4.

5-Belt Drive-In semi-automatic drain cleaner we have used belt drive for transmission of
power through the pulley. This manual cover v- belt drives used primarily for power
transmission in industrial applications. One of more V-belts may be used on a drive, as required
to transmit horsepower load. In general, the drives are in the integral horsepower class as
distinguished from light duty or fractional horsepower drives. We have used no 35 of V- belt
drive in semi-automatic drain cleaner. V belts (also style V-belts, vee belts, or, less commonly,
wedge rope) solved the slippage and alignment problem. It is now the basic belt for power
transmission. They provide the best combination of traction, speed of movement, load of the
bearings, and long service life. They are generally endless, and their general cross-section
shape is roughly trapezoidal (hence the name "V"). The "V" shape of the belt tracks in a mating
groove in the pulley (or sheave), with the result that the belt cannot slip off. The belt also tends
to wedge into the groove as the load increases—the greater the load, the greater the wedging
action improving torque transmission and making the V-belt an effective solution, needing less
width and tension than flat belts. V-belts trump flat belts with their small center distances and
high reduction ratios. The preferred center distance is larger than the largest pulley diameter,
but less than three times the sum of both pulleys. Optimal speed range is 1,000–7,000 fit/min
(300–2,130 m/min). V-belts need larger pulleys for their thicker cross-section than flat belts.
For high-power requirements, two or more V-belts can be joined side-by-side in an
arrangement called a multi-V, running on matching multi-groove sheaves. This is known as a
multiple-V-belt drive (or sometimes a "classical V-belt drive"). V-belts may be
homogeneously rubber or polymer throughout, or there may be fibers embedded in the rubber
or polymer for strength and reinforcement. The fibers may be of textile materials such as
cotton, polyamide (such as Nylon) or polyester or, for greatest strength, of steel
or aramid (such as Twaron or Kevlar). When an endless belt does not fit the need, jointed and
link V-belts may be employed. Most models offer the same power and speed ratings as
equivalently-sized endless belts and do not require special pulleys to operate. A link v-belt is
a number of polyurethane/polyester composite links held together, either by themselves, such
as Fanner Drives' Power Twist, or Nu-T-Link (with metal studs). These provide easy
installation and superior environmental resistance compared to rubber belts and is length-
adjustable by disassembling and removing links when needed

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 Figure 4.5 V-Belt drives

Figure 4.6 V-Belt with pulley

2
4.6-Journal Bearing-In semi-automatic drain cleaner we have used pedestal bearing. A pillow
block, also known as a Plummer block or housed bearing unit, is a pedestal used to provide
support for a rotating shaft with the help of compatible bearings & various accessories.
Housing material for a pillow block is typically made of cast iron or steel. A pillow block
usually refers to housing with an included anti-friction bearing. A pillow block refers to any
mounted bearing wherein the mounted shaft is in a parallel plane to the mounting surface, and
perpendicular to the center line of the mounting holes, as contrasted with various types of
flange blocks or flange units. A pillow block may contain a bearing with one of several types
of rolling elements, including ball, cylindrical roller, spherical roller, tapered roller, or metallic
or synthetic bushing. The type of rolling element defines the type of pillow block. These differ
from "plumber blocks" which are bearing housings supplied without any bearings and are
usually meant for higher load ratings and a separately installed bearing.

Table no-4.4
Specification No of pieces Internal Diameter (mm)

Bearing 4 20

Table no 4.4-Specifiaction of Bearing

Figure 4.7 Journal Bearing

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4.7-Geared head Electric Motor-The electric motor in its simple terms is a converter of
electrical energy to useful mechanical energy. The electric motor has played a leading role in
the high productivity of modern industry, and it is therefore directly responsible for the high
standard of leaving being employed throughout the industrialized world.
A gear motor is made up of an electric motor, AC
combined with a geared speed reducer. Spur, helical or worm. Gears may be use in single or
multiple stages. The configuration be either that of a parallel shaft, emerging from the front of
the motor, or right angle shaft. Gear motor are often rated in input horse power however, output
torque, commonly measured in inch-pounds and output speed are critical value.
Table 4.5
Specification Power (W) Input(RPM) Output(RPM)

