Design and Developement of Fatigue Life Enhancement CNC Shot Peening Machine

Project Title

Design and Developement of Fatigue Life Enhancement CNC Shot Peening Machine

Project Area of Specialization Mechanical EngineeringProject Summary

The aim of the project is to Design and Develope  a Fatigue life Enhancement Shot peening Machine with computer numeric control system using new specimen fatigue testing approach.After the development of machine we have proved that shotpeening process increases the fatigue life and hardness of shafts. This machine is only applicable for shotpeening of shafts, but with certain iteration we can make it applicable to do shot peening of other components.

First of all we do literature review and find many components under cyclic loading fails inspite of the calculation of parameters such as factor of safety, allowable loadings, stresses etc. Components such as gears, shafts, leaf springs and other rotating components can have cyclic or fatigue type loading so component fails abruptly. than we do research and findout how we can improve this process. Than we do many industrial visits to know how this machine works in real life. After certain research we find out another way of doing shotpeening that is specimen approach method. After that we design the machine in solidworks according to our needs. Than we do Simulations in ansys to check weather this machine is applicable in real life. Their are many electrical systems in this machine for the simulation of those components we use labview software. Than we use use matlab sofware to check weather the indentation and compressive residual stresses are useful for us or not. After getting some results we validate those results with shotpeening results from abaqus. In the second phase we started fabrication of machine. After fabrication we do certain tests on the shot peened components and comeup with the results that shotpeening increases the fatigue life and hardness by 50 percent.

Project Objectives

Objectives:

The main objective of this project is to:

1. Design and Develop a CNC Shot peening machine.
2. Selection of shot balls and peening material.
3. Validate the process of shotpeening by testing hardness and fatigue life of shafts after shotpeening process.

Project Implementation Method

The method of our project implementation is based on the different technical phases of project. On industrial scale, before the start shot peening process .We must have knowedge about the work-piece material, strength of material. According to the strength of material we select the shot peening balls media e.g CW-32 or S.280 stainless steel balls.

Before the start of experiment on workpiece, first we perform experiment on the specimens of the same material and note down the shot peening parameters of machine then compare with  the simulations parameters which we already known from the ABAQUS and ANSYS results.

After all the calculations and simulations we start shot peening on the actual workpiece.

After the shot peening experiment, fatigue testing machine and surface hardness machine is required for the comparison of  experment before and after shot peening.

Summary of Implementation Requirements:

• Selection of Work piece Material
• Selection of Shot Peening Balls 
• Experimetation on the Test Specimen
• ANSYS & ABAQUS Simulations
• Decision of final shot peening parameters
• Implementation of parameters on the actual work piece.
• Fatigue Testing Machine 
• Surface hardness Tesing Machine

Benefits of the Project

Many components under cyclic loading fails inspite of the calculation of parameters such as factor of safety, allowable loadings, stresses etc. Components such as gears, shafts, leaf springs and other rotating components can have cyclic or fatigue type loading so component fails abruptly. According to the statistics, over 90% of mechanical failures are caused because of fatigue loading. Since the motion of the engineering products is maintained by the automatic systems (car engines, turbo engines, etc.), the repeated loads on the mechanical parts are inevitable. Hence, if the body of the engineering product contains surface discontinuities or stress concentrating points (sharp edges etc.), failure of the metal body is inevitable too. The fatigue life cycles play an important role in any industry to calculate the life of any component, so that we can replace the component before the failure point.

After this project we will able to enhance the fatigue life and hardness of shafts. Due to which we will be able to use for longer period of time.

Technical Details of Final Deliverable

Design of Machine:

Mechanical assemblies and sub-assemblies of machine is listed below;

1. Rectangular Main Frame
2. Acme-Screw Axis System
3. Boron Carbide Nozzle
4. Assembly of Rotating Chuck
5. Reservoir for the Shot Peening Balls
6. Shot Peening Balls CW-32 and S-280

Working of Machine:

The technical working of CNC Shot Peening Machine is based on three parameters,

1. Rotation of workpiece
2. Velocity of shot peening balls
3. Distance between nozzle and work-piece

Technical Detail:

Technical detail of machine components is listed below;

1. We have  control the rpm's of work piece with the help of motor by regulating the voltage using dimmer.
2. We have designed the machine bed in such a way that both rotating table as well as chuck are mounted on it.
3. Stepper Motors are used for the axis movement 
4. Software Based system in which micro-controllers are used for the operating of machine equipments
5. We have designed the shot peening adapter assembly.
6.  we have designed a shot peening reservoir for the balls which is operated through the compressor and connected with the shot peening nozzle.

Final Deliverable of the Project Hardware SystemCore Industry ManufacturingOther IndustriesCore Technology OthersOther TechnologiesSustainable Development Goals Decent Work and Economic Growth, Industry, Innovation and Infrastructure, Responsible Consumption and ProductionRequired Resources

Item Name	Type	No. of Units	Per Unit Cost (in Rs)	Total (in Rs)
			Total in (Rs)	79843
Stainless Steel Rectangular Tube	Equipment	3	2500	7500
5mm Cutting Disks	Equipment	1	200	200
Delivery Rent	Miscellaneous	1	1000	1000
20 Gage Stainless Steel Sheet	Equipment	31	268	8308
Round Holed Stainless Steel Sheet (21-22G)	Equipment	2	390	780
Stainless Steel Screws	Equipment	1	500	500
Belt and Pulleys	Equipment	1	220	220
Quater Valve	Equipment	2	260	520
valve	Equipment	0	0	0
nozzle	Equipment	2	140	280
pipe	Equipment	1	280	280
pipe clips	Equipment	5	10	50
Carbide Nozzle	Equipment	1	1900	1900
Acme Screw Axis System	Equipment	1	11206	11206
Custom Duty of Axis System	Miscellaneous	1	4309	4309
Pulley Machining Size Adjustment	Miscellaneous	1	600	600
Chuck Bush	Miscellaneous	1	700	700
Motor and motor bush	Equipment	1	1700	1700
Paint	Miscellaneous	3	750	2250
Varnish	Miscellaneous	1	250	250
Nozzle Fabrication Cost	Equipment	1	1500	1500
Labour & Welding Cost	Equipment	1	20000	20000
Micro-controllers	Equipment	5	2500	12500
Steel Plates & Mounting Cost	Miscellaneous	1	500	500
Screws, nuts and bolts	Miscellaneous	1	390	390
Tapping	Equipment	1	800	800
Spray Aluminum Color	Equipment	1	250	250
Steel Puteen	Equipment	1	350	350
Other Miscellanious Expense	Equipment	2	500	1000