AUTOMATIC HAMMERING AND PUNCHING MACHINE

A Project Report

Submitted to the Faculty of Engineering of

JAWAHARLAL NEHRU TECHNOLOGICAL UNIVERSITY, KAKINADA

In partial fulfillment of the requirements for award of the Degree of

Bachelor of Technology
In

MECHANICAL ENGINEERING
By

CH. SAI RAM PRASAD - 17KP5A0304

Under the guidance of

Mr. K. RAMBABU
Assistant professor

Department of MECHANICAL Engineering

NRI INSTITUTE OF TECHNOLOGY
(Approved by AICTE, Affiliated to JNTU, KAKINADA)
Visadala (P.O.), Medikonduru Mandal, Guntur-522438
ANDHRA PRADESH
2020

i
 DEPARTMENT OF MECHANICAL ENGINEERING

NRI INSTITUTE OF TECHNOLOGY

(Approved by AICTE, Affiliated to JNTU, KAKINADA)

Visadala (P.O), Medikonduru (M), Guntur -522438

ANDHRA PRADESH

CERTIFICATE
This is to certify that project report entitled “AUTOMATIC HAMMERING
ANDPUNCHING MACHINE” is a bonafied record of work carried out by CH. SAI RAM
PRASAD (17KP5A0304) under my guidance and supervision in partial fulfilment of the
requirements for the award of degree of Bachelor of Technology in Mechanical Engineering
of Jawaharlal Nehru Technology University, Kakinada.

PROJECT GUIDE HEAD OF THE DEPARTMENT

Mr. K. RAMBABU Sri. P. RAVI KUMAR

Assistant Professor Associate Professor

EXTERNAL EXAMINER

ii
 ACKNOWLEDGEMENT

Firstly, I would like to thanks PARENTS extend their directly

and indirectly for completion of project in time and deep and sincere gratitude to our
institution NRI INSTITUTE OF TECHNOLOGY for providing us with all the required
equipment for the fulfillment of Bachelor of Technology in Mechanical Engineering.

I express our heartful thanks to the principal Dr.Y.V.S.S.S.V PRASADA RAO.

We also show our token of gratitude to Head of the Department Mechanical Engineering
Prof.P.RAVI KUMAR, for fastening an excellent academic atmosphere in the institution

I would like to express our unbounded gratefulness to our project guide Mr. K.
RAMBABU, Mechanical Department for his valuable guidance and encouragement
throughout the project.

I thank all FACULTY MEMBERS for the help they extended, in completing this project, I
also concede for the creative criticism of our CLASSMATES AND FRIENDS in our pursuit
towards a great academic endeavor

CH. SAI RAM PRASAD - 17KP5A0304

iii
 DECLARATION

We hereby declare that the work which is being presented in this dissertation entitled
“AUTOMATIC HAMMERING AND PUNCHING MACHINE” Submitted towards the
partial fulfillment of requirements for the award of the degree in Bachelor of technology and
authentic record of our work carried out under the supervision of Mr. K. RAMBABU,
Assistant professor in department of Mechanical Engineering.

The matter embodied in this dissertation report has not been submitted by us for the
award of any degree. Further the technical details furnished in the various chapters in this
report are purely relevant to the above project and there is no deviation from the theoretical
point of view for design, development and implementation.

CH. SAI RAM PRASAD - 17KP5A0304

iv
 CONTENTS
Title page i
Certificate ii
Acknowledgement iii
Declaration iv
List Of Contents v
List of figures viii
Abstract xi

S.NO. NAME OF THE CHAPTER PAGE NO

Chapter 1 INTRODUCTION 01-04

1.1 Concept 02
1.2 Scope of work 03
1.3 Project planning 04

Chapter 2 LITERATURE REVIEW 05-14

2.1 Cam operated 7
2.2 Forging hammer 7
2.3 Hammer tool 7
2.4 Compound hammer 8
2.5 cam operated ,single shot 8
2.6 Powered impact wrench 8
2.7 Rotary hammer 8
2.8 Study of power hammers 9
2.9 Types of power hammers 9
2.10 Recent research of power hammer 11
2.11 Mechanism 12
2.12 Drop forging 14
v
Chapter 3 COMPUTER AIDED DESIGN DRAWING 15-16
3.1 Drawing 15

Chapter 4 COMPONENTS 17-26

4.112V Battery 18
4.2 60 rpm DC motor 18
4.3 Cam 19
4.4 Hammer 20
4.5 Pedestal bearing 20
4.6 Chain drive 21
4.7 Shaft 22
4.8 Connecting link 22
4.9 Frame 23
4.10 Bolt 23
4.11 Nut 24
4.12 L key 25
4.1.3 Punching tool 25

Chapter 5 FABRICATION 27-35

5.1 Making frame 28
5.2 Placing of battery 29
5.3 Joining of dc motor 30
5.4 Connecting of gear spockets 31
5.5 Arrangement of pedestal bearing 33
5.6 Arrangement of disc 34
5.7 Fitting of hammer 34
5.8Connecting link rod 35
5.9 Overall construction 35

vi
Chapter 6 WORKING PRINCIPLE 36-44

6.1 Methodology 37
6.2 Operation 37
6.3 Calculations 44

Chapter 7 CONCLUSION 45-47

7.1 Advantages 46
7.2 Disadvantages 46
7.3 Application 47

Chapter 8 FUTURE SCOPE 48-49

Chapter 9 REFERENCES 50-57

vii
 LIST OF FIGURES
Fig. No. Particulars Page No.
Fig.2.9.1 six bar mechanism 10
Fig.2.11 four bar mechanism 12
Fig.2.12 Drop forging 14
Fig.3.1 Drawing 16
Fig.3.2 Cad design 17
Fig.4.1 12 v battery 18
Fig.4.2 Dc motor 18
Fig 4.3 cam 19
Fig 4.4 Hammer 20
Fig 4.5 Pedestal bearing 20
Fig 4.6 Chain drive 21
Fig 4.7 Shaft 22
Fig 4.8 Connecting link 22
Fig 4.9 Frame 23
Fig 4.10 Bolt 23
Fig 4.11 Nut 24
Fig 4.12 L key 25
Fig 4.13 Punching tool 25
Fig 5.1.1 Iron frame 28
Fig. 5.1.2 Making frame 28
Fig 5.1.3 Overall frame 29
Fig 5.2.1 Battery placement 29
Fig 5.2.2 Battery 30
Fig. 5.3.1 Joining of dc motor 30
Fig 5.3.2 Top view of motor 31