Geared Motor 60 W(AC) 1400 rpm 90 rpm

Table 4.5-Specification of Motor

Figure 4.8 Geared head motor Figure 4.9 Section View

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4.8-Pulley- In semi-automatic drain cleaner we have used pulley for transmitting the power
through motor. Pulleys are also assembled as part of belt and chain drives in order to transmit
power from one rotating shaft to another. A pulley is a wheel on an axle or shaft that is
designed to support movement and change of direction of a taut cable, supporting shell is
referred to as a "block." used to lift weights. Pulleys are assembled to form a block and
tackle in order to provide mechanical advantage to apply large forces.

Table 4.6
Specification Internal dia (mm) External dia (mm)

Pulley (Attached with motor) 15 75

Pulley (Attached with Shaft) 20 165.1

Table 4.6- Specification of Pulley

Figure 4.10- Pulley

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4.9-Lifter-In semi-automatic drain cleaner we have used lifter to collect the floating material
from the drain. As a lifter, we have used refrigerator net. Lifter material is mild steel.

Figure 4.11 Lifter

4.10-Nuts and Bolts- In semi-automatic drain cleaner we have used Nuts and Bolts to fastened
Bearing and angle. A nut is a type of fastener with a threaded hole. Nuts are almost always
used in conjunction with a mating bolt to fasten two or more parts together. The two partners
are kept together by a combination of their threads' friction (with slight elastic deformation), a
slight stretching of the bolt, and compression of the parts to be held together. In applications
where vibration or rotation may work a nut loose, various locking mechanisms may be
employed: lock washers, jam nuts, specialist adhesive thread-locking fluid such as Loctite,
safety pins (split pins) or lock wire in conjunction with castellated nuts, or slightly oval-shaped
threads. We have used eight nuts and bolts with washer.

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 Figure 4.12-Nuts & Bolts with washer

4.11-Mild Steel Net-In semi-automatic drain cleaner we have used iron net to prevent the west
material to go through the frame. Its material is cast iron and size of net holes are 8 mm and
thickness is 5 mm. The area of the net is 914.4mm x 762 mm.

Figure 4.13-Mild steel net

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4.12-Plastic Sheet-In Mechanical semi-automatic drain cleaner we have used plastic sheet to
cover the collecting bin box.

Figure 4.14-Plastic Sheet

4.13 Grease- Grease is a semi-solid grease. Grease

is soap emulsified with mineral or vegetable oil. The characteristic feature of greases is that
they possess a high initial viscosity, which upon the application of shear, drops to give the
effect of an oil-lubricated bearing of approximately the same viscosity as the base oil used in
the grease. This change in viscosity is called shear thinning. Grease is sometimes used to
describe lubricating materials that are simply soft solids or high viscosity liquids, but these
materials do not exhibit the shear-thinning properties characteristic of the classical grease. For
example, petroleum jellies such as Vaseline are not generally classified as greases. Greases are

8
applied to mechanisms that can only be lubricated infrequently and where lubricating oil would
not stay in position. They also act as sealants to prevent ingress of water and incompressible
materials. Grease-lubricated bearings have greater frictional characteristics due to their high
viscosity.

Grease anatomy-As this definition indicates, there are three components that form lubricating
grease. These components are oil, thickener and additives. The base oil and additive package
are the major components in grease formulations, and as such, exert considerable influence on
the behavior of the grease. The thickener is often referred to as a sponge that holds the lubricant
(base oil plus additives).

