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Thursday, 14 July 2011
CYCLONE SEPARATOR FABRICATION
CYCLONE SEPARATOR FABRICATION
Production activity consists transforming a raw material into final product by sequential operation performing on material. Before this stage a complete design is done for how to fabricate it to done its desire function efficient. In this stage design of product is converted into actual product.
Cyclone separator consist following parts
• Cylinder
• Conical portion
• Top cover
• Exhaust pipe
• Inlet pipe
• Dust collector
First of all to make cyclone separator we use M.S SHEET (50×55cm) thickness of 16 gauge (approx. 2mm) as raw material. Measurement and marking operation is done on it according to design. Now from this sheet we cut profile of different parts (cylinder, cone) by automatic hacksaw machine. After cutting the profile of various parts we take them to rolling machine to roll it into desired shape as per drawing. Now we done spot welding is done is both end to provide support and then continuous arc welding is done. After making individual different parts we join it by welding according to design.
Top cover as a hole in it which has diameter of 50cm for exhaust. Exhaust pipe is welded in it. Now for making inlet for our cyclone separator we make a hole by gas cutter in top portion of cylinder. Gases enter the separator in tangential direction. Because of radial direction there is a tendency of gathering gas near the exhaust pipe and we cannot get sufficient swirl to produce separation of particle. To provide tangential inlet profile is cut on inlet pipe and cylinder such that it make 8-10 degree angle. Thus swirl of inlet gases is produce in the cylinder.
Now due to the centrifugal force heavy particles are forced to the wall and they are collected into the dust collector at the bottom of the conical portion. Due to the conical portion the velocity of gas is increased so it is effectively exhaust through pipe which is fitted at a top.
After the complete fabrication of separator we done grinding on it to remove slag due to the welding process and also achieve perfect finishing. We use hand grinder machine for this purpose. Finally black colour is done on it to protect it from corrosion, and to reduce effect of bad weather.
VARIOUS PROCESS USED FOR MANUFACTURING CYCLONE SEPARATOR
Following processes used are as below.
• Arc-welding process
• Gas cutting process
• Rolling process
• Grinding process
Arc-welding ( PRESSURE POWER GENERATOR, )
Arc-welding :--
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity, SMAW continues to be used extensively in the construction of steel structures and in industrial fabrication. The process is used primarily toweld iron and steels but aluminum, nickel and copper alloys can also be welded with this method.
OPERATION:-
To strike the electric arc, the electrode is brought into contact with the work piece by a very light touch with the electrode to the base metal then is pulled back slightly. This initiates the arc and thus the melting of the work piece and the consumable electrode, and causes droplets of the electrode to be passed from the electrode to the weld pool. As the electrode melts, the flux covering disintegrates, giving off shielding gases that protect the weld area from oxygen and other atmospheric gases. In addition, the flux provides molten slag which covers the filler metal as it travels from the electrode to the weld pool. Once part of the weld pool, the slag floats to the surface and protects the weld from contamination as it solidifies. Once hardened, it must be chipped away to reveal the finished weld. As welding progresses and the electrode melts, the welder must periodically stop welding to remove the remaining electrode stub and insert a new electrode into the electrode holder. This activity, combined with chipping away the slag, reduce the amount of time that the welder can spend laying the weld, making SMAW one of the least efficient welding processes. In general, the operator factor, or the percentage of operator's time spent laying weld, is approximately 25%.
The actual welding technique utilized depends on the electrode, the composition of the work piece, and the position of the joint being welded. The choice of electrode and welding position also determine the welding speed. Flat welds require the least operator skill, and can be done with electrodes that melt quickly but solidify slowly. This permits higher welding speeds. Sloped, vertical or upside-down welding requires more operator skill, and often necessitates the use of an electrode that solidifies quickly to prevent the molten metal from flowing out of the weld pool.
Shielded metal arc welding (SMAW), also known as manual metal arc (MMA) welding, flux shielded arc welding or informally as stick welding, is a manual arc welding process that uses a consumable electrode coated in flux to lay the weld. An electric current, in the form of either alternating current or direct current from a welding power supply, is used to form an electric arc between the electrode and the metals to be joined. As the weld is laid, the flux coating of the electrode disintegrates, giving off vapors that serve as a shielding gas and providing a layer of slag, both of which protect the weld area from atmospheric contamination.
Because of the versatility of the process and the simplicity of its equipment and operation, shielded metal arc welding is one of the world's most popular welding processes. It dominates other welding processes in the maintenance and repair industry, and though flux-cored arc welding is growing in popularity, SMAW continues to be used extensively in the construction of steel structures and in industrial fabrication. The process is used primarily toweld iron and steels but aluminum, nickel and copper alloys can also be welded with this method.
