INTRODUCTION

Spring rolling industry is a large and growing industry, where

many special purpose machines are used. The proper selection of
the machine depends upon the type of the work under-taken by the
particular industry. There are many examples of spring, which can be
seen in our everyday life. The metals generally used for spring rolling
work include iron, copper, tin, aluminium, stainless steel and brass.
Our project “SPRING ROLLING MACHINE” will find huge
application in all spring rolling industries. Rolling is the process of
bending a metal wire to the curved form. The article in the shape of
circle is made by spring roller shaft. Rolling operation can be done by
hand or by power in rolling machines. In forming the spring shape a
gradual curve is to be put in the metal rather than the sharp bends.
The gap between the springs can be regulated by proper
arrangement.

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COMPONENTS
 Induction motor

 Worm drive

 Pulley

 V-Belt

 Shaft

 Coupling

 Spur gear

 Bearing

 Frame

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 A.C Motor
CLASSIFICATION
A.C motors are classified as followed.
1. Single phase induction motor
2. Three phase induction motor
3. Synchronous motor
According to the construction and method of starting, single phase
induction motors are classified into:
1. Split phase motor
2. Capacitor type motor
3. Shaded pole motor
4. Universal motor
5. Repulsion type motor
Capacitor type motors
There are three general types of capacitor motors.
1. Capacitor start motor.
2. Permanent capacitor motor.
3. Capacitor start capacitor run motor.
Here we used capacitor start induction motor.
CAPACITOR START INDUCTION MOTOR
In capacitor start motor, two windings are provided in the
stator. They are main winding and auxiliary starting winding. The
auxiliary winding has high resistance and low reactance. A capacitor

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connected in series with the starting winding through centrifugal
switch and connected across the single phase supply. The current in
the starting winding at standstill can be made to lead in the current
by about 90 degree, by properly selecting the capacitance value. The
capacitor used in the general of electrolytic type, which is usually
mounted on the outside of the motor. The rotor is of squirrel cage
type.

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Working Principle of a capacitor start induction motor
The starting winding current is leading by an angle from V as
shown in the vector diagram because the capacitor is in series with
this winding. The main winding current is more lagging from V as
shown in the vector diagram, because the main winding as high
reactance and low resistance.

When single phase supply is given to stator, a rotating magnetic

field is produced. This rotating magnetic field cut the rotor conductor
and the magnetic field is produced in this rotor. Due to the
interaction of the stator and rotor magnetic field, a torque is
developed and hence the motor continues to rotate. When the
motor attains about 75% of its rated speed, this centrifugal switch
disconnects the auxiliary winding and capacitor from the supply. The
direction of rotation of motor is reversed by reversing the terminal
connection of anyone winding.

APPLICATIONS

It is used in fans, centrifugal pumps, blowers, washing machine,

lathes, drilling machines, compressors and wet grinders etc.,

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SPECIFICATION Of MOTOR

TYPE : Capacitor start single phase induction motor.

POWER : 0.5 hp (186 Watts).

CURRENT : 0.266 Amps

VOLTAGE : 230 V, 50Hz

SPEED : 1440 Rpm.

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 WORM DRIVE
A worm drive is a gear arrangement in which a worm screw
meshes with a worm gear . A worm drive can reduce rotational
speed or transmit higher torque. The major advantages of worm gear
drive unit is that they can transfer motion in 90 degrees.

A gearbox designed using a worm and worm-wheel is

considerably smaller than one made from plain spur gears, and has
its drive axes at 90° to each other.

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Advantages of Worm Drives:
1. Worm gear drives operate silently and smoothly.
2. They are self-locking. They occupy less space.
3. They have good meshing effectiveness.
4. They can be used for reducing speed and increasing torque.
5. High velocity ratio of the order of 100 can be obtained in a single
step.

Disadvantages of Worm Drives:

1. Worm gear materials are expensive.
2. Worm drives have high power losses and low transmission
efficiency.
3. They produce a lot of heat.