viii
Fig 5.4.1 Chain drive 31

Fig 5.4.2 Connecting of gears 32

Fig 5.4.3 Arrangement of gears 32

Fig 5.5 Arrangement of pedestal bearing 33

Fig 5.6 Arrangement of disc 34

Fig. 5.7 Fitting of hammer 34

Fig 5.8 Connecting link rod 35

Fig 5.9 Overall construction 35

Fig 6.2.1 Battery connection 37

Fig 6.2.2 Battery to motor connection 38

Fig6.2.3 Pulley placement 38

Fig 6.2.4 Bearings 38

Fig.6.2.5 Joining of circular disc 39

Fig.6.2.6 Connecting link rod 39

Fig6.2.7 Connections checking of machine 40

Fig6.2.8 Overall machine view 41

Fig.6.3.1 Free body diagram 42

ix
 ABSTRACT

In many industries various type of machines and equipment have been used for various
operation such as forging, Hammering , cutting etc. But different problem such a slow power
supply, less man power and also heavy laborious work force, safety etc. this projects relates
to operation performed by can be achieved by either using electric motor power or by
manually by means of simply rotating a hand lever attached to the shaft and hammering
action can be provided . If there is good power supply it can be run automatically for
automatic operation A.C motor is provided .belt drive governor are also provided for speed
control purposes so that the suitable speed can be achieved. When no electric power supply is
there the advance cam operated hammer can be used manually by simply rotating the hand
lever also the handling is simple and ,maintenance is easy of the project.

This paper discuss about cad modeling, design and analysis of automatic hammering
machine. Our goal for this paper is to design and Fabricate an automatic hammering machine.
And for this, we have calculated the maximum torque, impact velocity for hammering, torque
force and also shear failure in bolt joint. In our project we are using torque force to perform
various manufacturing operation in industries like riveting, upset forging, punching etc. Also
time required for operation is less so it is useful in mass production.
In this project we have prepared solid model of project assembly by using CATIA v5R20
software {Computer aided three dimensional interactive application}. The snapshots of every
component are attached in the file in design section. The model consists of motor, shaft,
hammer, jigs and fixtures. From this we fabricate conceptual model of automatic hammering
machine. Automatic portable hammering machine is one of the new techniques proposed in
design in order to achieve instant Hammering accurate repetition and impacting, fast
Hammering process. It should be user friendly without any risk and worker manual Effort can
be used easily automatically. In the past, a labor used hammer for to drive nail, fit parts,
break apart and more. It would be used manually with more effort and man power used in
process. But now a day it is possible to make it process easy by invented automatic
Hammering. There are very clear benefits that the industry sees while using automated
systems. These advantages can be very beneficial in the long run. We assure that our products
are one of the best and they are long lasting.

Automatic portable hammering machine can be considered as the backbone of any

hammering operation in mass production its principle function is to safely and preciously
hammering work like to perform the punching operation, filleting operation, riveting
operation and smithy operation i.e. upset forging etc for all designed operating conditions.
This paper describes cad modeling, design and analysis of automatic portable hammering
machine. Aprogrammed hammering machine self-working machine going to assume an
imperative part in the assembling procedure (hammering process). Hammering machine
utilized as a part of the generation of material extending from instruments, to pivots, car
frame forming, molding of metal and so forth.
x
The present development identified with metal squeezing machine and forming machine
included certain outstanding challenges in regard of to drive nail, fit parts, forge metal and
break
separated question. The innovation has for its question cure this downside and to empower,
by including helper implies, to drive nail, fit parts, manufacture metal and break separated
protest the like. Hammering is the most generally utilized in mechanical operation and also
development action. Hammering or screws

xi
 CHAPTER 1

INTRODUCTION

1
Definition of Hammering machine

As a open die hot forging in which billet is compressed and deformed by continuous
blows of upper die. In addition, for a given weigh , parts produced by forging exhibit better
mechanical and metallurgical properties and reliability than do those manufactured by casting
or machining.

1.1 Concept

Hammering is the most widely used industrial as well as construction

activity hammering or screw, metal sheet, parts etc. required a lot of time and effort so here
we proposed an automated hammering system that allows for fully automatic hammering
whenever and whenever needed using the person just needs to insert work piece and start the
This machine Can be used a for automatic hammering works as and when needed use here a
DC motor consist of a pulley attached to it which is connected to a hammering machine .
larger pulley for efficient power transfer and to increase torque this large pulley is connected
to a shaft that has a connecting rod is used to achieve lateral motion from the spinning shaft
we now connect the order end of hammer to this connecting a rod through amid swinging
arrangement in order to achive desired hammer motion with enough torque we can use a
suitable bed where work piece can be placed

The advance cam operated hammer is a device which can be used for
multipurpose operation by either automatically of manually it is mainly used of hammering
of work piece it can also be used for various purpose such an punching forging bending etc.

2
Advantages

1. Instant Hammering.
2. Fast Hammering process.
3. No manually effort.
4. Portable system.
5. Multi operation.
6. Easy maintenance
7. Low initial cost
8. User friendly
9. Low tooling cost.
10. Accurate repetition and Impact

Objective

To operate the cam hammer machine electric motor .which is having RPM with the
Operating voltage of AC single phase with the continues rotating its horsepower is used to
rotate the camshaft , grinding , drilling .

1.2 Scope of Work

i. Literature review on the knowledge of mechanism design

ii. To design the mechanical part of a automatic portable hammering machine using CAD
software Solid Work.
iii. Develop the model automatic portable hammering machine using bending process,
welding process, drilling process and cutting process.
iv. Fabricate the model automatic portable hammering machine using welding skill and
machining.

1.3 Project Planning

To start of this project, a meeting with supervisor in the first week is done to manage
the schedule of weekly meetings. The purpose is to inform the supervisor on the progress of

3
 The project and guided by the supervisor to solve difficulty. Briefing based on the
introduction and next task of the project is given by supervisor. Make research of literature
review with the means of the internet, books, available published articles and materials that is
related to the title.
Designing phase start of by sketching few model models using manual sketch on A4
papers.

