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DESIGN AND FABRICATION OF MANUALLY OPERATED
RECIPROCTING PUMP USING FLYWHEEL
A PROJECT REPORT
Submitted in partial fulfillment for the requirements for the award
Of the degree of
BACHELOR OF TECHNOLOGY
In
(MECHANICAL ENGINEERING)
SUBMITTED By
BHOOPATHY. R 5021140012
ELAYARAJA. K 5021140023
HARISH KUMAR. K 5021140031
MARISELVAN. T 5021140053
Under the guidance of
Mr. Dinakar. N. ME.
(Asst. professor, school of Mechanical Engineering)
FACULTY OF ENGINEERING AND TECHNOLOGY
SRM UNIVERSITY
VADAPALANI

SRM UNIVERSITY
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,
BHOOPATHY. R 5021140012
ELAYARAJA. K 5021140023
HARISH KUMAR. K 5021140031
MARISELVAN. T 5021140053
Towards the partial fulfillment of the requirements for the award of the
degree of bachelor of technology in Mechanical Engineering in SRM university,
Chennai during the academic year 2014-2015
HEAD OF THE DEPARTMENT INTERNAL GUIDE
Mr. Dinakar. N. ME,
EXTERNAL EXAMINER INTERNAL EXAMINER
PLACE: CHENNAI
DATE:

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 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 manually operated reciprocating pump.
Working principle;
This manuallyoperatd reciprocating pump consists of a pair of foot pedal
,seating arrangement, chain drive , connecting rod , crank shaft, flywheel and a
reciprocating pump,
` The pump 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 to10 to 20meters of total head. It could be very
useful in those areas where electricity is irregular or insufficient.

LIST OF CONTENTS
Chapter Topic Page No.
No
Acknowledgement (i)
Abstract (ii)
List of Figures (iv)
List of Tables (v)
1 Introduction
1.1 Project planning
1.2 Operation planning
1.3 Purchase consideration
1.4 Advantages and disadvantages
1.5 Applications
2 Literature Review
2.1
2.2
2.3
3 Design and Calculations
3.1 basic designs
3.2 speed ratio
3.3 chain drive calculation
3.4 theoretical analyses
4
4.1 constructions
4.2 fabrications
4.3 assemblies
4.4 working principle
5 TESTING AND CALCULATION
5.1 formula used
5.2 trail 1
5.3 trail 2
5.4 trail 3

6 PHOTO VIEW
6.1
6.2
6.3
6.4
7 conclusions
7.1 result and discursion
7.2
7.3

Chapter 1
INTRODUCTION
1.1 PROJECT PLANNING
CONCEPT OF THE PROJECT
Before starting every project its planning is to be done. In planning functions
is 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 detail 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
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.

1.2 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.

1.3 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.
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.

1.4 ADVANTAGES AND DISADVANTAGES
ADVANTAGES
 Compared to hydraulic and, pneumatic system, it is economical.
 No extra skill is required for operating this system.
 Operation is very smooth and in this system we can get more output by
applying 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 up to 10 TO 20 meter head.
DISADVANTAGES
 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 20 meter head ...

1.5 APPLICATION;-
 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
insufficient.

CHAPTER 3
DESIGN AND CALCULATION

3.1 BASIC DESIGN
Fig 3.1 Basic design of our project

4.1CONSTRUCTION
The project consist of
1. Foot Pedal
2. Chain drive
3. M.S.Frame Stand
4. Crank shaft and connecting rod
5. Flywheel
6. Reciprocating 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.
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.
Fig 4.1(a) cycle pedal

2. Chain drives mechanism;
Fig 4.1(b) sprocket and chain
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.

Fig 4.1(c) chain drive
This chain drive is used to transmit the rotary motion from the pedal wheel to crank
wheel. The driver sprocket has 50 teeth and the driven sprocket has 12 teeth. Hence
for every rotation is multiplied to four times the rotational output to crank wheel.
This chain drive is lubricated with oil using servo 60 oil in order to eliminate the
wear and corrosion.

FABRICATION (DRIVEN GEAR)
FABRICTION – (DRIVER GEAR)
Fig 4.1(d) driver gear and driven gear

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;
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 crank shaft.

5. FLYWHEEL;
Fig 4.1(e) 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.
o Releases it when it is more than 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 depends 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

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.

Fig 4.1(f) sectional view of flywheel
Applications;
Typical applications for flywheels include;
• Dynamic balancing of rotating elements.
• Energy storage in small scale electricity generator sets.
• Automotive applications such as clutches.

6. Reciprocating pump;
Fig 4.1(h) block diagram of reciprocating 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 allow the
water from the cylinder to outlet pipe line and at the same time the suction valve is
closed. The functions 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 vacuum gauge is connected at the suction side and pressure gauge
is connected at the discharge side.

4.2 FABRICATION
FABRICTION - (FITTING)
FABRICTION-(PRESSURE & VACCUM GAUGE)

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 Graford is credited
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
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)
#Bronzes
#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.

4.4 WORKING PRICIPLE
To function the pump, the operator sits on the seat and pedal
continuously. The foot pedal is used to drive the pump by manually. By
pedaling, the driver sprocket transmits rotary power to driven sprocket
though the chains 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 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.

5. TESTING AND CALCULATION
5.1FORMULA USED
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)
 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)
 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)

7.1RESULT 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
. This is also one of the pedal operated drilling machines which are now
operated through the cycle pedal .The operation and mechanism of this unit
and its function has been studied.
At the end, the machine is assembled.
This machine is more advantages of other types of power drilling since it
has easier to operate computable seating arrangement and good exercise to our
body and also less time consumption, easy handling etc.

7.2FEATURES OF THIS PROJECT
 It is compact in size
 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.

7.3SAFETY, 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.
(2) Check the alignment of connecting rod and piston in the unit.
(3) Don’t insert the any material or object between the during
operation of flywheel.
(4) Check the lubrication of chain drive and bearing in the unit.
(5) Sit carefully while driving the pedal.

7.4CONCLUSION
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 pedaling
pump work at our Institute.
Once again we express our sincere thanks to our staff members

7.3SAFETY, CARE AND MAINTENANCE
Before using the machine, some of the points to be noted for safety purpose,
2. Before starting the operation, check the following items
(1) Check the mechanism for proper operation.
(2) Check the alignment of connecting rod and piston in the unit.
(3) Don’t insert the any material or object between the during
operation 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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