Figure 4.15-Anatomy of grease

Figure 4.16-Grease

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4.14 Screw-A screw is a type of fastener, sometimes similar to a bolt typically made of mild
steel and characterized by a helical ridge, known as a male thread (external thread) or
just thread. A screw is an inclined plane wrapped around a nail. Some screw threads are
designed to mate with a complementary thread, known as a female thread (internal thread),
often in the form of a nut or an object that has the internal thread formed into it. Other screw
threads are designed to cut a helical groove in a softer material as the screw is inserted. The
most common uses of screws are to hold objects together and to position objects. A screw will
usually have a head on one end that contains a specially formed shape that allows it to be
turned, or driven, with a tool. Common tools for driving screws
include screwdrivers and wrenches. The head is usually larger than the body of the screw,
which keeps the screw from being driven deeper than the length of the screw and to provide
a bearing surface. There are exceptions; for instance, carriage bolts have a domed head that is
not designed to be driven; set screws often have a head smaller than the outer diameter of the
screw; J-bolts have a J-shaped head which is not designed to be driven, but rather is usually
sunk into concrete allowing it to be used as an anchor bolt. The cylindrical portion of the screw
from the underside of the head to the tip is known as the shank; it may be fully threaded or
partially threaded. The distance between each thread is called the "pitch".

Figure 4.17-Screw

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4.15 Primer-A primer undercoat is a preparatory coating applied on materials before painting.
Priming ensures better adhesion of paint to the surface, increases paint durability, and provides
additional protection for the material being painted. Primer is a paint product that allows
finishing paint to adhere much better than if it was used alone. For this purpose, primer is
designed to adhere to surfaces and to form a binding layer that is better prepared to receive the
paint. Because primers do not need to be engineered to have durable, finished surfaces, they
can instead be engineered to have improved filling and binding properties with the material
underneath. Sometimes, this is achieved with specific chemistry, as in the case of aluminum
primer, but more often, this is achieved through controlling the primer's physical properties
such as porosity, tackiness, and hygroscopic. Some metals, such as untreated aluminum,
require a primer; others may not. A primer designed for metal is still highly recommended if a
part is to be exposed to moisture. Once water seeps through to the bare metal, oxidation will
begin (plain steel will simply rust). Metal primers might contain additional materials to protect
against corrosion, such as sacrificial zinc.

Metal hydroxides/oxides do not provide a solid surface for the paint to adhere to, and paint will
come off in large flakes. Using a primer will provide extra insurance against such a scenario.
An additional reason for using a primer on metal could be the poor condition of the surface. A
steel part can be rusty, for example. Of course, the best solution is to thoroughly clean the
metal (blasting), but when this is not a viable option, special kinds of primers can be used that
chemically convert rust to the solid metal salts. And even though such surface is still lacking
in comparison to the shiny clean metal, it is yet much better than weak, porous rust.

. A fast drying, one component anti-corrosive alkyd primer

 Primer in alkyd systems for steel surfaces exposed to weathering.

 Ideal for use in assembling plants and painting stations with rapid production cycles.
 Recommended for steel structures, agricultural, construction and other machinery.
 Can also be used without any topcoat for steel surfaces in dry indoor areas.

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 Figure 4.18-Primer

4.16 Paint-Paint is the most commonly used material to protect steel. Paint systems for steel
structures have developed over the years to comply with industrial environmental legislation
and in response to demands from bridge and building owners for improved durability
performance. Previous five and six coat systems have been replaced by typically three coat
alternatives, and the latest formulations have focused on application in even fewer numbers of
coats, but with increasing individual film thickness. Examples of this are epoxy and polyester
glass flake coatings that are designed for high build thickness in one or two coat applications,
and single coat high build elastomeric urethane coatings, up to 1000μm thick. Modern
specifications usually comprise a sequential coating application of paints or alternatively
paints applied over metal coatings to form a ‘duplex’ coating system. The protective paint
systems usually consist of primer, undercoat(s) and finish coats. Each coating ‘layer’ in any
protective system has a specific function, and the different types are applied in a particular
sequence of primer followed by intermediate / build coats in the shop, and finally the finish or
top coat either in the shop or on site.

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 Figure 4.19-Paint

4.17 Paint Brush-A paintbrush is a brush used to apply paint or sometimes ink. A paintbrush
is usually made by clamping the bristles to a handle with a ferrule. They are available in various
sizes, shapes, and materials. They may be subdivided into decorators' brushes used for painting
and decorating and artists' brushes use for visual art.

