MODIFIED METHOD OF

LINK PRODUCTION

A THESIS

Submitted in partial fulfillment for the award of the deg

BACHELOR OF ENGINEERING

In

MECHANICAL ENGINEERING

By

R.SUNDARAMOORTHY (01107404098)

P.SURESH KANNA (01107404101)

GUIDED BY

Dr. T. SENTHIL KUMAR, ME, PhD

Department of Mechanical Engineering

ANNA UNIVERSITY

TRICHIRAPPALLI-620 024

NOVEMBER - 2010
 DEPARTMENT OF MECHANICAL ENGINEERING

ANNA UNIVERSITY

ANNA UNIVERSITY TRICHIRAPPALLI- 620 024

NOVEMBER-2010

BONAFIDE CERTIFICATE

Certified that the thesis titled MODIFIED METHOD OF LINK

PRODUCTION is the bonafide work of R.SUNDARAMOORTHY
(01107404098) who carried out the project under my supervision.
Certified further that to the best of knowledge the work reported herein
does not form part of another thesis or dissertation on the basis of which
degree or award was conferred on an earlier occasion on this or any other
candidate.

Faculty Guide Head of the Department

Certified that the candidate was examined in the university examination

held on _________________________

Internal Examiner External Examiner

2
 ACKNOWLEDGEMENT

I would like to thank Dr. T. Senthil kumar (Head of the Department,

Mechanical Engineering) for guiding and correcting various documents of mine with
attention and care.

I would also like to thank all professors and lectures of Department of

Mechanical Engineering for extending their friendship towards me and making a
pleasure-training environment in the college promises. A paper is not enough for me
to express the support and guidance I received from them almost for all the work I did
there.

Knowledge is power and unity is strength. Finally I thank to my team

mate and friends who shouldered me to complete this project with ease.

3
 TABLE OF CONTENTS

TITLE PAGE NO

CHAPTER 1 - INTRODUCTION

1.1 INTRODUCTION 7
1.2 NECESSITY OF THE PROJECT 7
1.3 AIM OF THE PROJECT 10
1.4 PRINCIPLE USED IN THE WIRE FORMING 10

CHAPTER 2- PRODUCTION OF LINK BY

OLD METHOD
2.1 FIRST STAGE OF PRODUCTION 11
2.2 SECOND STAGE OF PRODUCTION 11
2.3 THIRD STAGE OF PRODUCTION 12

CHAPTER 3- STAGES INVOLVED IN THE CREATION OF

DEVELOPED METHOD
3.1 MAIN STAGES INVOLVED 14
3.2 PLANNING (FIRST STAGE) 14
3.2.1 BRAIN STORMING OF NEW METHODS 14
3.2.2 SELECTED NEW METHOD 15
3.2.3 ALTERNATE METHOD OF LINK PRODUCTION 15
3.3 DO (SECOND STAGE) 15
3.4 CHECK (THIRD STAGE) 15
3.5 ACT (FOURTH STAGE) 15

CHAPTER 4 - COMPONENTS OF THE FIXTURE USED

IN THE DEVELOPED METHOD

4.1 LINK FORMING FIXTURE 17

4.1.1 SPRING PACK CYLINDER 17
4.1.2 RECTANGULAR ENDED MANDREL 17
4.1.3 WIRE FEEDER 23
4.1.4 PIPE GUIDE ARRANGEMENT 23
4.1.5 LATHE MACHINE 23
4.2 LINK CUTTING FIXTURE
4.2.1 LINK CUTTING SCISSORS 23
4.2.2 LATHE MACHINE 23
4.2.3 PLATE CAM 35