4
 CHAPTER 2
LITERATURE REVIEW

5
Leonardo‟s invention the cam hammer is another example of thinking centuries ahead of his
time. This machine would be used extensively several hundreds of years after his death
during the
industrial revolution. They would be powered by Steam engine and could hammer at up to
twenty times per second. They were used to draw out the sheet metal for ships and armored
machines for war such as the tanks in world war 1.
Below is his original drawing for the cam hammer –
As you can see it was intended to be hand cranked. This would rotate the cam upon which the
hammer mechanisms rests and follows. When the cam is rotated the weight of the hammer
ensures that the bar connected to it always wants to be tight up against it due to the force of
gravity. Eventually the hammer and its mechanism follow to cam all the way around until the
cam suddenly drops off – this makes the hammer fall also. Below is an animation sowing the
cam hammer in action Hammers like these would continue to be in use until the early 20th
century where they were replaced by rolling mills, these were much more powerful and
efficient at rolling sheet metal down to its desired dimensions, they rely on the brute force
that can be utilized with today‟s modern machinery using hydraulics.

John Byron Henry, et.al. Invention relates to power hammers, and particularly to steam forge
hammers including a supporting frame, a hammer operating power cylinder provided with a
piston and piston rod carrying a ram or hammer attached. Richard W. Hall, et.al, invention is
to double acting forging hammers and, more particularly, to forging hammers actuated by
pressurized gas and/or hydraulic fluid. Accordingly, there is a need for double-acting forging
hammer which utilizes pneumatic and/or hydraulic hammer driving systems, yet does not
have the energy losses associated with pneumatic systems or the complex and sophisticated
of hydraulic systems. Howard Terhune, et.al, invented this project is simply is an
improvement of forging hammers used for industrial purposes. As we aware that in forging
operation the temperature of the metal is so high that manual hammering operation is quite
difficult for this purpose. So in this project they provided control valves which directing the
ram up or down by the steam power. Invention relates generally to portable motor-operated
and manually controlled machine tools or implements, and more specifically to an improved
hammer tool and operating mechanism of the reciprocating, rotary cam actuated type, and
designed for interchangeable us as a portable power-operated hammer, wood chisel, scaling
chisel, piercing punch, rock drill, and other similar power tools. John I. Kupta et.al, invention
herein disclosed relates to steam and air hammers of the pile driver type and in which,
usually, the motive fluid is just admitted to lift and then released to drop the ram. „Operating
in this manner such hammers naturally are inetiicient the use of steam or air and since gravity
is the force relied on for the striking blow, the ram and other parts have had to be heavy and
bulky. David A. Giardino, et.al, invention relates to the art
of rotary impact wrenches of a type in which a rotating member is periodically reciprocated
into and out of rotary impacting relation with an anvil portion of torque output shaft.
From the detailed literature review it can be observed that there was not any simple and
compact machine designed.
6
All the research was heavy and complex machine related. So, we have been trying to
modeling a simple power hammer machine to perform forging operation easily.
2.1 Cam operated, FOR A RIFLE James Kepnar, Lawrenceville, GA (US), United
States Patent office journals, Application filled – March 23, 2001, Serial no. 09/815,677,
Patented

September. 26, 2002, Published no. US 2002/0133997 A1 This invention relates to the field
of
firing mechanisms for single shot rifles, more particularly to a cam operated, falling block
firing
mechanisms incorporating a pivoted breechblock link.
High power inside the machine is generated by using the cam by which strong action is
generated to the bullets while switching i.e. engaging the cam switch.
So from this review we decide to take the advantage of using the cam as a vital impact factor
of the hammering action by switching the hammer supported ram.

2.2 Forging hammer (fluid operated) J.J. Kupta Et Al, United States Patent office
journals, Application – December 2, 1955, Serial no. 550718, Patented Oct. 23, 1957,
Published no. US2789540 This project found very useful when finding out during the
literature survey. This project is simply is an improvement of forging hammers used for
industrial purposes. As we aware that in forging operation the temperature of the metal part is
so high that manual hammering operation is quite difficult for this purpose. So in this project
they provided control valves which directing the ram up or down by the steam power. So that
ram is moved up and down with attached hammer automatically. So we can provide
automatic control over hammer for the purpose of vital operation like forging

2.3 Hammer tool Howard Terhune, Cleveland, Ohio, United States Patent office
journals, Application – September 27, 1944, Serial no. 555977, Patented Oct. 28, 1947,
Published no. US2429780 This invention relates to portable motor operated and manually
controlled machine tools or implements, and more specifically to an improved hammer tool
and operating mechanisms of the reciprocating, rotary cam actuated type, and designed for
interchangeable use as a portable power operated hammer, wood chisel, scaling chisel,
piercing punch, rock drill, and other similar power tools. The novel operating mechanism of
the project is an attachment, is adapted for combination with and receives power from a
motor, as an electric motor, which is manually controlled to supply rotary power and motion
that is translated, or converted by the operating mechanism into reciprocating motion and
power for a tool holder having selective interchangeable tools.

7
2.4 Compound hammer Harold S. Sheldon, Tekoa, Washington DC, United States
Patent office journals, Application – October 15, 1947, Serial no. 779931, Patented – March
21, 1950, Published no. US2501542 The invention herein disclosed relates to steam and air
hammers of the pile driver type and in which, usually the motive fluid is just admitted to lift
and then released to drop the ram to achieve a strong downward force to executing any
hammering operations. The another objective of this invention is also taking less time and
reducing the breaking probability of the load or other parts attached to the ram providing
hammering action down the line.

2.5 Cam operated, single shot, falling block firing mechanism for a rifile
James Kepnar, Lawrenceville, GA (US), United States Patent office journals, Application
filled – March 23, 2001, Serial no. 09/815,677, Patented September. 26, 2002, Published no.
US 2002/0133997 A1 This invention relates to the field of firing mechanisms for single shot
rifles, more particularly to a cam operated, falling block firing mechanisms incorporating a
pivoted breechblock link. High power inside the machine is generated by using the cam by
which strong action is generated to the bullets while switching i.e. engaging the cam switch.
So from this review we decide to take the advantage of using the cam as a vital impact factor
of the hammering action by switching the hammer supported ram.