Figure 4.20- Paint Brush

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 5.FABRICTATION PROCESS
5.1 Cutting the L type angle-Angle iron is versatile steel product that can be used to create
just about anything from furniture like bed frames, utility tables and shelving unit, to larger
projects likes trailer frames metal building panels and utility sheds. While it is possible to work
with angle iron using simple tools likes drill to bore holes through them angle iron, also known
as angle bars or L-brackets are usually very long, flat metal struts shaped in the form of 90-
degree fold or “L” that can be also be bolted and welded together and iron and metals offers a
wide variety angle iron for contractors.
First of all, measure the L-angle as per dimensions then cut by cutting machine. Cut
the front base part of Semi-automatic drain cleaner that dimension is 609.6 mm then making
edges of the L-angle for welding. After that cut, the side base part of the semi-automatic drain
cleaner that dimensions are 762 mm then making the edges of L-angle for the purpose of
welding.

Figure 5.1-Measuring of L-angle

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 Figure 5.2 Cutting of L-angle

Edges preparations of all the L-angle by file. After edges preparation, we will have to go
Electric arc welding. In Electric arc welding contains Electrode holder, Step-up transformer,
Consumable electrode, Electricity power.

5.2 Joining of frame- Arc welding is one of several fusion processes for joining metals. By
applying intense heat, metal at the joint between two parts is melted and caused to intermix -
directly, or more commonly, with an intermediate molten filler metal. Upon cooling and
solidification, a metallurgical bond is created. Since the joining is an intermixture of metals, the
final weldment potentially has the same strength properties as the metal of the parts. This is in
sharp contrast to non-fusion processes of joining (i.e. soldering, brazing etc.) in which the
mechanical and physical properties of the base materials cannot be duplicated at the joint. In arc
welding, the intense heat needed to melt metal is produced by an electric arc. The arc is formed
between the actual work and an electrode (stick or wire) that is manually or mechanically guided
along the joint. The electrode can either be a rod with the purpose of simply carrying the current
between the tip and the work. Or, it may be a specially prepared rod or wire that not only conducts
the current but also melts and supplies filler metal to the joint. Most welding in the manufacture
of steel products uses the second type of electrode.

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 Figure 5.3-Electric arc welding

Figure 5.4-Machine of Electric Arc welding

16
5.3 Basic Welding Circuit

The basic arc-welding circuit is illustrated in Fig.5.3. An AC power source, fitted with
whatever controls may be needed, is connected by a work cable to the work piece and by a
"hot" cable to an electrode holder of some type, which makes an electrical contact with the
welding electrode. An arc is created across the gap when the energized circuit and the electrode
tip touches the work piece and is withdrawn, yet still with in close contact. The arc produces a
temperature of about 6500ºF at the tip. This heat melts both the base metal and the electrode,
producing a pool of molten metal sometimes called a "crater." The crater solidifies behind the
electrode as it is moved along the joint. The result is a fusion bond.

First of all, Weld the base of Semi-automatic drain cleaner. At the time of welding we ensure
about the both diagonal length is same.

Figure 5.5- Welding of Base

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In the below figure, we have weld the corner of Semi-automatic drain cleaner.

Figure 5.6- Welding base of corner

Figure 5.7- Base of the Machine

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After the welding base of the Semi-automatic drain cleaner then we have to weld backside
vertical L-angle and that height is 1219.2 mm. After that weld, the front side vertical L-angle
and that height is 304.8 mm.

Figure 5.8- Welding of L-angle

After that we have to go for inclined part of Semi-automatic drain cleaner that is attached
through the base to top. Then fabrication of collecting bin of Semi-automatic drain cleaner.
After this welding process is over.