4
CHAPTER 5 CONSTRUCTION OF FIXTURE AND
PRODUCTION OF LINKS IN THE
DEVELOPED METHOD

5.1 FIXTURE CONSTRUCTION 38

5.1.1 LINK FORMATION 38
5.1.2 LINK CUTTING 40

5.2 PRODUCTION OF LINK

5.2.1 LINK FORMATION 40
5.2.2 LINK CUTTING 43

CHAPTER 6 COMPARATIVE STUDY OF COST AND

TIME ESTIMATION

6.1 ESTIMATION OF TIME 44

6.2 BENEFITS OF OPERATORS 45
6.3 COMPARATIVE STUDY
6.3.1 RATE OF PRODUCTION VERSUS LIFE OF THE 46
MACHINERIES
6.3.2 COST OF MAINTENANCE VERSUS LIFE OF THE 48
MACHINERIES

CHAPTER 7 - RESULTS OF THE PROJECT

7.1 GUIDE LINES USED IN THE PRODUCTION OF LINKS 50

7.2 ADVANTAGES BY OVERCOMING THE OLD METHOD 50
7.3 RESULTS OF THE PROJECT 51

5
 LIST OF FIGURES
Page No

1.1 Hinge Link 8,9

2.1 Old Method of Link Formation 13
3.1 Cause and Effect Diagram 16
3.2 Stages of Project 16
4.1 Spring Back Cylinder 18
4.2 Mandrel for Hinge Link Production 19,20
4.3 Mandrel for Catch Link Production 21,22
4.4 Wire Feeder 24
4.5 Pipe Guide 25,26
4.6 Guide Roller 27,28
4.7 Scissor s Cutter 29,30
4.8 Cam operated Lever 31,32
4.9 Vertical Frame for Link Cutting Fixture 33,34
4.10 Plate Cam 36,37
5.1 Assembled view of Link Forming Unit 39
5.2 Assembled view of Link Cutter Unit 41
5.3 New Method of Link Production 42
6.1 Machine Life Vs Production Rate 47
6.2 Machine Life Vs Maintenance Cost 49
 6
CHAPTER 1

INTRODUCTION

1.1 Introduction
Heavy Alloy Penetrator Project is also engaged in the production of IFD items
namely, BOX-H2A Components for the use of military service even though its major
product is the anti tank kinetic energy projectiles.
Some of the components which includes in the assembly of BOX-H2A are
Catch Assembly, Hinge Assembly and Link for Handle. In the above three
components a rectangular shaped wire product will be used as a sub- unit. This
project deals with the simplified method to get the rectangular shape in the wire. The
wires which will be used in the production of links (rectangular shaped wire products)
for the Catch Assembly and Hinge Assembly have the diameter of 4.06 mm. But, for
manufacture the component of Link for Handle, a 3.15 mm diameter wire will be
used.

1.2 Necessity of the Project

At the earliest day of production of the above IFD components in HAPP,
the link is formed by step by step processes to get the desired shape. It takes more
time to produce the link.

That is given in the order of operation in steps:

(1) Cutting the wire to the required length by manually.

(2) The rectangular shape is obtained by the progressive operation of the cut wire in
the two press machines.
3) The shape coming from the first pressing machine is in the form and the second
pressing machine gives the final shape of requirement which may be in bulk
quantities. But the above operations gives only limited number of links in a period
of time.

So, as to increase the production of links as to meet the bulk requirements,

this project was developed.

7
1.3 Aim of the Project:
This project strives to achieve highest Customer satisfaction level and to
achieve annual supplies as per laid down targets in conformance with the customers
requirements.
This Project helps the production in the following ways:
(1) It can maximize the production and so the target can be reached in short period
of time.
(2) The manufacturing cost of link components can be reduced.
(3) The human work involvement in the manufacturing the link components
can be reduced.
(4) It can ensure the consistency in the quality of the product.

1.4 Principle used in the wire forming:

When a wire is fed in between a revolving element and a flat surface roller
which may cushioned by the help of tension springs, the wire will get the shape of
rolling flat surface and feed in to front side.