2.6 Powered impact wrench David A. Giardino, Utica; William K. Wallace,

Barneveld; Joseph R. Groshans, Clinton, all of N.Y, United States Patent office journals,
Application – September 25, 1989, Patented Jan. 28, 1992, Patent no. 5083619 Published
no.US5083619 This invention relates to the art of rotary impact wrenches of a type in which
a rotating member is periodically reciprocated into and out of rotary impacting relation with
an anvil portion of a torque output shaft. The object of the invention is to provide an
improved power operated impact wrench including camming arrangement which permits the
use of light weight tool housing without the inertia effect on the operator who is holding the
tool. By reviewing various research papers we have concluded that Advance cam operated
hammer design is feasible so we decide to make it work.

2.7 Rotary hammer Ulrich Demuth, Erbach-Ernsbach; Winrich Habedank, Diez, both of
Germany, United States Patent office journals, Application - November 20, 1996, Patented
August 29, 2000, Patent no. 6109364, Published no. US006109364A

Review
It relates to a hammer with a tool holder and a hammer mechanism for the transmission of
impact energy onto the drilling and/or chiseling bit in the tool holder has a switching device
which with a single actuator makes it possible to switch between pure drilling operation,
rotary hammering operation and pure hammering operation. The cam part is provided at the
section of the actuator projecting inwardly over the slide part. The object of the invention is
to develop a rotary hammer and is particular its switching device in such a way that it has a
compact structure and can be operated without being prone to disturbance.

8
Objectives
 The main objective of our project work is to reduce or neglect the defined problem and
provide an idea to overcome various problems by fabricating the concept as well as
working model which represents a solution given to the existing problem.
 So our objective is to provide an electric motor driven mechanism so that the machine can
perform operations with the help of electricity and automatically. The another objective is
to give manual handling attachment by means of hand lever in the same model so that
without power supply the operator can perform the various hammering operations without
disrupting or stopping the machine.
 Another objective of our project is to get an impact from the hammer to the work piece by
using the effective way by Snail cam. So that the complicated mechanisms get neglected
and cost of the system can be reduced very much.

2.8 Study of power hammers

Until now we have confined ourselves to study of hand tools used in smithy work They
certainly perform very well so far as the hand- forging is concerned, butt heir use for
satisfactory production is limited to small forging only. It would not be difficult to understand
that the intensity of blows, however great one may try to achieve through hand hammering,
will not be sufficient enough to effect the proper plastic flow in a medium sized or heavy
forging. For this, a power hammer is usually employed. The capacity of these hammers is
given by the total weight of their falling parts i.e., t up or ram and die. A 200 kg hammer will
be one of which the falling parts weigh 200 kg. The heavier these parts and greater the height
from which they fall.
The higher will be intensity of blow the hammer will provide. Power hammers in common
use are of different types e.g. spring power hammers, pneumatic power hammers, Steam
hammers and Drop or Forge hammers and six bar slider crank power hammers. These
hammers are named partly after their construction, partly according to their way of operation.
Apart from these, a large number of forging presses and machines are used in forging work.
In the following articles these hammers and machines will be discussed in detail.

2.9 Types of Power Hammers

Helve hammer
Helve hammers are well adapted for general engineering work where the size of the stock is
changed frequently. They consist of a horizontal wooden helve, pivoted at one end with a
hammer at the other end. An adjustable eccentric raises the hammer which when falls strikes
a blow. They are made in sizes from 5 to 200kg.
Trip Hammer
Trip hammers have a vertically reciprocating ram that is actuated by toggle connection driven
by
9
a rotating shaft at the top of the hammer. Trip hammers are also built in sizes from 5 to 200
kg. The stroke range of both helve and trip hammers ranges from about 400 per minute for
small sizes to about 175 for large size.
Lever-Spring Hammer

They are mechanical driven hammers with a practically constant lift and an insignificantly
variable striking power. It only increases with increasing operating speed and thus has
increases number of strokes per minute. The ram is driven from rocking lever acting on an
elastic rod. The rocking lever consists of a leaf spring so that an elastic drive is brought
about. They are suitable for drawing out and flattening small forgings produced in large
numbers. Their disadvantage is the frequent breaking of springs due to vibrations when in
operations. Spring hammers are built with rams weighing from 30 to 250 kg. The number of
strokes varies from 200 to 40 blows per minute.

Pneumatic hammer
The hammer has two cylinders compressor cylinder and ram cylinder. Piston of the
compressor cylinder compresses air, and delivers it to the ram cylinder where it actuates the
piston which is integral with ram delivering the blows to the work. The reciprocation of the
compression piston is obtained from a crank drive which is powered from a motor through a
reducing gear. The air distribution device between the two cylinders consists of rotary valves
with ports through which air passes into the ram cylinder, below and above the piston,
alternately. This drives the ram up and down respectively.

Six bar slider crank power hammer mechanism

Fig 2.9.1 six bar mechanism

10
Present scenario of power hammer and mechanisms

Power hammers

Unfortunately, using presently available power hammers and formers can subject users to a
number of inherent disadvantages. Generally, presently available power hammers and
formers are expensive and may cost on the order of tens of thousands of dollars putting them
out of reach of all but the largest metal working operators. Presently, available power
hammers and formers tend to be bulky and occupy large footprints making them unsuitable
for small-scale operations. In addition, presently available power hammers and formers can
require precise, custom machined die sets, which may be unusable with other machinery, in
order to provide proper operational clearance. Finally, presently available power hammers
and former scan be operated by linkage drives that have the capacity to literally destroy the
machines if proper die set-ups and clearances are not maintained.