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5.4 Making holes on the angle- Drilling is a cutting process that uses a drill bit to cut a hole
of circular cross-section in solid materials. The drill bit is usually a rotary cutting tool, often
multipoint. The bit is pressed against the work piece and rotated at rates from hundreds to
thousands of revolutions per minute. This forces the cutting edge against the work piece,
cutting off chips (swarf) from the hole as it is drilled. In rock drilling, the hole is usually not
made through a circular cutting motion, though the bit is usually rotated. Instead, the hole is
usually made by hammering a drill bit into the hole with quickly repeated short movements.
The hammering action can be performed from outside of the hole (top-hammer drill) or within
the hole (down-the-hole drill, DTH). Drills used for horizontal drilling are called drills. In rare
cases, specially-shaped bits are used to cut holes of non-circular cross-section; a square cross-
section is possible

Drilled holes are characterized by their sharp edge on the entrance side and the presence
of burrs on the exit side (unless they have been removed). Also, the inside of the hole usually
has helical feed marks. Drilling may affect the mechanical properties of the work piece by
creating low residual stresses around the hole opening and a very thin layer of
highly stressed and disturbed material on the newly formed surface. This causes the work piece
to become more susceptible to corrosion and crack propagation at the stressed surface. A finish
operation may be done to avoid these detrimental conditions. For fluted drill bits, any chips
are removed via the flutes. Chips may form long spirals (undesirable) or small flakes,
depending on the material, and process parameters. The type of chips formed can be an
indicator of the machinability of the material, with long chips suggesting poor material
machinability.

When possible drilled holes should be located perpendicular to the work piece
surface. This minimizes the drill bit's tendency to "walk", that is, to be deflected from the
intended center-line of the bore, causing the hole to be misplaced. The higher the length-to-
diameter ratio of the drill bit, the greater the tendency to walk. The tendency to walk is also
preempted in various other ways, which include:

20
Figure 5.9-Drilling on angle

21
5.5 Allignment of Bearing -In the drilling process we have made eight holes on the angle with
the help of drilling machine. Drill bit size is M12.After the drilling process we have attached
the padastel bearing with the help of nuts and bolts on the surface of L-angle. Tight the bearing
with the help of ring wrinch.

Figure 5.10-Alignment of Bearing

5.6 Turning on lathe machine of Shaft- The simplest thing to do on a lathe and one that will give
the apprentice opportunity to become thoroughly familiar with all levers, etc., is turning a mild
steel shaft. while the forms of lathe dogs and proper use of centers are fully outlined (Lathe Work).
The first thing to do is to provide centers in the shaft with a combined drill and center countersink
in order to support it properly on the lathe centers.
The steps are first, to mark the end of the shaft which is done by scratching two lines
at right angles. The point of intersection of the lines is where the center should be. To mark the
place, a center punch is used. Place the shaft between the lathe centers after prick punching both
ends and see if it runs true when revolved by hand. If it runs out hold a piece of chalk to the shaft
while it turns and mark the high spots. Drive the center hole over in the direction necessary to have
the shaft run true with center punch; in most cases, it will mean moving the center nearer the high
spot. The method of countersinking a shaft. A drill chuck is placed in the lathe spindle and fitted

22
with a combined drill and countersink. Place one end of the shaft on the tail center and feed the
bar in by turning the hand wheel at the end of the tail stock. Allow the countersink to feed in deep
enough, then reverse the shaft and countersink the other end in the same manner. The countersink
should be drilled deep enough so the point of the center will not be called upon to do any of the
work of supporting the shaft. The countersink should have the same taper as the lathe center or 60
degrees.

Figure 5.11. -Preliminary Steps to Turning and Facing Steel Shaft of the Lathe.

The shaft is then provided with a dog at one end that engages with a slot in the face plate to drive
the piece and is supported by the tail stock center at the other end. Oil the centers well before
starting to turn the lathe. The shaft should have a slight play between the centers in order that it
turn easily. Select the proper tool for the character of the work and place it in the tool post, having
the cutting point or edge as near the tool post as possible to prevent the tool springing under a
heavy cut. The position of a turning tool is very important when machining metal. The usual
position is shown. This is about 5 degrees measured on the circumference of the piece to be turned
above the center line. If a tool is placed below center, it is apt to dig in. The proper speed and feed
to use is only determined by experience. It is best for the beginner to take light chips at the start.
After the tool has been properly set, move the carriage over to the tail stock end of the bar and feed
in the hand cross feed until the tool is slightly below the surface of the bar at one end. Set the lead
screw gears for medium speed and feed the tool into the bar slowly by hand to make sure that the
chip taken will not be too heavy for the lathe. After the chip is started, the automatic longitudinal

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