Pedal cycle flywheel pump final slide

B.E. PROJECTS = AVADI

CHENNAI9444863248

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DESIGN AND FABRICATION OF MANUALLY OPERATED RECIPROCTING PUMP USING FLYWHEEL

Submitted in partial fulfillment for the requirements for the award

of the degree of the

BACHELOR OF TECHNOLOGY

(MECHANICAL ENGINEERING)

By

K.BALU 08113121026

M.BASKAR 08131201038

V.DHANAPAL 08113201054

R.DHIKA 0811201057Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE

(Dr .M.G.R DEEMED UNIVERSITY) MADURAVOYAL,CHENNAI-600 095.

NAME :…………………………………

REG. NO. :………………………………….

SEC : ……………………………………….

DEPARTMENT : ………………………….

Dr. M.G.R. Educational and Research Institute(Dr. M. G. R. University)

Maduravoyal, Chennai – 600 095.

November 2010.

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Dr. M.G.R. EDUCATIONAL AND RESEARCH INSTITUTEDr. M.G.R. UNIVERSITY

DEPARTMENT OF MECHANICAL ENGINEERING

CHENNAI – 600 095.Dr.M.G.R EDUCATIONAL AND RESEARCH INSTITUTE (Dr .M.G.R DEEMED UNIVERSITY)

MADURAVOYAL,CHENNAI-600 095.

NAME :…………………………………

REG. NO. :………………………………….

SEC : ……………………………………….

DEPARTMENT : …………………………. BONAFIDE CERTIFICATE

This is to certify that the project work entitled

“DESIGN AND FABRICATION OF MANUALLY OPERATED RECIPROCTING PUMP USING FLYWHEEL” is a bonafide record of project work

done by,

K.BALAGANESH 0831201026 K.BASKARADEVAM 0811311038 V.DHANAPANDIAN 0831201054

R.DHIKA 0831201057

Students of B.Tech, (Mechanical) during the academic year 2011-2012.

(Signature of the supervisor) (Signature of the Head of the Department)

Mr. G. Rajamahendran, B.E,(M.E), Professor Mr. M. Ganesan, Lecturer, Dept. of Mechanical Engineering, Dept. of Mechanical Engineering, Dr. MGR university, Dr. MGR university.

Submitted for the project Viva-Voice Examination held on ______________

Internal Examiner External Examiner

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ACKNOWLEDGEMENTACKNOWLEDGEMENT

We wish to expand our sincere thanks and our whole-hearted gratitude to the

following persons. At the outset, we would like to convey our grateful thanks to our

Chairman Mr. A.C. Shanmugam, our Pro-Chancellor Mr. A.C.S. Arun Kumar,

our Vice-Chancellor Dr.Padmanaban. We profusely thank Prof. Mr. Ganeshan,

Head of the Department, Mechanical Engineering, for his imperceptible guidance

and implications, without which our project would not have been sculpted

successfully.

We express our heartfelt thanks to Mr. Rajamahendran, for his invaluable

guidance, utmost patience, inspirational coordination and constant encouragement in

completing this project successfully.

We would like to thank all the staff members, students and parents who have

helped us to complete our project as scheduled.

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CONTENTS

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CONTENTS

1. INTRODUCTION

2. ABSTRACT

3. PROCESS PLANNING

4. CONSTRUCTION DETAILS

5. WORKING PRINCIPLE

6. SPARE PARTS DRAWING

7. INTRODUCTION TO PUMP

8. APPLICATION

9. ADVANTAGES AND DISADVANTAGES

10. FEATURES OF THIS PROJECT

11. SAFETY,CARE AND MAINTENANCE

12. PAINTING AND FINISHING

13. COST ESTIMATION

14. CONCLUSION

15. BIBLIOGRAPHY

16. PHOTO VIEW

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INTRODUCTION

INTRODUCTION

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This is a self – assessment test on the part of the students to assess his

competency in creativity.

During the course of study, the student is put on a sound theoretical

foundation of various mechanical engineering subjects and of course, to a

satisfactory extent. Opportunities are made available to him to work on different

kinds of machines, so that he is exposed to various kinds of manufacturing process.

As a students learn more and more his hold on production technology

becomes stronger. He attains a stage of perfection, when he himself is able to

design and fabricate a device.