Applications of Worm Gear Drives:

Worm drives are used in:

1. Gate control mechanisms

2. Hoisting machines
3. Automobile steering mechanisms
4. Lifts
5. Conveyors
6. Presses
SPECIFICATIONS
No. of teeth in worm shaft : 7
No. of teeth in worm gear : 140

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 PULLEY

A pulley is a wheel on an axle or shaft that is designed to

support movement and change of direction of a taut cable or belt, or
transfer of power between the shaft and cable or belt. In the case of
a pulley supported by a frame or shell that does not transfer power
to a shaft, but is used to guide the cable or exert a force, the
supporting shell is called a block, and the pulley may be called a
sheave.

A pulley may have a groove or grooves between flanges around

its circumference to locate the cable or belt. The drive element of a
pulley system can be a rope, cable, belt.

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BELT AND PULLEY SYSTEMS

Flat belt on a belt pulley Belt and pulley system

Cone pulley driven from above by a line shaft

A belt and pulley system is characterized by two or more

pulleys in common to a belt. This allows to transfer mechanical
power, torque, and speed across axles. If the pulleys are of differing
diameters, a mechanical advantage is realized.

A belt drive is analogous to that of a chain drive; however, a

belt sheave may be smooth so that the mechanical advantage is
approximately given by the ratio of the pitch diameter of the sheaves
only, not fixed exactly by the ratio of teeth as with gears and
sprockets.

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 In the case of a drum-style pulley, without a groove or flanges,
the pulley often is slightly convex to keep the flat belt centered. It is
sometimes referred to as a crowned pulley. Though once widely used
on factory line shafts, this type of pulley is still found driving the
rotating brush in upright vacuum cleaners, in belt sanders and band
saws.

Specification of pulley

Pulley type : A – type pulley

Belt used : V- type belt
Diameter of smaller pulley : 2.5 inches(63.50 mm)
Diameter of larger pulley : 5 inches(127 mm)
Bore diameter of smaller pulley : 22 mm
Bore diameter of larger pulley : 19 mm

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 BELT

A belt is a loop of flexible material used to link two or more

rotating shafts mechanically, most often parallel. Belts may be used
as a source of motion, to transmit power efficiently or to track
relative movement. Belts are looped over pulleys and may have a
twist between the pulleys, and the shafts need not be parallel.

In a two pulley system, the belt can either drive the pulleys
normally in one direction (the same if on parallel shafts), or the belt
may be crossed, so that the direction of the driven shaft is reversed
(the opposite direction to the driver if on parallel shafts). As a source
of motion, a conveyor belt is one application where the belt is
adapted to carry a load continuously between two points. The belt
drive can also be used to change the speed of rotation, either up or
down, by using different sized pulleys.

TYPES OF BELTS

1. ROUND BELTS
2. FLAT BELTS
3. V-BELTS
4. TIMING/TOOTHED BELTS

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V-BELTS

V belts are arguably the most widely used belts in industries. V

belts have a V shaped cross-section, which rests against the side of V
pulley under tension. The V shaped cross-section prevents belt from
slipping off.

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 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 various members such as pulleys and gears are
mounted on it.

TYPES
They are mainly classified into two types.

 Transmission shafts are used to transmit power between the

source and the machine absorbing power; e.g. counter shafts
and line shafts.
 Machine shafts are the integral part of the machine itself;
e.g. crankshaft.

MATERIAL
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.

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 JAW COUPLING
A jaw coupling is a type of general purpose power transmission
coupling that also can be used in motion control (servo) applications.
It is designed to transmit torque (by connecting two shafts) while
damping system vibrations and accommodating misalignment, which
protects other components from damage. Jaw couplings are
composed of three parts: two metallic hubs and
an elastomeric insert called an element, but commonly referred to as
a "spider". The three parts press fit together with a jaw from each
hub fitted alternately with the lobes of the spider. Jaw coupling
torque is transmitted through the elastomeric lobes in compression.

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 SPUR GEAR

Spur gears or straight-cut gears are the simplest type of gear.

