DUST COLLECTOR

Introduction – Once the full welding of coils are done, they are subjected to various tests which ensures that following operations namely projection welding, bending and full welding are performed accurately and the coil will then be sent for Radiography testing.

These tests includes:

·         Ball test.

·         Hydraulic test.

In ball test,a metallic ball of diameter same as that of internal diameter of the coil’s pipe is passed via pneumatic process i.e. passing compressed air through the pipe. This process ensures that the bends are perfect.

But it has been observed that huge amounts of dust get generated from the pipes. To eradicate the above mentioned problem we developed a device and named it as DUST COLLECTOR.

MANUFACTURING FLOW PROCESS –

We started with searching used metallic cans which are being used for painting coil modules. So after finding them we cleaned them with the help of thinner for removing inner solidified paint. After that our next aim was obtaining PVC(polyvinyl chloride) pipes and an accurate hole(diameter same as that of pvc pipe) was made on the lid of the can. Now one end of pvc pipe was inserted into the can(which is filled with water) and other end is fitted to a piece of pipe. Now the successive end of m/s pipe was calibrated with a butt joint clamp. The clamp acts as a junction between the dust collector and the coil.

Now for pipes/coils of different diameter we use butt-joint clamps of same diameters as well. Now when the compressed air is passed , the dust gets collected into the dust collector and we must ensure that the lid of the can is perfectly sealed which inturn prevent sudden splash of water coming out of the water filled can.

FURTHER MODIFICATIONS-

Since the container in dust collector is completely sealed, passage of high pressure compressed air can act as a potential threat because the pressure is around 10 bar. To nullify the threat we provided a vent in the form of of a bent tube welded and attached at the top of the collector .This tube is TIG welded with high precision on the lid.

###pictures to be uploaded soon##

Projection Welding using xpandrel technique

Hey guys, its been a couple of months i have written a blog since i was busy with semester exams and nowadays industrial training of 6 long months.
So this present post is on the revolutionary technique of attaching fins on the tubes of various diameters without using resistance spot welding rather making the use of XPANDREL Technique.
Let me give you a basic idea of what it is? Actually what we are going to do is,we'll use a mandrel and by inserting it in the tube(generally mild steel) it will expand and due to that the fins will get fused on the periphery of the tubes!!!

Further calculations and observatory results in the next post,till then keep guessing! ;)

MY LATEST CLICKS!!

                                          1.Tap in my home..

                                         

                                              2.Candle flame..

                                                3.Flowers...

                                            4.View from my balcony
P.S- For any suggestions please mail me at - sangram_patil2010@yahoo.com 
                                               THANK YOU!!!

Sangram's fotografia

Well i like to try my hands on my new CANON SX150.....

## HOLIDAYS AND PHYSICS @ Mt. ABU ##

##Second semester exams just over and it was the time for a nice outing.So me and my friends decided to go to Udaipur(Rajasthan,INDIA).After spending a couple of days there, we left for Mount. Abu(approx. 6000 feet above mean sea level).On reaching there,we experienced a perfect weather at Mt. abu(specially when you come from 40degree C  temp.).It was all in all a mix blend of culture.heritage and nature for us.We didnt noticed how two days passed by. So on third day we decided to return to udaipur.On our journey back to udaipur we have to travel down 22kms of steep slopes of Mt abu.And since we were travelling in  a government bus ,the driver was driving very rashly although he seemed pretty experienced.He turned blindly on the brisk turns of Mt.I still remember we suddenly encountered a bus infront of us after a sharp turn.That journey was a real close shave for all three of us.

After reaching safely to udaipur i thought,that the boundries along that roadside was hardly half a  feet long which is sufficient to encourage toppling of any bus at greater speeds.So to prevent such accidental and fatal topplings on turns(~10m radii) i underwent some calculations.The result I  calculated was for minimum/threshold height of such boundaries.

OBJECTIVE--To calculate minimum height of boundaries of roads on hilly terrains.
Various dimensions are as follows-
1.Mass of bus ~ 10000kgs(average passenger bus of 84 capacity)
2.Speed of bus ~ 60kmph(16.6mps)
3.Track length of bus(distance between two rear wheels) ~ 2.6m
4.Average coefficient of  kinetic friction between road and tyre ~ 0.8
5.Radii of curvature/turn ~ 10m
6.Height of bus ~ 10 feet

Calculations-

Just balancing torques which are applied on bus when get accidently in contact with boundaries.
CENTRIFUGAL FORCE APPLIED ON BUS(F) = mv^2/r
                                                                              = 10000*16.6*16.6/10
                                                                              = 275560 Newtons
FRICTIONAL FORCE ON ONE TYRE(REAR) = coefficient of friction*mass of bus*acceleration due to gravity
                                                                             = 0.8*10000*9.81
                                                                            = 78480 Newtons
WEIGHT OF BUS                                              = mass of bus*acc due to gravity
                                                                            = 10000*9.81
                                                                           = 98100 Newton
Torque equations----
===> (1.5-H)*F-f*H-W*D/2=0
So after putting above values we will obtain a quadratic equation as follows
===>  78480 H^2 - 413340 H^1 + 127530 = 0
SO, the final value of H after solving above equation is
===> H= 0.33 metres/ 1.08 feets

SO THE ABOVE CALCULATED IS THE THRESHOLD HEIGHT THAT I THINK IS REQUIRED FOR PREVENTING ANY SORTS OF ACCIDENTS ESPECIALLY AT HILLY TERRAINS.
                            ## NEXT POST WILL BE UP SOON.......##

LAW OF CONVERGENCE(L.O.C)

Hey buddies,
I am back!! these university exams really sucks... duh..whateva i'll not take much of your valuable time and will take off with my new post.
One fine day,just running through T.V channels ,i stopped on to one of the channels displaying SHARE MKT....
It showed various crest and trough in terms of profits and loss.I murmured myself "what is that bullshit?...why people invest in share market even if they know that there are much more chances of a loss rather than gain//"
I gave a thought on it and asked myself...."Is it possible to cut down the chances of a possible loss dramatically??...if so how can we?""
I wondered "is it possible to do it mathematically?.....and BINGO!! a new idea landed on my top floor"
The most tricky part(as always) is the nomenclature of the theory.So by observing  the diagrams and calculations involved,i thought of giving it a name as"LAW OF CONVERGENCE (L.O.C)".Sounds cool right?? :P
BASIC PRINCIPLE INVOLVED-
This theory/law simply deals with the predictions relating to the gain or loss in share mkt.(as there can't be any accurate predictions in it)
The figure displayed below shows us a RED box with a pair of inclined lines.
For minimizing any sort of losses our basic aim is to pass the red boxes through the space provided between the inclined lines.(sounds crazy isn't it!!?? ;))...For now this much info. as i think is enough for today !..The later half of this post , which explains its working , its practical applications , and its use for minimizing losses will be covered in my next post.
Till then.....keep guessing///

as is it well said"One who uses his/her brains daily....lives a good long life"... ;)

Hey guys!!!! wasssup...
Semesters on head. Goin to post a new blog ASAP!!! :)