2.10 Recent research of power hammer

The present disclosure addresses a power hammer assembly providing users with the metal
forming advantages associated with power machinery at a reduced expense and in a smaller
footprint than presently available power hammer systems. In general, the power hammer
assembly of the present invention provides three dimensional shaping capabilities, which
have application in the forming of custom metal products such as, for example, customized
motorcycle and automotive parts. The power hammer assembly of the present disclosure can
be fabricated and assembled in a kit fashion with commonly available tools to reduce costs.
Alternatively, the power hammer assembly of the present disclosure can be purchase din an
assembled configuration. In one aspect, a power hammer assembly of the present disclosure
provides powered forming capabilities while remaining economical with respect to
performance, vibration, and footprint size and acquisition costs.
In some embodiments, the power hammer assembly can comprise a power assembly for
providing a single stroke speed and/or a single set stroke with respect to the striking of die
assemblies against a piece of metal. In some embodiments, the power hammer assembly of
the present invention can comprise a larger throat area and/or a larger die gap than presently
available power hammers to facilitate ease of use. In some embodiments, the power hammer
assembly of the present invention can comprise adjustment features allowing for the use of
die sets of varying configurations such as, for example, shank size, shank length or
alternatively, die sets fabricated for use with other machinery. In some embodiments, the
power hammer assembly of the present invention can comprise a belt transmission assembly
designed to slip in the event of die interference during set-up or operation so as to avoid
damaging the power hammer assembly.
11
 In some embodiments the power hammer assembly of the present invention includes fine
adjustment means for spacing between the upper and lower die.
2.11 Mechanism
Four bar parallel linkage mechanism for toe movement

Fig 2.11 Four bar mechanism

ANAUTOMATIC PORTABLE HAMMERINGMACHINEBY ABHIJEET
DHULEKAR1, SUYASH SHIRBHATE2, RIZWAN SHAIKH3, M
INGALKAR4
This paper discuss about cad modeling, design and analysis of automatic hammering
machine. Our goal for this paper is to design and Fabricate an automatic hammering machine.
And for this, we have calculated the maximum torque, impact velocity for hammering, torque
force and also shear failure in bolt joint. In our project we are using torque force to perform
various manufacturing operation in industries like riveting, upset forging, punching etc. Also
time required for operation is less so it is useful in mass production. In this project we have
prepared solid model of project assembly by using CATIA v5R20 software {Computer aided
three dimensional interactive application}.

12
The snapshots of every component are attached in the file in design section. The model
consists of motor, shaft, hammer, jigs and fixtures. From this we fabricate conceptual model
of automatic hammering machine. Automatic portable hammering machine is one of the new
techniques proposed in design in order to achieve instant Hammering accurate repetition and
impacting, fast Hammering process. It should be user friendly without an risk and worker
manual Effort can be used easily automatically. In the past, a labour used hammer for to drive
nail, fit parts, break apart and more. It would be used manually with more effort and man
power used in process. But now a day it is possible to make it process easy by invented
automatic Hammering. There are very clear benefits that the industry sees while using
automated systems. These advantages can be very beneficial in the long run. We assure that
our products are one of the best and they are long lasting.

Design Of A Recycle Bin Hammering machine By Muhammad Hanis Bin

Muhammad Zulkifli.

In many industries various types of machines and equipment have been used for various
operations such as forging, hammering, cutting etc. But different problems such as low power
supply, less man power and also heavy laborious work force, safety etc. This projects relates
to operation performed by this can be achieved by either using electric motor power or by
manually by means of simply rotating a hand lever attached to the shaft and hammering
action can be provided. If there is good power supply it can be run automatically. For
automatic operation A.C. motor is provided. Chain drive, belt drive, governor are also
provided for speed control purposes so that the suitable speed can be achieved. When no
electric power supply is there the advance cam operated hammer can be used manually by
simply rotating the hand lever. Also the handling is simple and maintenance is easy of the
project.

Cam operated, For a rifile James Kepnar, Lawrenceville, GA (US), United

States Patent office journals, Application filled – March 23, 2001, Serial no. 09/815,677,
Patented September. 26, 2002, Published no. US 2002/0133997 A1 This invention relates to
the field of firing mechanisms for single shot rifles, more particularly to a cam operated,
falling block firing mechanisms incorporating a pivoted breechblock link. High power inside
the machine is generated by using the cam by which strong action is generated to the bullets
while switching i.e. engaging the cam switch. So from this review we decide to take the
advantage of using the cam as a vital impact factor of the hammering action by switching the
hammer supported ram.
2.12 Drop forging
Drop forging is the process of Heating metal and shaping it using a metal die cast to produce
products. Manufactures use this process to produce strong and durable parts for a range of
industries.
13
Forging is one of the oldest metal working practices and it can be traced back to 8000 B C
.Parts can be produced from various types of metal including al, brass and various grades of
steel .There two type of drop forging open-die dropped forging and closed – die dropped
forging and closed-die dropped forging
Open – Die dropped Forging
Open-die forging is the shaping of heated metal between a top die and bottom die, after every
Press of the die the metal taken a new shape.
Open- die forging is usually used for large less intricate parts.

Closed - Die dropped Forging

Closed-Die Forging is the most popular method of forging as it allows manufactures
to produce smaller and more intricate parts. These include things like seat belt buckles,
climbing gear, spanner and tractor parts for harvesting.

Fig 2.12 Drop forging

14
 CHAPTER 3

COMPUTER AIDED DESIGN DRAWING

15
3.1 Drawing

After a design has been selected, the next step in designing process is dimension in . The
design is separated into part by part and the dimensioning process is firstly sketched on the
paper. The dimensioning is based on relevant dimensions and also referring the automatic
portable hammering machine so that the design is fit into other part. After dimensioning, the
drawing of the design is drawn using Solid Works application; at this stage solid 27odeling
method is used. Part by part solid modeling create according to the dimension done before,
after all part create, the 3d model is assemble with each other base on the design.

Fig3.1 drawing
The drawings are diving into two categories, which are: Sketching: all the ideals for
automatic portable hammering machine are sketched on the paper to ensure that ideas
selection can be made after the selected design choose. Solid Works Application: The design
or concept sketched is transfer to solid modeling and drawing using Solid Work Application.

Fig 3.2 cad design

16
 CHAPTER 4
COMPONENTS

17
4.1 12v battery

Fig 4.1 12v battery

12vbattery is a rechargeable battery that supplies electrical current to a motor vehicle. Its
main purpose is to feed the starter, which starts the engine. Once the engine is running, power
for the car‟s electrical systems is still supplied by the battery with the alternator charging as
demands increase or decrease
4.2 60 rpm DC motor

Fig 4.2 dc motor

A DC motor is any of a class of rotary electrical motors that converts direct current electrical
energy into mechanical energy. The most common types rely on the forces produced by
magnetic fields.

