Design, Fabrication, and Performance Evaluation of an Electric Abrasive Wheel Metal Cutting Machine for Small Workshop Applications

Demand for low-cost and energy-efficient metal-cutting machines in small and medium-scale industries is increasing, thereby prompting a need for an indigenous and adapted fabrication machine that can reduce the reliance on costlier foreign machines. Nearly all existing abrasive cutting machines are prohibitively expensive and energy-consuming as well as difficult to maintain in developing countries; however, no prior literature study has coupled engineering design with structural simulation, fabrication, and experimental validation of a suitable application for SMEs. Therefore, this project aimed at the design and fabrication of a low-cost, energy-efficient, and structurally stable electric abrasive-wheel-based metal cutting machine for workshop applications. The method of the study involves conceptualization, modeling using CAD, engineering calculations, selection of materials, Finite Element Analysis (FEA), fabrication and assembly of the machine, experimental analysis of its performance, and subsequent analysis of results obtained. Mild steel, cast iron, and aluminum were selected as the components of the machine based on strengths, vibration resistance, and corrosion resistance. Mild steel rods with diameters of 5, 10, 15, and 20 mm were used to determine the performance of the machine. The parameters studied were cutting time, rise in temperature, energy consumption, and vibration stability, as well as accuracy of the cutting operation. It was experimentally found that a rod of 20 mm in diameter of mild steel can be cut within 6 seconds. Regression analysis indicated that strong linear relation exists between thickness of material and cutting time ( = 0. 0.988) and between energy consumption and cutting time ( = 0. 0.997). The temperature rise study indicated the temperature of the grinding wheel reached a maximum of 57 °C, which is within operating safety limits, and stress distribution analysis from FEA indicated that stresses generated are much less than the yield strength of the materials chosen for designing each part. Also, the study showed that about a 60-75% reduction in fabrication cost was observed compared to imported machines.