This is the project work. That is the testimony for the strenuous training,

which the student had in the institute. This assures that he is no more a student, he

is an engineer.

This report discuses the necessity of the project and various aspects of

planning , design, selection of materials, fabrication, erection, estimation and

testing.

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ABSTRACT

ABSTRACT

Electrically operated pumps and immersed jet pumps are widely

used in domestic, industrial and commercial applications. The capacity of these

pump heads varies from 5Meter to 100 meter . In many places , the drinking water

supplied by the government through the pipeline is below the ground level and are

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collected in sumps of residential plots. The private agency supply the water through

the water tank lorry to many places where we have taken to multistoried building by

manually.

In this project , we consider this above problem in order to deliver the water

to the tank which is above the ground level and also to overcome the during the

electricity failure time we made a pedal operated reciprocating pump.

Working principle;

This pedal pump consists of a pair of foot pedal ,seating arragment, chain

drive , connecting rod , crank shaft, flywheel and a piston pump,

` The pedal is rotated by the foot and hence the chain rotates causes the

connecting rod rotates to reciprocate the piston via connecting rod... Thus the water

is discharged to tank without using electric power.

It is used to pump the water up to 25meters of pressure head. It could be very

useful in those areas where electricity is irregular or insufficient.

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PROJECT PLANNING

PROJECT PLANNING

CONCEPT OF THE PROJECT

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Before starting every project its planning is to be done. In a planning

functions are life the functions of nerves in our body. Planning a project is a very

important task and should be taken up with great care as the efficiency of the whole

project largely depends upon its planning, While planning a project each and every

details should be worked out in anticipation should be carefully considered with all

the relative provisions aspects.

PROJECT CAPACITY

The capacity of the project must be decided considering the amount of

money which can be invested. The availability of material and machines and

usefulness of the project.

DESIGN AND DRAWING

Having decided about the project to be manufactured at must be designed.

Design work should be done very considering all the relevant factors.

After design the project detailed drawing are prepared. Detailed

specification for raw material and finished products should be decided carefully

along with the specification of the machine required for the manufacture.

MATERIAL REQUIREMENTS

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The list of material required for manufacture is prepared from the

drawing. The list is known as “Bill of materials”. Availability of these materials is

surveyed and purchased from the market.

OPERATION PLANNING

Next work of planning is to “select the best method” manufacture the

product, so that the wastage of materials, labor, machines and time can be

eliminated by considering various methods. The best method is to be selected for

fabrication and other works.

The proper method and proper person and the purposes of operation,

necessity operation, proper machine planning. The best method is the developed

and is applied to fabricate the project.

MACHINE LOADING

While planning proper care should be taken to find the machining time

for the operation as correct as possible. So that arrangement of full use of machines

can be made and the machine loading program can be decided.

PURCHASE CONSIDERATION

It is difficult to manufacture all the components needed for the project in

the machine shop. In each case, we should decide whether to make or buy about a

particular item. It is decided during the planning after making a complete study of

relative merits and demerits.

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EQUIPMENT PROCEDURE

Results obtained from “operation planning” and machine loading help in

calculating the equipment require Specification of the equipment should be laid

down by considering then drawings. Drawings will also help in deciding the

necessary requirement of tools and accessories.

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CONSTRUCTION

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CONSTRUCTION

The project consist of

1. Foot Pedal

2. Chain drive

3. M.S. .Frame Stand

4. Crank shaft and connecting rod

5. Flywheel

6. Piston pump

7. inlet and outlet valve in pump cylinder

8. Suction and delivery pipeline with pressure gauges

9. operator seat

1. Foot pedal ;

This foot pedal is used to drive the pump by manually . A cycle pedal is

the part of a bicycle that the rider pushes with their foot to propel the bicycle.

Here in this kit,It provides the connection between the cyclist's foot or shoe and

the crank allowing the leg to turn wheel spindle and propel the crank wheel.

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Pedals usually consist of a spindle that threads into the end of the crank and a

body, on which the foot rests or is attached, that is free to rotate on bearings with

respect to the spindle. Pedals were initially attached to cranks connecting directly to

the driven (usually front)sprocket wheel.

cycle pedal

2. Chain drive mechanism;

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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,[1] 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.