18
Nearly all types of DC motors have some internal mechanism, either electromechanical or
electronic, to periodically change the direction of current in part of the motor.

DC motors were the first form of motor widely used, as they could be powered from existing
direct-current lighting power distribution systems. A DC motor‟s speed can be controlled
over a wide range, using either a variable supply voltage or by changing the strength of
current in its field windings. Small DC motors are used in tools, toys, and appliances. The
universal motor can operate on direct current but is a lightweight brushed motor used for
portable power tools and appliances. Larger DC motors are currently used in propulsion of
electric vehicles, elevator and hoists, and in drives for steel rolling mills. The advent of power
electronics has made replacement of DC motors with AC motors possible in many
applications.

4.3 Cam

Fig 4.3 cam

A cam is a rotating or sliding piece in a mechanical linkage used especially in transforming

rotary motion into linear motion. It is often a part of a rotating wheel (e.g. an eccentric wheel)
or shaft (e.g. a cylinder with an irregular shape) that strikes a lever at one or more points on
its circular path. The cam can be a simple tooth, as is used to deliver pulses of power to a
steam hammer, for example, or an eccentric disc or other shape that produces a smooth
reciprocating (back and forth) motion in the follower, which is a lever making contact with
the cam. In mechanical engineering, an eccentric is a circular disk (eccentric sheave) solidly
fixed to a rotating axle with its center offset from that of the axle (hence the word "eccentric",
out of the center).

It is used most often in steam engines, and used to convert rotary into linear reciprocating
motion to drive a sliding valve or pump ram. To do so, an eccentric usually has a groove at its
circumference closely fitted a circular collar (eccentric strap). An attached eccentric rod is
suspended in such a way that its other end can impart the required reciprocating motion.

19
 A return crank fulfills the same function except that it can only work at the end of an axle or
on the outside of a wheel whereas an eccentric can also be fitted to the body of the axle
between the wheels. Unlike a cam, which also converts rotary into linear motion at almost
any rate of acceleration and deceleration, an eccentric or return crank can only impart simple
harmonic motion

4.4 Hammer

Fig 4.4 hammer

A hammer is a tool consisting of a weighted “head” fixed to a long handle that is swung to
deliver an impact to a small area of an object. This can be, for example, to drive nails into
wood, to shape metal (as with a forge), or to crush rock. Hammers are used for a wide range
of driving, shaping, and breaking applications.

A sledgehammer is a tool with a large, flat, often metal head, attached to a long
handle. The long handle combined with a heavy head allows the sledgehammer to gather
momentum during a swing and apply a large force compared to hammers designed to drive
nails. Along with the mallet, it shares the ability to distribute force over a wide area. This is
in contrast to other types of hammers, which concentrate force in a relatively small area.

4.5 Pedestal bearing

Fig 4.5 pedestal bearing

20
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 to the
directions of the loads (forces) applied to the parts.

4.6 Chain drive

fig 4.6 chain drive

Chain drive is a way of transmitting mechanical power from one place to another. It is often
used to convey power to the wheels of a vehicle, particularly bicycles and motorcycles. It is
also used in a wide variety of machines besides vehicles.

Most often, the power is conveyed by a roller chain, known as the drive chain or transmission
chain, passing over a sprocket gear, with the teeth of the gear meshing with the holes in the
links of the chain. The gear is turned, and this pulls the chain putting mechanical force into
the system. Another type of drive chain is the Morse chain, invented by the Morse Chain
Company of Ithaca, New York, United States. This has inverted teeth.

Sometimes the power is output by simply rotating the chain, which can be used to lift or drag
objects. In other situations, a second gear is placed and the power is recovered by attaching
shafts or hubs to this gear. Though drive chains are often simple oval loops, they can also go
around corners by placing more than two gears along the chain; gears that do not put power
into the system or transmit it out are generally known as idler-wheels. By varying the
diameter of the input and output gears with respect to each other, the gear ratio can be altered.
For example, when the bicycle pedals' gear rotate once, it causes the gear that drives the
wheels to rotate more than one revolution.

21
4.7 Shaft

Fig 4.7 shaft

A shaft is a rotating machine element, usually circular in cross section, which is used to
transmit power from one part to another, or from a machine which produces power to a
machine which absorbs power.

The material used for ordinary shafts is mild steel. When high strength is required, an alloy
steel such as nickel, nickel-chromium or chromium-vanadium steel is used.

Shafts are generally formed by hot rolling and finished to size by cold drawing or turning and
grinding.

4.8 Connecting link

Fig 4.8 connecting link

Connecting link rod is used to connects the disc of one end of the eccentric holes and other
end of the connecting rod is connects to the hammer shaft .This connecting link rod
transverse the rotary motion into reciprocating motion ,this is the main linkage of machine by
this link only the operation will be done. This is about the connecting rod link

22
4.9 Frame

Fig 4.9 frame

A frame is often a structural system that supports other components of a physical construction
and/or steel frame that limits the construction's extent.

L = 530mm

W = 460mm

H = 580mm

4.10 Bolt

Fig 4.10 bolt

Material : Stainless Steel
Size : 5 Ani , 4 Ani
Bolt, is a type of fastener characterized by a helical ridge, known as an external thread or just
thread, wrapped around a cylinder. Some screw threads are designed to mate with a
Complementary thread, known as an internal thread, often in the form of a nut or an object
that has the internal thread formed into it.
23
 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 and to position objects.

4.11 Nut

Fig 4.11 nut

Material : Stainless Steel Material

Size : 5 Ani ,4 Ani

A nut is a type of fastener with a threaded hole. Nuts are almost always used in conjunction
with a mating bolt to fasten multiple 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,
nylon inserts (nylon nut), or slightly oval-shaped threads.

24
4.12 L key

Fig 4.12 l key

A hex key, Allen wrench or Allen key, is a simple tool used to drive bolts and screws with
hexagonal sockets in their heads.

The tool is usually formed of a single piece of hexagonal rod of hard steel, with blunt ends
that are meant to fit snugly into the screw's socket, bent in an "L" shape with unequal arms.
The tool is usually held and twisted by the long arm, creating a large torque at the tip of the
short arm. Reversing the tool lets the long arm reach screws in hard-to-reach places.