OPERATION:-
To strike the electric arc, the electrode is brought into contact with the work piece by a very light touch with the electrode to the base metal then is pulled back slightly. This initiates the arc and thus the melting of the work piece and the consumable electrode, and causes droplets of the electrode to be passed from the electrode to the weld pool. As the electrode melts, the flux covering disintegrates, giving off shielding gases that protect the weld area from oxygen and other atmospheric gases. In addition, the flux provides molten slag which covers the filler metal as it travels from the electrode to the weld pool. Once part of the weld pool, the slag floats to the surface and protects the weld from contamination as it solidifies. Once hardened, it must be chipped away to reveal the finished weld. As welding progresses and the electrode melts, the welder must periodically stop welding to remove the remaining electrode stub and insert a new electrode into the electrode holder. This activity, combined with chipping away the slag, reduce the amount of time that the welder can spend laying the weld, making SMAW one of the least efficient welding processes. In general, the operator factor, or the percentage of operator's time spent laying weld, is approximately 25%.
The actual welding technique utilized depends on the electrode, the composition of the work piece, and the position of the joint being welded. The choice of electrode and welding position also determine the welding speed. Flat welds require the least operator skill, and can be done with electrodes that melt quickly but solidify slowly. This permits higher welding speeds. Sloped, vertical or upside-down welding requires more operator skill, and often necessitates the use of an electrode that solidifies quickly to prevent the molten metal from flowing out of the weld pool.
GAS WELDING AND CUTTING PROCESS ( PRESSURE POWER GENERATOR )
GAS WELDING AND CUTTING PROCESS :--
Oxy-fuel is one of the oldest welding processes, though in recent years it has become less popular in industrial applications. However, it is still widely used for welding pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artwork.
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded.
In oxy-fuel cutting, a cutting torch is used to heat metal to kindling temperature. A stream of oxygen is then trained on the metal and metal burns in that oxygen and then flows out of the cut as an oxide slag.
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel welding/cutting generally requires two tanks, fuel and oxygen). Most metals cannot be melted with a single-tank torch.
Oxy-fuel is one of the oldest welding processes, though in recent years it has become less popular in industrial applications. However, it is still widely used for welding pipes and tubes, as well as repair work. It is also frequently well-suited, and favored, for fabricating some types of metal-based artwork.
In oxy-fuel welding, a welding torch is used to weld metals. Welding metal results when two pieces are heated to a temperature that produces a shared pool of molten metal. The molten pool is generally supplied with additional metal called filler. Filler material depends upon the metals to be welded.
In oxy-fuel cutting, a cutting torch is used to heat metal to kindling temperature. A stream of oxygen is then trained on the metal and metal burns in that oxygen and then flows out of the cut as an oxide slag.
Torches that do not mix fuel with oxygen (combining, instead, atmospheric air) are not considered oxy-fuel torches and can typically be identified by a single tank (Oxy-fuel welding/cutting generally requires two tanks, fuel and oxygen). Most metals cannot be melted with a single-tank torch.
ROLLING PROCESS ( PRESSURE POWER GENERATOR )
ROLLING PROCESS :- In metalworking, rolling is a metal forming process in which metal stock is passed through a pair of rolls. Rolling is classified according to the temperature of the metal rolled. If the temperature of the metal is above its recrystlization temperature, then the process is termed as hot rolling. If the temperature of the metal is below its recrystallization temperature, the process is termed as cold rolling. In terms of usage, hot rolling processes more tonnage than any other manufacturing process and cold rolling processes the most tonnage out of all working processes.
Roll bending produces a cylindrical shaped product from plate or steel metal...
In press brake forming, a work piece is positioned over the die block and the die block presses the sheet to form a shape. Usually bending has to overcome both tensile stresses as well as compressive stresses. When bending is done, the residual stresses cause the material tospring back towards its original position, so the sheet must be over-bent to achieve the proper bend angle. The amount of spring back is dependent on the material, and the type of forming. When sheet metal is bent, it stretches in length. The bend deduction is the amount the sheet metal will stretch when bent as measured from the outside edges of the bend. The bend radius refers to the inside radius. The formed bend radius is dependent upon the dies used, the material properties, and the material thickness.
GRINDING PROCESS (PRESSURE POWER GENERATOR)
GRINDING PROCESS :--Grinding is traditionally use to finish part whose geometries have already been created by other operation surface grinding is manufacturing process which moves or grinding wheel relative a surface in a plane while a grinding wheel contacts the surface and removes minute amount of material such that flat surface is created.We use the hand grinder machines to finish the outer surface of our separator and also remove the slag particles which are formed due to the welding process.