This chain drive is used to transmit the rotary motion from the pedal wheel to crank

wheel. The driver sprocket has 50 tooth and the driven sprocket has 12 tooth. Hence

for every rotation is multiplied to four times the rotational output to crank wheel.

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This chain drive is lubricated with oil using servo 60 oil in order to eliminate the

wear and corrosion.

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3.Frame Stand

This base frame stand made in 40 mm x 3mm M.S. material square tube and is

used to hold the entire mechanism and support the operator seat also.

First of all the frame is designed and The base is constructed by

using the welded joints and cut the material with the required size by

using hacksaw machine.

The stand frame material is used to mild steel at low cost is widely

and is used

4. Crank and connecting rod mechanism;

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A crankshaft has one (or more) offset sections where a connecting rod is attached

around it. The connecting rod moves back-and-forth (or up-and-down) ONCE for

every rotation of the crankshaft. The crank will always move in a circle, moving the

connecting rod in a smooth sine wave like motion. The power can flow in either

direction. That is, the crankshaft can drive the connecting rod, or the connecting rod

can drive the crankshaft.

5.FLYWHEEL;

A rotating mechanical device that is used to store rotational energy.

It acts like a reservoir and stores the energy in mechanical form

It Supply energy when required.

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o Releases it when it is more then required.

Energy is stored by the formula

E = ½ Iω2

o Where “I” is the moment of inertia and it can vary for different shapes

of wheels. For solid disk the “I=Mr2/2”.

o “ω” is the rotational velocity and it is in (rad/sec).

• Fly wheel smoothen out variations in the speed of a shaft caused by torque

fluctuations if source of driving torque is fluctuating.

• It is also used to provide continuous energy in system.

It is also used to supply intermittent pulses of energy at transfer rates that exceed the

abilities of its energy source

Design Approach:-

There are two stages for it

• The degree at which energy is required to smoothen and its moment of inertia.

• The geometry of flywheel.

Design Parameters:-

• It depend upon acceptable changes in the speed.

Speed fluctuation:-

• The change in the shaft speed during a cycle is called the speed fluctuation

and it is given by

Fl =ωmax−ωmin

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Geometry of Flywheel;

• It can be a solid cylindrical disc.

• It can be like conventional wheel design.

But energy requirements and size of the flywheel increases the geometry

changes to disc of central hub and peripheral rim connected by webs and to hollow

wheels with multiple arms.

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Applications;

Typical applications for flywheels include;

• Dynamic balancing of rotating elements.

• Energy storage in small scale electricity generator sets.

• Automotive applications such as clutches.

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6. piston pump;

• Pushing of liquid by a piston that executes a reciprocating motion in a closed

fitting cylinder.

• Crankshaft-connecting rod mechanism

• Conversion of rotary to reciprocating motion.

• Entry and exit of fluid

7. Inlet and outlet valve in pump cylinder

During the suction stroke the inlet valve is used to allow water into the

cylinder and at the same time the delivery valve is closed . During the delivery

stroke when piston moves in opposite direction and the outlet valve is used to

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allow the water from the cylinder to outlet pipe line and at the same time the suction

valve is closed. the function of inlet and outlet valves are shown in figure.

8.Suction and delivery pipeline with pressure gauges;

Here 18MM DIA flexible PVC pipe line is connected at suction and delivery

pipe line in order to deliver the water from sump to tank. To show the

pressure a vaccum gauge is connected at the suction side and pressure gauge

is connected at the discharge side.

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9.operator seat;

A  bicycle seat, unlike a bicycle saddle, is designed to support the rider's

buttocks and back, usually in a semi-reclined position. Arthur Garford is credited

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with inventing the padded bicycle seat in 1892, and they are now usually found

on recumbent bicycles.

10. BEARINGS;

A bearing is a machine element that constrains relative motion between moving

parts to only the desired motion. 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. Bearings are classified broadly according to the type

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of operation, the motions allowed, or to the directions of the loads (forces) applied

to the parts.

A journal bearing consists of an approximately cylindrical body around a rotating

shaft. This journal bearing is used either for supporting a radial load, or simply as a

guide for smooth transmission of torque. Most common applications of bearings are

the plain circular bearings type (with a 360 degrees arc). Lubrication usage, on the

other hand, range from a simple inlet hole to axial, circumferential, and helical

grooves for efficient lubrication distribution.