10
 CHAPTER-2

PRODUCTION OF LINK BY OLD METHOD

\
2.1 First stage of production

The mild steel wire from the roll condition is utilized for make
the links after involved it in to the several stage of operations. In that the first stage of
operation is given below:
The required diameter wire from the roll is first straightened and cut
to the required length for make the link. This operation is carried in a straightening
and wire cutting machine. The straightening of the wire can be obtained by the
rotation of two meshing pulleys those having a groove over its periphery on its outer
surface.
When the pulleys are rotating, the wire will be fed in between the
grooves. So the wire got straightened stage and also feed in to the front side. In the
front side one cutter having the vertical movements, cut the wire to the required
length during its downward stroke. The cutter got its movements from a cam operated
drive unit. The required length of cut wire for make the links are collected in a basket.
Then the basket is transferred to the first pressing machine, where the
first stage in the link formation will be takes place.

2.2 Second stage of production

This stage of operation is carried out in the first pressing machine. In

this press the die and punch assembled are enable the wire to get the first stage in the
link formation, as shown in the figure.
This press is a hydraulically operated one. It may be the capacity of
5 tons. This press must have the safety provisions, to ensure the safety of operators
from the accidents. The punches are fitted in the ram which was operated by the
hydraulic piston. The die unit is assembled in the bottom table.
After the bulk collection of the first form stage links, they are
transferred to the second pressing machine for reach the link its final shape.

11
2.3 Third stage of operation

The first form stage links are converted in to the final shape in the
second press in this stage of operation. Here also one hydraulic press having 5 tons
capacity is used for the forming. The die and punch used in this press ensure the final
shape of link as the output. Here also suitable safety provisions are required for the
operators.
The links in the final shape obtained from the second press are collected
in a basket and then they are transferred to the welding spot for carrying the welding
operation at the edges of the links for further assemble work of the links to make the
Hinge Assembly.

12
 CHAPTER-3

STAGES INVOLVED IN THE CREATION OF DEVELOPED

METHOD

3.1 Main Stages involved

The developed method of production was implemented after passed the
four stages in the project. They are given below:
(1) Plan
(2) Do
(3) Check
(4) Act

3.1.1 Planning

In this stage, the causes of problems which affect the production rate in the
old method are discussed with the help of elements of cause and effect diagram. The
main elements involved in the diagram are Man, Machine, Material and Method.
The first element Man involves the operators who operate the machines
and the presses. Here, the skill of the operators in operating the machines and the
presses are thoroughly checked and improved by giving better training and facilities.
The Machine includes the straightening and cutting machine and the two
numbers of Hydraulic Presses. Those are maintained in good operating condition by
the replacement of necessary spare parts.
The third element Material involves the mild steel wire used for the
production of link components. The hardness of the mild steel wire is maintained in
the required range.
After found the variations in the causes from all the above elements are
in satisfactory level, then only the Method of producing the link was involved in to
modification.

3.2.1 Brain storming of New Methods

In the Modification of old method of production, several new ideas are
considered for the production of link components. It is found that, there may be two
methods, which satisfied the main expectation, and from that one is selected as a
better in all the ways.

14
3.2.2 Selected new method
In this method, two lathes are utilized for manufacture the link
components. One lathe is used for formation of the link, whereas the other lathe is
used for cut the links separately from the coil of link which was produced in the first
lathe.
The first lathe is used for the rotation of the mandrel, which forms the
wire in the link shape over its surface. The second lathe is used for the rotation of a
plate cam, which actuates the cutter blades by a lever drive arrangement for cut the
links from the coil of link. The complete detail of this method is given in the
forthcoming chapters.

3.2.3 Alternate method of link production

The drives for the mandrel rotation can also be got from a motor through chain
and sprocket or belt and pulley arrangement.
Because the speed of the mandrel may not be a changeable, it can prefer the
chain and sprocket arrangement for drive the mandrel. So, the use of lathe may be
eliminated.
But the existence of slip in the belt drive arrangement due to the development
of load during the coiling and cutting times, this method was not preferred for the
outcome.

3.3 Do (second stage)

In this stage the new and developed method for the production of links
coming to the existence. All the fixtures for produce the links are made and
assembled as per the design.