Each key is meant to be used with screws of a specific socket size, with rather tight
tolerances; so the tool is commonly sold in kits that include half a dozen or more keys of
different sizes. Usually the length of the key increases with the size of the socket, but not
necessarily in direct proportion.

Variants of the tool have the short end inserted in a transverse handle, which may contain
multiple keys that can be folded into the handle when not in use.

4.13 Punching tool

Fig 4.13 punching tool

25
Punching is a forming process that uses a punch press to force a tool, called a punch, through
the work piece to create a hole via shearing. Punching is applicable to a wide variety of
materials that come in sheet form, including sheet metal, paper, vulcanized fibre and some
forms of plastic sheet. The punch often passes through the work into a die. A scrap slug from
the hole is deposited into the die in the process. Depending on the material being punched
this slug may be recycled and reused or discarded.

Punching is often the cheapest method for creating holes in sheet materials in medium to high
production volumes. When a specially shaped punch is used to create multiple usable parts
from a sheet of material the process is known as blanking. In metal forging applications the
work is often punched while hot, and this is called hot punching. Slugging is the operation of
punching in which punch is stopped as soon as the metal fracture is complete and metal is not
removed but held in hole.

26
 CHAPTER 5
FABRICATION

27
FABRICATION OF THE PROJECT

5.1 Making frame

 First of all iron frame will be taken with a dimension of 45cm X 53cm with equal
measurement

Fig 5.1.1 Iron frame

 These iron frames are joined by using of arc welding process by giving negative terminal
to the frame pieces and positive terminals are given to the transformer so the welding
process will be done

Fig 5.1.2 making frame

28
 In that frame the sitting place of motor and battery will be place so that the these two
items will be fixed properly so that there is no vibrations of equipment will be occurred

Fig 5.1.3 Overall frame

 After welding operation frame will be as shown in the fig.

5.2 Placing of battery

Fig 5.2.1 Battery placement

 After completion of the frame. The 12 v battery is placed in the corner position of the
frame
 In this project we are using 12 v battery this is rechargeable battery we can charge any
time

29
 Fig 5.2.2 battery
 This is the placing of battery after completion of the frame. By using this battery we will
give the power supply to the motor then it converts electrical energy into the mechanical
energy.
 This 12 v battery plays a vital role in the project.
 After battery positioning the project will be as shown in the fig.

5. 3 Joining of dc motor

Fig 5.3.1 joining of dc motor

30
 In this project we are using 60 rpm dc motor because the weight of the hammer is 1 ½ kg
so to lift this hammer we are using this dc motor.

Fig 5.3.2 top view of motor

 This is connected to the battery by the connection of the wire so that the motor will rotate
with heavy speed .
 The fig showing placing of 60 rpm dc motor in the frame.
5.4 Connecting of gear spockets

Fig 5.4.1 chain drive

These are the gear spockets used in this project to transverse the rotary motion from one
position to another position
31
 Fig 5.4.2 connecting of gears
 smaller pulley and larger pulley is placed some distance beside the motor

 The larger pulley is connected to the motor shaft and smaller pulley is connected to the
pedestal bearing

Fig 5.4.3 arrangement of gears

 This is the fig showing arrangement of gear spockets in the project.

32
5.5 Arrangement of pedestal bearing

Fig 5.5 Arrangement of pedestal bearing

 We are using 2 pedestal bearing to reduce the friction between the shafts
 In between the 2 bearings the shaft will be placed in that shaft the smaller pulley will be
arranged
 By using this bearings the movement of gear spockets will runs smoothly
 The adjustment of bearings will be operated by the L key
 This is the arrangement of bearings in the frame

33
5.6 Arrangement of disc

Fig 5.6 Arrangement of disc

 These circular disc is joined to the shaft is placed between the bearings .This circular disc
is rotates with more rpm
 In this circular disc the small strip type screw will be joined by rotating of gears the disc
will also rotates.
 This is the arrangement of circular disc.

5.7 Fitting of hammer

Fig 5.7 Fitting of hammer

34
 The hammer will be fitted by using bolt and nut by tightening of screws
 We are using 1 ½kg hammer for bending ,forging , crushing etc..
 This is the arrangement of hammer as shown in the fig.

5.8 Connecting link rod

Fig 5.8 connecting link rod

 This connecting link rod transverse the rotary motion into the linear motion
 One end of the connecting link rod is connected to the circular disc and other end is
connected to the hammer end
 By that the linkage of the hammer and disc will be done
 This is the arrangement of connecting link rod as shown in the fig.

5.9 Overall construction

Fig 5.9 overall construction

35
 CHAPTER 6
WORKING PRICIPLE

36
6.1 Methodology
In designing and hammering machine, a flow of methods had to be used the design and
hammering machine. First of all, a process planning had to be charted out. This acts as a
guide line to be followed so that, the final model meets the requirement and time could be
managed. This would determine the efficiency of the project to be done. Regulating and
analysing these steps are very important as each of it has its own criteria to be followed.

6.2 Operation

To operate the CAM Hammer machine electric motor which is having RPM with operating
voltage of AC in single phase with the continues rotating its horsepower is used to rotate the
CAM profile , Shaft , Grinding , Drilling

 The 12 v battery is placed in the corner position of the frame

 This is the placing of battery after completion of the frame. By using this battery we will
give the power supply to the motor then it converts electrical energy into the mechanical
energy.

 This 12 v battery plays a vital role in the project.

Fig 6.2.1 Battery connection

37
 Fig 6.2.2 Motor to battery connections

 In this project we are using 60 rpm dc motor because the weight of the hammer is 1 ½ kg
so to lift this hammer we are using this dc motor.
 This is connected to the battery by the connection of the wire so that the motor will rotate
with heavy speed .


Fig 6.2.3 Pulley placement

smaller pulley and larger pulley is placed some distance beside the motor larger pulley is
connected to the motor shaft and smaller pulley is connected to the pedestal bearing

We are using 2 pedestal bearing to reduce the friction between the shafts

Fig 6.2.4 Bearings


In between the 2 bearings the shaft will be placed in that shaft the smaller pulley will be
arranged

By using this bearings the movement of gear spockets will runs smoothly




Fig 6.2.5 Joining of circular disc
These circular disc is joined to the shaft is placed between the bearings .This circular disc is
rotates with more rpm
In this circular disc the small strip type screw will be joined by rotating of gears the disc
will also rotates
The hammer will be fitted by using bolt and nut by tightening of screws
We are using 1 ½kg hammer for bending ,forging , crushing etc..