The plain bearing applications include reciprocating sliders, rotating or oscillating

cylindrical members sliding in annular sleeves, and rotating or rotationally

oscillating disks sliding on mating disks.

The advantages of plain bearings are as follows:

- lower first cost- simple design- small radial space required- quiet operation

- not so sensitive to dust or grit- less likely to be subjected to fatigue failure- easy to replace

Materials:Plain bearings must be made from a material that is durable, low friction, low wear to the bearing and shaft, resistant to elevated temperatures, and corrosion resistant.#Babbitt (metal)#Bronze

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#Graphite#Plastic-Solid plastic plain bearings are now increasingly popular due to dry-running lubrication-free behavior. Solid polymer plain bearings are low weight, corrosion resistant, and maintenance free.

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WORKING PRINCIPLE

WORKING PRINCIPLE

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The project consist of

1. Foot Pedal

2. Chain drive

3. M.S. .Frame Stand

4. Crank shaft and connecting rod

5. Flywheel

6. Piston pump

7. inlet and outlet valve in pump cylinder

8. Suction and delivery pipeline with pressure gauges

9. operator seat

To function the pump , the operator sit on the seat and pedal

continuously. The foot pedal is used to drive the pump by manually . By

pedaling , the driver sprocket transmit rotary power to driven sprocket

though the chain drive. This chain drive is used to transmit the rotary motion

from the pedal wheel to crank wheel . The crank wheel converts the rotary motion

into linear motion of piston inside the cylinder. During the suction stroke the inlet

valve is used to allow water into the cylinder and at the same time the delivery

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valve is closed . During the delivery stroke when piston moves in opposite

direction and the outlet valve is used to allow the water from the cylinder to outlet

pipe line and at the same time the suction valve is closed.

Thus the water is discharged to tank without using electric power.

FORMULA USED FOR RECIPROCATING PUMP  

SUCTION HEAD

Hs = ps*sm/1000

Hs = suction head (m of water)

Ps = suction pressure (mm of Hg)

Sm= specific gravity of Hg = 13.6

DELIVERY HEAD

Hd = Pd * 104/ ρ

Hd = Delivery head (m of water)

Pd = Delivery pressure (kg/cm2)

P = unit weight of water = 1000kg/m3

COLLECTING HEAD = 0.13m (constant)

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TOTAL HEAD

H=Hs+Hd+Hc (m of water)

 DISCHARGE

Q= lby/t1 (m3/s)

Q = discharge (m3/s)

L = length of collecting tank (m)

Y = rise of water in collecting tank (m)

Y = 0.1m

t = time taken for ‘y’ rise of water/sec

OUTPUT POWER

OP = ρgQH/1000 (kW)

ρ = unit weight of water 1000 kg/m3

g = specific gravity 9.81 m/s2

Q = discharge (m3/s)

H = total head (m of water)

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INPUT POWER

IP = 2πNT/60

Torque = force × radius

Force = mass × acceleration

F = m × a (or) m × g

T = m × g × r

M = flywheel mass

g = specific gravity 9.81 m/s2

r = flywheel radius

OVERALL EFFICIENCY

η = OP/IP %

COLLECTING TANK DETAILS(using in FM lab)

l = 0.5m

b = 0.5m

Hc =0.13m (constant)

No electric power required.

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Equipment cost is less.

It is portable.

Manually pedaling (20 to 30 min) good for body exercise.

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SPARE PARTS AND ASSEMBLY DRAWING

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ADVANTAGES

ADVANTAGES ;

Compared to hydraulic and ,pneumatic system, it is economical.

No extra skill is required for operating this system.

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Operation is very smooth and in this system we can get more output by ap-

plying less effort.

Single person is enough to operate this efficiently to drill the job..

Easy and efficient handling of this unit without wastage of job or damage

to unit and any other parts.

low maintenance cost and life of equipment also increased..

Least maintenance of the equipment.

Need not require any individual work place.

Can be worked in the work spot.

Suited for pumping the water upto 25 meter head.

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DISADVANTAGES

DISADVANTAGES

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Manual power required to operate .