3.4 Check (Third stage)

The trial run for produce the links are carried out in this stage. The
necessary adjustments in the moving parts, for example, position of guide roller and
wire feeder, speed of the lathe, guide tubes height, actuation of the cam pin over the
lever, the cutting action of the scissor and etc, are thoroughly checked and adjusted
according to the condition to give required link output.

3.5 Act (fourth stage)

In this stage, the production of links started in mass numbers from

the newly designed machines. Necessary training must be given to the operators for
enhancing the rate of production.
15
 Man Machine
(Operator)

Link
Production

Material Method of Link Production

(M.S.Sheet& Wire) (Old Method)

Fig.3.1 Cause and Effect Diagram

Act Planning

Check Do

Fig.3.2. Stages of Project

16
 CHAPTER - 4

COMPONENTS OF THE FIXTURE USED

IN THE PROJECT

4.1 Link forming fixture

This fixture arrangement is used to make the wire formation in the desired
size and shape of our requirement. The mandrel takes the main role in the wire
formation .Because, when the forming operation the wire will roll over the
rectangular surfaces of the mandrel.

4.1.1 Spring pack cylinder

One number tension spring is packed inside a cylinder and one end of
that cylinder provided with a spring adjustment bolt with a lock nut.
A push rod called plunger is fitted with the cylinders other end. The
push rod is a cylindrical rod .This rods one end is pressed by the spring and the other
end is connected with a roller .During forming operation, this roller guides the
mandrel and makes the rectangular formation in the wire which is fed from the wire
feeder.
There are 3 numbers of such type of spring packed cylinders are used for
get the link shape.

4.1.2 Rectangular end mandrel

The mandrel will have the rectangular projection at one end and a
cylindrical surface at the other end. This cylindrical surface is hold by the lathe chuck
at the time of coiling .The rectangular end must be a hardened one. This rectangular
portion will have a slot on its face. The link formation is developed in the rectangular
end. After assembled all the units in the link cutting fixture, the rectangular mandrel
must project out through the hole in the vertical plate and also at the bottom of
vertical spring back cylinder.

The mandrels outer dimension must be equal to the inner dimensions of

the link which require to be manufacture. The mandrel is made in tool steel to enable
to withstand the load. The rectangular portion of the mandrel requires hardening
before use of this mandrel for take the production. It is necessary to avoid the damage
of bulging at the edges of the rectangular portion during link formation.

17
4.1.3 Wire Feeder
It consists of a base frame with four legs. The top side of the base frame is
welded with a flat plate in the middle portion. One number vertical shaft of 50 mm
diameter made in stainless steel is mounted in the flat plate through bearings.
The flat plate also welded with a circular frame to support the coiled wire.
The vertical shaft can be rotated by the pulling motion developed over the wire by the
rotation of lathe spindle.

4.1.4 Pipe Guide Arrangement:

This is simply a mild steel pipe mounted over the V support. The support is
fitted on a base plate which is placed in the tail end of the lathe bed. The length of the
pipe will ensure the length of the coil formation at one time of cutting.
The one end of the pipe should be placed in a distance which will be
somewhat nearer to the mandrels front end.

4.1.5 Lathe Machines

In this project two lathe machines are used for manufacture the links.
One lathe carries the arrangement which produces links in the form of spring.
The other lathe carries the arrangement, which produce the individual links.

4.2 Link cutting Fixture

This fixture mainly consists of two cutting levers operated as a scissoring

unit for cut the links separately from the spring like chain of link.

4.2.1 Link Cutting Scissors

This is an arrangement of two levers and one of them is operated by the cam
unit which will be fixed in the spindle of the lathe .The another lever having cutting
edge on one side is fitted rigidly with the fasteners in a vertical support. The vertical
support is fixed on the cross slide. The cutting edges of the scissors are made with
hardened nature so as to prevent the earlier damage of the cutter.

23
4.2.2 Plate Cam

It is a simple circular plate having a thickness of 20 mm. At the one face

of this plate, a small length shaft is welded in the middle. The lathe chuck is hold the
shaft for connect the plate.