They consist of a cylinder or disk with teeth projecting radially
though the teeth are not straight-sided (but usually of special form
to achieve a constant drive ratio, mainly involutes but less
commonly cyclical), the edge of each tooth is straight and aligned
parallel to the axis of rotation. These gears mesh together correctly
only if fitted to parallel shafts. No axial thrust is created by the tooth
loads. Spur gears are excellent at moderate speeds but tend to be
noisy at high speeds.

Spur gear teeth are manufactured by either involutes profile or

cyclical profile. Most of the gears are manufactured by involutes
profile with 20° pressure angle. When two gears are in mesh at one
instant there is a chance to mate involutes portion with non-
involutes portion of mating gear. This phenomenon is known as
"interference" and occurs when the number of teeth on the smaller

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of the two meshing gears is less than a required minimum. To avoid
interference we can have undercutting, but this is not a suitable
solution as undercutting leads to weakening of tooth at its base. In
this situation Corrected gears are used. In corrected gears Cutter
rack is shifted upwards or downwards.

Terminology for Spur Gear

Terminology:

Addendum: The radial distance between the Pitch Circle and the top
of the teeth.

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Dedendum : It is a radial distance from the pitch circle to the bottom
of the tooth space.

Addendum circle : It is the circle passing through the top of the

teeth. It is concentric with the pitch circle.

Dedendum circle : It is the circle passing through the bottom of the

teeth. It is also known as root circle.

Clearance : It is a radial distance from the top of the teeth to bottom

of the teeth in a meshing gear.

Face of the tooth : It is the surface of the tooth above the pitch
surface.

Top land : It is the top of the surface of the tooth.

Tooth flank : It is the surface of the tooth below pitch surface.

Pinion : It is the smaller of the two mating gears.

Wheel : It is the larger of two meshing gears.

Rack : It is a gear wheel with infinitively large number of teeth.

Pitch circle: It is an imaginary circle which by pure rolling action

would transmit the same motion as the actual gear.

Pitch circle diameter : It is the diameter of the circle which by pure

rolling action would transmit the same motion as the actual gear
wheel.

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Pitch point : It is the point of contact of two pitch circles.

Pressure angle : It is the angle between common normal to two gear

teeth at the point of contact and the common tangent at the pitch
point.

Module : It is a ratio of pitch circle diameter in mm to the number of

teeth.

Circular pitch : It is a distance measured along the pitch circle

circumference from the point on one tooth to the corresponding
point on the next tooth.

Diametrical pitch : It is the ratio of no. of teeth to pitch circle

diameter in mm.

Backlash: It is the difference between the tooth thickness and the

tooth space measured along the pitch circle.

SPECIFICATION OF GEAR :

SPECIFICATION DRIVER GEAR DRIVEN GEAR

No. of teeth 25 50
Pitch diameter 69 mm 144 mm
Bore diameter 19 mm 17 mm
Outside diameter 81 mm 156 mm
Weight 0.900 kg 2 kg

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 BEARING
A ball bearing is a type of rolling element bearing that uses balls
to maintain the separation between the bearing races. Ball bearings
are used to provide smooth, low frictional motion in rotary
applications. Ball bearing consists of the following parts namely outer
race, inner race, rolling element(balls) and retainer. Ball bearings are
able to provide high performance and long lifetime in order to
transfer the load from the balls to the inner races.
The bearing is a circular type supporting element for rotating
shafts, It supports the shaft, at a same time it transmits the
rotational power from one place to another place without loss due to
friction. Ball bearings are usually made of a stainless steel, chrome
steel, and ceramic material. In this project we use 2 numbers of ball
bearings for supporting and transmitting the power through shaft.
ADVANTAGES OF BALL BEARINGS
 Low starting and running friction at very high speeds.
 Ability to withstand momentary shock loads.
 Accuracy of shaft alignment.
 Low cost of maintenance, as no lubrication is required while in
service.
 Small overall dimensions.
 Reliability of service.
 Easy to mount.