The time taken for pumping the water is more when

compared to electric power unit.

It cannot be used for more than 25 meter head ...

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APPLICATION

APPLICATION;-

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We can use this equipment to lift the water from ground floor to 1st floor in housing

purpose.

During rainy season we can pump the unwanted water from the required place.

Using for irrigation purposes.

It could be very useful in those areas where electricity is irregular or insuffi-

cient.

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\PAINTING AND FINISHING

FINISHING AND PAINTING

JOB PREPARATION

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Before welding, remove any bend in the L angle with the sludge hammer on

the anvil block. Then it is cut to the required length with the hacksaw blade and

fabricated to required dimensional shape with arc welding.

FINISHING OPERATION BEFORE PAINTING

After welding, any slag on the welded area is removed with the chipping

hammer and cleaned with the metal wire brush. Then all the surfaces are rubbed

with the emery sheet.

Metal primer is applied on the surfaces with the brush. After drying the metal

primer, the second coating is applied with the paint.

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SAFTY,CARE AND MAINTENANCE

SAFTY,CARE AND MAINTENANCE

Before using the machine, some of the points to be noted for safety purpose,

1. Before starting the operation, check the following items

(1) Check the mechanism for proper operation .

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(2) Check the alignment of connecting rod and piston in the unit.

(3) Don’t insert the any material or object between the during op-

eration of flywheel.

(4) Check the lubrication of chain drive and bearing in the unit.

(5) sit carefully while driving the pedal .

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FEATURES OF THIS PROJECT

FEATURES OF THIS PROJECT

It is compact in size

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It can be move

No electrical power consumption

It can be utilized at our work shop

It is simple in construction

Low cost

Less weight and easy to handle

It reduces the man power

It is simple in operation..

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RESULT AND DISCUSSION

RESULT AND DISCUSSION

Hand operated portable drilling as well as electrically operated drilling machines

are widely used in domestic, industrial and commercial applications. The capacity

of this drilling varies from 1mm to 25mm dia hole . This pedal operated drill is

fitted with a drill bit, used for drilling holes in various materials

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. This is also one of the pedal operated drilling machine which is now operated

through the cycle pedal .The operation and mechanism of this unit and its function

have been studied.

At the end, the machine is assembled.

This machine is more advantages of other types of power drilling since it has

more easier to operate compotable seating arrangement and good exercise to our

body and also less time consumption, easy handling etc.

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COST ESTIMATION

COST ESTIMATION

1. Piston block unit 5200,00

2. Pedal base unit 800.00

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3. Chain drive with wheel 1000.00

4. M.S. Fabricated base unit 2600.00

5. Seat unit 600.00

6. Pressure gauges 1200.00

7. Suction and delivery pipe 20 meters 600.00

8. Primer and enamel paint 200.00

9.fasteners and clip for pipe 100.00

6. Transport cost 200.00

TOTAL COST 11500.00

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CONCLUSION

CONCLUSION

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We make this project entirely different from other projects. Since

concepts involved in our project is entirely different that a single unit is used

to various purposes, which is not developed by any of other team members.

By doing this project we gained the knowledge of fabrication work and

how the welding is doing and material selection for particular components

etc.,

It is concluded that any fabrication work can be done with the help of

welding.

We have successfully completed the project work on using pedalling

pump work at our Institute.

Once again we express our sincere thanks to our staff members.

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BIBLIOGRAPHY

BIBLIOGRAPHY

WORKSHOP TECHNOLOGY : W.J. CHAPMAN

PRODUCTION TECHNOLOGY : R.K. JAIN

PRODUCTION TECHNOLOGY : R.K. JAIN & S.C. QUPTA

METAL FORMING PROCESS : R.S. KURMI

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MANUFACTURING PROCESS : K. RAMACHANDRAN

MACHINE SHOP TECHNOLOGY : S.S. MANIAN & RAJAGOPAL & G. BALAJI SINGH

DESIGN OF MACHINE ELEMENTS : R.S. KURMI & P.N. VENKATESAN

DESIGN OF MACHINE ELEMENTS : RAMACHANDRAN

DESIGN DATA BOOK : P.S.G. COLLEGE OF TECHNOLOGY

www.google.com

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PHOTO VIEW

PHOTO VIEW

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