Fig 6.2.6 connecting link rod

 connecting link rod transverse the rotary motion into the linear motion
One end of the connecting link rod is connected to the circular disc and other end is
connected to the hammer end
By that the linkage of the hammer and disc will be done
A hammer is a tool or device that delivers a blow (a sudden impact) to an object. Most
hammers are hand tools used to drive nails, fit parts, forge metal, and break apart objects.
Hammers vary in shape, size, and structure, depending on their purposes. Hammering is the
most widely used industrial as well as construction activity. The hammering of screws, metal
sheets, metal parts etc. requires a lot of time and effort. So, to minimize the time and effort
here you are going to build an automated hammering system.

Fig 6.2.7 connections checking of machine

We are using DC battery for the power supply purpose which will give supply to the dc
motor which is being used in this project. The cam is connected with the DC motor. We are
using a switch which will turn on and off the DC motor. The Soil leveling tool is attached
with the CAM through shaft. When the switch is “TURNED ON” it will give supply to the
DC motor and DC

40
 Fig 6.2.8 overall machine view

motor will start rotating the CAM hence the hammer which is attached with the CAM
through shafts will start moving UP and DOWN. It will level up the soil in a fine and smooth
way.

After completion of this project you can observe that hammering process is fully automated
and the time and effort required for hammering is drastically reduced.

41
6.3 Calculations

1) To calculate maximum torque by mot

Motor rating,
Given Data:-
N = 30 RPM
I=8A
V = 12v
Power Transmitted by Motor,
P=V×I
= 12 × 8
p = 96w
Then,
P = 2 πNT /60
96 = 2π30×T /60
T = 30.55 N-m
Distance of rod BA,

Free body diagram

Fig 6.3.1 free body diagram

To find the distance of BA,

By Pythagoras theorem
(AB) 2 + (BC) 2 = (CA) 2
(AB) 2 + (153) 2 = (420)2
(AB) = 391.14 mm

42
B) To find torque force transmitted we have two cases

Case 1: when hammer moves downward

Given:
(BC) = h = 153 mm = 0.153 mm
Maximum torque = 30.55 N-m
= 30.55 × 103 N-mm
Length of hammer rod = 420 mm
= 0.42 m

Torque Force = T max /h × Length of hammer rod

Tf = (30.55/0.135) × 0.42
Tf = 83.86 N-m

Case 2: when hammer goes upward, torque force will be decreased

Tf = Tmax/h × ( length of hammer ) – weight of hammer

Tf = Tmax/0.153 × 0.42 -14.71

Tf = 69.15 N-m

C) To find impact velocity of hammer

Given:-
H =153 mm = 0.153 m
T (time required for one re revolution of Disc) = 2 sec.
So,
V=h×T
V = 0.15 × 2
V = 0.306 m /sec

So the impact velocity of hammer is 0.306 m /sec.

Result

Thus for riveting of 2mm rivet calculated the impact velocity is 0.306 m/sec with a torque
force of 83.86 N-m is sufficient and it is calculated successfully.

43
D) To calculate shear stress in bolted joint

We have bolted joints so there is torsional shear stress in joints,

We have,
T = 30.55 N-m.
d = Diameter of bolt 10 mm.
J = polar moment of inertia.

4
J = π/64 x (0.1)

-6 4
J = 4.90 x 10 m

T/J = /r

30.55/4.90 = /0.05……………….r = d/2 = 0.05

 = 311.7.3 x 103 N/m2

6.4 Result

As the standard permissible value of shear stress for M10 bolt is 396.8 × 103 N/mm2 and the
calculated value of shear stresses is 311.73 × 103 N/m2 so Therefore the value of shear stress
is less than permissible shear stress the design is safe.

44
CHAPTER 7

CONCLUSION

45
During working on project we have been gone through learning of many feasibility study
production process and controlling with team work.

We have come across the practical and the manufacturing world. We have
gained theoretical as well practical knowledge so far through study workshop and completed
our project. This experience and knowledge will be further helpful to our professional career.

The project work has provided us an excellent opportunity and experience, to

use our limited knowledge. We gained a lot of practical knowledge regarding. Planning,
Perching, assembling and machining while doing this feel that the project work is good
solution to bridge the gates project work. We between institutions and industries. We are
proud that we have completed the work with limited time successfully Automatic hammering
machine is working with satisfactory condition. We have done to our ability and skill making
ma work.

7.1 Advantages

 Available in wide variety of sizes.
 Maintain good control and required force.
 Low cost.
 Save man power.
 Saves time.
 Time delay can be achieved easily.
 Mass production.

7.2 Disadvantages

 This mechanism is only suitable for few operations.
 As torque force required is more there is difficult to find the motor to achieve the required
torque.
 Having little wear.

46
7.3 Application

 In manufacturing industries to perform different operations as follows.
 To perform smithy operation i.e. upset forging.
 To perform the punching operation.
 To perform filleting operation as torque force produce is sufficient for the operation.
 To perform riveting operation etc.

47
 CHAPTER 8
FUTURE SCOPE

48
 The concept of an automatic hammering machine in this paper has been shown to
have a place in the actual market and to fill a need demanded by potential customer. IN
this paper, the concept of automatic hammering machine prototype will have to fulfill the
basic design requirement, let us add the proposed concept will a few more lines about our
impression project work. Help in production line where many workers are used for the
material handling purpose it also reduce the cost and threshing time requirement of more
number of worker will completely eliminated as only two workers can carried out the be
complete operation. The project objective originally is to reduce human efforts in
manufacturing industries. The in future the complete stress analysis of the project model
could be done. This analysis could be done by us. Moreover, for the automatic
hammering machine to achieve fully success in the future, many collateral improvement
must be done in terms of systems (autopilot technology, for instant) and time delay
management (pedal operated control will be required) and some modification can will be
done in this project.

49
CHAPTER 9
REFERENCES

50
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