One short lengthened pin is welded on the other Face of the plate
eccentrically from the middle. This pin acts like a toggle, to actuate the lever of the
link cutting scissor. During cutting operation, each revolution of the plate cam gives a
link, by the above actuation of the toggle over the lever of the scissoring unit.

35
 CHAPTER 5

CONSTRUCTION OF FIXTURE AND PRODUCTION OF LINKS

IN THE DEVELOPED METHOD

Details of the link components

The links in different sizes are used as a sub assembly for the components
of Catch, Handle and Hinge.
For the catch and hinge components the link is require to be made from the
of 4 mm steel wire. But for the handle component, it will require to make from the
diameter of 3.15 mm steel wire.
The links require for the above 3 components also have different dimensions
in length and width wise.
So, forming the shapes in required dimensions from the above diameter
wires must require separate arrangements of punch, die and fixtures, when we use the
hydraulic press.

5.1 Fixture construction

5.1.1 Link Formation

One fixture which includes three numbers of spring cushioned cylinders is
mounted over the bed of the first lathe. The fabrication of this fixture may be
completed by welding the fixture components as per the design.

Among the three cylinders, two cylinders are fitted in the fixture in vertical
axis at top and bottom, facing the rollers towards the spindle axis.

But one cylinder is fitted horizontally facing its roller towards the axis of
the spindle. The chuck holds the circular portion of the rectangular ended mandrel.

The pipe guide arrangement mounted over the tail stocks base plate after
the removal of the tail stock center arrangement. The pipe guides axis must be
adjusted in the way that should be matched in line with the spindle axis.

The wire feeder should be kept in opposite to the cross slide, in the back
side of the lathe as enable to supply the wire to the mandrel. Before the link
formation process the coil should be loaded over the wire feeder unit.

38
5.1.2 Link Cutting

Here the fixture carries the levers of the scissoring arrangement and the total
fixture is mounted over the bed of the second lathe. The lathe spindle holds the set of
plate cam arrangement.

The tray at the bottom of the bed should be placed in proper place to enable
to collect the links.

5.2 Production of links

The link production can be obtained from two stages of process.
They are explained below.

5.2.1 Link formation

This is the initial stage of operation in the production of link components.

This operation mainly covers the following two steps of procedure.

Initial set up

The mandrels back end should be hold with the Chuck .The use of the
three jaw chuck will ensure the self centering of the mandrel.

The mandrel rectangular portions dimension must be matched with the

inner dimension of the link to be manufacture.

The spring cushioned cylinders spring Tension should be adjusted

according to the plunger position. The roller fixed at the end of the plunger should be
positioned as it will be nearer to the mandrel surface to maintain the gap of wire
thickness.

The wire having the required cross sectional diameter is loaded around the
vertical shaft of the feeder unit. The one end of the wire is pulled and kept in the slot
of the side face of the mandrel.

40
 Formation of link

By the slow rotational adjustment of the spindle the wire can be brought in
between the roller and the mandrels flat surface. The further spindle rotation gives a
pulling force on the wire in the coil and also makes the defined rectangular formation
in the wire over the mandrel.

Because of the continual formation of the rectangular shape in the wire,

just like a spring, it is pushed out axially. The axially outcome coiled link passes
through the tube guide which is mounted over the bed along the spindle axis.
After formation of coiled link to the predetermined length (that is, up to
other end of the pipe guide), the coil is cut off and taken to the link cutting lathe. The
approximate number of links cut from the coil length can be found out by dividing the
length by the wire diameter.

5.2.2 Link Cutting

The link cutting scissor is mounted over the cross slide of the second lathe.
The scissor having two levers and one of its lever is operated by the projected pin of
the cam plate. The cam plate is held in the spindle.

When the coil of link length is manually introduced in between the two
edges of the scissor, the link is cut off one by one by the scissor for each actuation of
its one lever by the cam pin. The speed of introducing the coiled link in to the scissor
for cutting them may change from operator to operator.