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 The bearings are pressed smoothly to fit into the shaft and
column.
 BALL BEARING (6202) ZZ
 SIZE : 1. 20 X 40 X 12mm
2. 17 X 35 X 12mm
 MATERIAL : BEARING STEEL

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L-ANGLES
They are formed by bending a single angle in piece of a steel.
the most common type of steel angles are at 90 degree angle.

Frame
The L-shaped angles are cut to the required dimensions
and welded as per the required design.

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 WORKING PRINCIPLE
In our project we are going to use simple power transmission
mechanisms such as belt and pulley arrangement and spur gear
arrangement to transmit power from A.C motor to roller shaft. Spur
gear and the sleeve are fixed in the roller shaft with sleeve at its right
end. Smaller pulley is fitted at the end of the motor shaft and larger
pulley is fitted at one end of the idle shaft and a ‘V’ belt is used to
transmit the rotation of smaller pulley to larger pulley. Two spur
gears are used to transmit power from idle shaft to roller shaft. In
this the gear fixed in the idle shaft is taken as driver gear and the
gear fixed at the roller shaft is taken as driven gear. A screw rod is
coupled with a sleeve by means of cotter pin for positive power
transmission without slip. The driven gear is fixed at one end of roller
shaft and sleeve at other end. Provision is made on the
circumference of a screw rod such that it helps to fix one end of the
spring wire with tension during rotation. The spring wire is supplied
by a tare is called spring wire tare. This tare is fixed to the stand by
two end bearings. It can be rotated freely during the time of spring
rolling operation.
When the power supply is switched ‘ON’ the motor shaft
rotates and this rotation is transferred to screw rod through worm
type speed reduction gearbox, pulleys and spur gear arrangements.
When the screw rod rotates the spring wire tends to bend in a
curved form.
Based on the requirements the dimension of the spring can be
varied by changing the screw rod with different pitch distance and
diameter.

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ADVANTAGES OF SPRING ROLLING MACHINE
• Man power requirement is less.
• Length of the spring can be varied.
• Maintenance cost is very low.
• Less effort & more production.
• Skilled workers are not required.

APPLICATIONS OF SPRING ROLLING MACHINE

Used in Small Scale industries such as
• Wire rolling industries
• Spring rolling industries

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PHOTOGRAPHY

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 COST ESTIMATION

SL. No DESCRIPTION COST IN RUPEES

1 SINGLE PHASE INDUCTION MOTOR 1000

2 JAW COUPLING 150

3 WORM GEAR BOX 3,000

4 PULLEY 500

5 V – BELT 150

6 SHAFT 600

7 SPUR GEARS 1200

8 SCREW ROD 600

9 SPRING TARE 150

10 MACHINING AND FABRICATION 1500

11 FRAME 3150

12 TOTAL 12,000

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 CONCLUSION
This project work has provided us an excellent opportunity and
experience, to use our technical knowledge which we gained during
our diploma studies. We gained a lot of practical knowledge
regarding planning purchasing, assembling and machining while
doing this project work.

Our project can be used in small scale industries which reduces

the investment cost on special purpose machines and also the
operating procedure of this system is very simple, so that any person
can easily operate it .

When we were carrying out our project work as a team, we

gained more practical knowledge, and it helped us to learn more
practical concepts and functioning of machineries and components.
We feel proud that we have completed this project work successfully
with a limited period of time and we hope that our project work will
find more utility in industrial sector .

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 BIBLIOGRAPHY

BOOK REFERENCES

We have referred the following text books and websites to carry

out our project.

1. Machine design – R .S. Khurmi and Prof. J.K. Gupta

2. Design Of Machine Elements-V. B. Bhandari
3. Production Technology, P. C. SHARMA-Edn. X- S. Chand
4. Workshop Technology-Jain and Gupta-Khanna Publishers.
5. PSG Design Data Book, Compiled by the Faculty of Mechanical
Engineering, PSG college of Technology, Coimbatore.
6. Electrical Technology by B. L. Theraja

WEB REFERENCES

 http//:[Link]/spring rolling mechanisms.

 http//:[Link]
 http//:[Link]

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