamping. No need of fork lifts. No need to replace the tool guide components. Adjustment and clamping time will be very much less compare than formally used.

26. DISADVANTAGES Hydraulic system for height variation is excessive one. This components should be newly manufactured.

27. CONCLUSION This project will give good effort and easy use of machine. Easy implementation of the guide plate. This is feasible and possible to implement in that particular HMT multi drilling machine.

28. Thank you