So, the speed of the lathe must be changed depends upon the operator. For a
highly trained person, the speed of the lathe running at normal speed is suitable. But,
for the new operators, running the lathe at a slow speed can give the better results.

The reason for the above that, a trained person Can quickly introduce the
coil in between the cutting levers, according to the quicker actuation of the lever
occurred due to high spindle speed. But, a lesser skilled operator, may struggle for
this quicker response.

The links which are cut off from the link length are collected at the bottom
tray and the further works on that is carried on.

43
 CHAPTER-6

COMPARATIVE STUDY OF COST AND TIME ESTIMATION

6.1 Time estimation

Old method

Time for cutting of wire to the require length/100 numbers = 30 minutes

Time for setting the cut wire in the die /100 numbers =1 hour

Time for complete the link formation in the pressing

Machine /100 numbers =1 hour

-------------------
Total hours require for produce 100 numbers of links = 2-30
--------- - -----------

Developed method

When using the coiling machine, the production of quantity of links

which will equal to the RPM of the mandrel.
For example, if the mandrel is running at a speed of 20 rpm, 20
numbers of links in 1 minute and 1200 numbers of links in 60 minutes (or) 1 hour can
be produced.
The link cutting machine can also give the Output of individual links in
the quantities which will equal to the RPM of the spindle which is connected with the
cam plate.

Like the above calculation,

If the cam plates speed of rotation is 20 rpm,
Then scissor can cut as follows:
20 numbers of links in 1 minute
100 numbers links in 5 minute
200 numbers of links in 10 minutes
1200 numbers of links in 60 minutes (or)
1 hour

But, the total time require for produce 100 numbers of links will equal to the
Time taken by the coiling machine and cutting machine for produce 100 numbers of
links.
44
 So, the total time /100 links = (10+5) minutes

= 15 minutes

When viewing the details, through piece work (wages) system,

Normally, the standard man hours (SMH) given for 1 number of link is 0.001 hour
is used for calculating the output hours of an operator.

6.2 Benefit of employer/operator

Old method
For 1 hour of Input Hour,
The employee can get = Number of links produced in 1 hour X SMH
= 40 X 0.001
= 0.04 hour as the Output Hour.

Developed method,
For 1 hour of Input Hour,
The employee can get = Number of links produced in one hour X SMH
= 1200 X 0.001
=1.2 hour as the Output Hour.

Since, the employees salary

(in piece rate system) = Basic Pay X Output hours / Input Hours.

So, it is well known that, an employees output hours (which is relates with
the production) must be equal to or more than his input hours (relates with his
attendance in duty). Then only he can get his basic salary or profit respectively.

So, clearly it can be understood that, an Employee can get more benefits by the
use of the developed method.

In another way, the developed method also helpful to the management to reduce
the SMH (standard man hours) of the link component and thereby they can ensure
only the basic Pay to the employees. So, the Employers/Management can get benefits
by use of the developed method.

45
6.3 Comparative study

6.3.1 Rate of production versus Life of the machineries

The graph shows the relationship between the rate of production over the
entire life of the link producing machines in the old and new methods.

The line 1-2 represents the production rate in the new method over the
life of its machineries. It will be known that at the initial period of life of the
machineries in the new method can able to produce more components by the way of
increasing production rate. But in forthcoming life of the same machines, the rate of
production may be decreased due to the reason of maintenance works in the sliding
parts of the forming fixture due to the breakdown. It is denoted by the steeper slope in
the line 1-2 in the graph.

But in old method, because of the less output from the hydraulic press the
rate of production may be less and it is represented by a line 3-2 in the graph. The
line 3-2 represents the rate of production in the old method over the life of its
machineries. Because of the hydraulic presses may able to give an approximately a
constant production rate, the 3-2 line is drawn nearly horizontal in the graph.

Consider the point at 2 both the lines may meet and the corresponding
life of the machines is approximately 4 years and the production rate may be same in
both the methods. The area under the both the lines3-2 and1-2gave the total
quantity of the links produced in the corresponding methods.

It is clearly understood that the new method gives more quantity of links
compared with the old method.