CYCLONE DESIGN & CONFIGURATION ( PRESSURE POWER GENERATOR)
CYCLONE DESIGN:-
The maxth tangential velocity according to kalen and zenz is given by Max UT=22.6 gµ pp (kb)1.2 D0.201/p2f(1-kb)
We have to determine the cyclone diameter (D) by this equation
So, D0.201 = UT p2f(1-kb)/22.6 gu Pp(kb)1.2
We have been measured various parameter related to smoke particles
Exhaust volume =330 cm3
UT = 7.7 m/s = 49.203 ft/sec
g = 9.81 m/s2 = 32.2 ft/sec2
µ = 8.9×10-2 kg/m-hr = 16.61×10-6 lbs /ft- sec
Pf = 0.788 kg/m3at 175’c exhaust gas temperature.
= 0.04919 lbs/ft3
Pp = 0.9 g/cc
= 0.9×62.43 lbs/ft3 = 56.187lbs/ft3
Kb = 0.2
Substituting this value in above equation
D0.201=49.2×(0.04919)2(1-0.2)/22.6×32.2×16.61×10-6×56.187×(0.2)1.2
= 0.0952376×106/98447.747
D0.201 =0.9674
D =0.4162 ft = 0.4162/3.2802 m
D =0.125 m
D =12.5 cm =130mm
CYCLONE DESIGN CONFIGURATION:-
For selecting high efficiency
Body diameter D = 130 mm
Inlet pipe diameter a = 3.80 cm
Inlet width b = 0.21 D = 5.25 cm
Outlet length S = 0.5 D = 12.5 cm
Outlet diameter De = 0.4 D = 50 mm
Cylinder height h = 1.4 D = 180 mm
Overall height H =3.0 D = 325 mm
Dust outlet diameter B = 0.4D =52 mm
Cone height he = 145 mm
M.S sheet thickness = 2mm (16 gauge)
TESTING AND PERFORMANCE ( TESTING AND PERFORMANCE )
TESTING AND PERFORMANCE :-
TESTING AND PERFORMANCE:-
Testing is the last but not least stage of our project to check the effectiveness of cyclone separator and to know whether it work efficiently or not we conduct two type of test on diesel engine
1st :
In this test we run the diesel engine at no load and some load for approximate specified time 5 minute. And collect the carbon through a exhaust pipe .now we attach the cyclone separator at the end of exhaust pipe after this as describe above we run diesel engine at same load and time and collect particles that separate in collector. By comparing the both weight of carbon particles for same time we know idea about its performance.
2nd :-
In this test we run diesel engine at various load like at no load ,5 kg ,10 kg ,15 kg and full load.Now first we collect particles on “ FILTER PAPER” for 1 minute without use of separator and then by using cyclone separator we collect particles on “ FILTER PAPER” for same load and time as describe as above. By comparing these reading as shown in figure we check it’s performance .
CONCLUSION ( A PRESSURE POWER GENERATOR )
CONCLUSION:-
From the result it is seen that performance of the cyclone separator is coming satisfactory. The aim of this project to use the same at the exhaust pipe of diesel engine operated 3-wheeler used for passenger and goods, which when are overloaded gives lot of dense smoke from the engine. To overcome this condition if the silencer of the engine is replace by this small cost unit will minimize the level of smoke, hence the environmental pollution while conducting various testing on diesel engine through cyclone separator we can know that by increasing length of conical portion and reducing diameter the efficiency can increase.
From the result it is seen that performance of the cyclone separator is coming satisfactory. The aim of this project to use the same at the exhaust pipe of diesel engine operated 3-wheeler used for passenger and goods, which when are overloaded gives lot of dense smoke from the engine. To overcome this condition if the silencer of the engine is replace by this small cost unit will minimize the level of smoke, hence the environmental pollution while conducting various testing on diesel engine through cyclone separator we can know that by increasing length of conical portion and reducing diameter the efficiency can increase.
Historical Development of Huygens Gunpowder Engine
HISTORICAL DEVELOPMENT :--
Huygens Gunpowder Engine (1680) :- The earliest internal combustion engine can be credited to famous Dutch physiciat Christian Huygens in the year 1680. Huygens engine employing gunpowder, is shown in Fig
It consisted of a vertical cylinder having a sliding fit type of piston.Explosion of a gunpowder in te cylinder drove the piston on its upward stroke and teh return stroke was caused by atmospheric pressure acting on the piston and arising from the drop of pressure in the cylinder as the gaseous of the explosion began to cool. The useful power was produced on the downward stroke of the piston and arrangement of ropes and pulleys, was applied to raise loaded platfor. Huygens took a one foot (30.5 cm ) diameter tube and evacuated half the air. With this he lifted the platform with four men on it into the air. That engine worked with single explosive charge but it was not found possible to produce means for delivering the sequence of charges necessary for continuous operation and controlling the rate of explosion. These difficulties prevented the development of this early concept of an internal combustion engine.
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