46
6.3.2 Cost of production versus Life of the machineries
The graph shows the relationship between the two methods when
comparing the cost of production over its life of machines.

In the new method the cost of production is slowly increased

throughout the life of the machineries. It is shown by the line 5-6 in the graph.
The cost of production will be increased from the starting onwards of the new link
forming machines when it comes to produce the links from its installation stage. This
is because of the necessity of the cost of maintenance service for the small adjustment
to major replacement of spares, like, bearing, gears etc, in the lathe in throughout the
period of its life.

When comparing the old method, the requirement of cost of

production will not be increased, due to the use of Hydraulic presses in the old
method. But when the cost exists, it may be a sudden increasing one. This is because
of the replacement of high cost of spares in the Hydraulic presses. This is shown in
the graph by a line 7-6.

At one of the point the cost of production of both the methods are
same in a same life of year. When cumulatively comparing the total cost of
production in that particular year (say at 6) the cost of new method is somewhat
higher than the old one.

When considering the ratio of Total quantity of links produced per

unit cost of production for a particular year of life the machines, the new method is an
advantageous one. The above detail can be collected by the comparative study of both
the graphs.

48
 CHAPTER 7

RESULT OF THE PROJECT

7.1 Guide lines used in the production of links

(1) Proper lubrication of oil is required for spring back cylinder.
(2) The mandrels working face should be checked in proper interval of time.
(3) The speed of the lathes in both the link forming & cutting machines should be
maintained at a constant one, and in that speed, the link formation and the
cutting operation must be carried in a good manner.
(4) The wire feeder should freely permit the wire for its formation over the mandrel
according to the spindle speed. For that, the wire feeders guide should be fixed
in proper place. Proper lubricants should be applied at proper interval in the
bearing provided at the bottom of the vertical shaft.
(5) The longitudinal and crosswise movement of the saddle and the cross slides
should be arrested respectively, after setting the link forming and cutting units
in the correct position for carrying their particular operation.
(6) The cutting portion of the scissor should be checked properly. The stress
developed in the cutting operation should be maintained to a minimum in
positively, otherwise, there is a possibility of breakage of cutting edges.

7.2 Advantages by overcoming the Old method

(1) Elimination of hydraulic press in the developed method, gives the following
benefits
The inventory cost can be reduced due to the elimination of the press. The
maintenance cost can also be reduced due to this press elimination.

(2) The spare parts requirement is less compared with the Hydraulic press.
Benefits can obtain by the operators in the following ways,
Because of the increase of the production rate, the operators can expect more
profits from the management.
The operators can escape from the mental stress in the developed method
compared with the old method in the production of the link components.

(3) Even less skill is enough for the operators. The operators may require to do
minor corrective works in the settings of the machine and it also not required
always.

50
(4). Benefits by the management point of view,
Quality of the product is ensured always in this method. More out come is one
of the important beneficial to the management. Reduction in the rejection of the
products, increase the quantity of the production. Management can challenge
with the other competitors who are supplying the similar products, by giving
good quality of the products to the customers.

7.3 Result of the project

Utilization of less man power:

The previous method of link formation requires more man power. But this
developed method requires less man power. It is because of the developed method has
less steps of operation in comparison with the previous method.

Reduced chances of accidents:

In this developed method, there is a rare chance to the finger injuries.

Normally after START of the link formation process the man- machine contact is
reduced or eliminated up to the start of cut off the link operation.

Easy tool changing:

It can be got different size of links by simply change of the mandrel. But in
previous method, obtaining of each size links, require separate punch, die and fixture
arrangement.
So, Setting of tool in the developed method can be done in few minutes and it
also nothing but simple replacement of mandrel and spring pressure adjustment in the
roller.

Economic power consumption:

Usage of press is eliminated in the developed method and so the

consumption of power for drive the hydraulic pump is totally eliminated.

Reducing the rejection level:

Maintaining the uniformity of jobs in size and shape reduces the rejection level
of products and that ensure the quality.

51