Acknowledgements .....................................................................................................................

Abstract ......................................................................................................................................ii

List of figures ...........................................................................................................................iii

List of tables ..............................................................................................................................V

Content

Abstract...........................................................................................................................ii

1. Introduction..............................................................................................................6

1.1 Problem Statement......................................................................................................... 7

1.2 Objective......................................................................................................................... 7
1.3 Scope............................................................................................................................... 8
1.4 Methodology................................................................................................................... 8
CONSTRUCTION................................................................................................................. 9
1.5 Organization of Dissertation..........................................................................................11

2. Literature Survey....................................................................................................12

2.1 Research paper..............................................................................................................12

Other reviews.................................................................................................................. 13

3. Design and Calculation...........................................................................................16

3.1 Construction.................................................................................................................. 16
Frame...............................................................................................................................16
MS SHEET METAL:............................................................................................................21
Spray paint can:............................................................................................................... 24
PROCESS SHEET:.............................................................................................................. 25
Cutting: -.......................................................................................................................... 26
Welding: -........................................................................................................................ 27
Drilling..............................................................................................................................28
Finishing...........................................................................................................................30

i
 Polishing...........................................................................................................................31
Turning.................................................................................Error! Bookmark not defined.
Safety Precautions........................................................................................................... 32
3.2 Decision Making Process...............................................................................................33
3.3 Project Pan.................................................................................................................... 34
3.4 Cad drawing...................................................................................................................35
3.5 Calculations................................................................................................................... 38
EN 10083 C45 steel carbon steel.....................................................................................38
DESIGN.............................................................................................................................41
1. DESIGN OF CYLINDER: -............................................................................................ 42
2. Load of person on piston rod, so it may fail under bending.....................................43
3. Design of bolt:- tension................................................Error! Bookmark not defined.
4. Design of MS flat used for making mechanism.........................................................47
5. Design of transverse fillet welded joint:-..................................................................48
3.6 COST ESTIMATION.........................................................................................................49
EXPENSES.........................................................................................................................51
RAW MATERIAL & STANDARD MATERIAL........................................................................54
TOTAL COST..................................................................................................................... 55
3.7 Plan of execution:..........................................................................................................56
Activities.......................................................................................................................... 56
3.8 PROJECT FLOW CHART.................................................................................................. 57

4. Experimental Validation.........................................................................................59

5. Concluding remark.................................................................................................60

5.1 Conclusion................................................................................................................ 60
5.2 Scope of future work................................................................................................60
5.3 Advantages....................................................................................................................60
5.4 Disadvantages................................................................................................................61
5.5 Applications..............................................................................................................61

6. References..............................................................................................................63

Websites.......................................................................................................................... 64

ii
 ABSTRACT

It is very difficult to stand and work for overall shift in the company by a worker. This
will reduce the efficiency of the worker. The solution to this problem is to have a portable
device, which has an ergonomic design, low-cost exoskeletons. In this work a mechanical
ergonomics device that is designed around the shape and function of the human body, with
segments and joints corresponding to those of the person it is externally coupled with. It
functions as a chair whenever it is needed and is coined as Chair less Chair. Worker in
industrial can wear it on legs like an exoskeleton. It locks into place and you can sit down on
it. The device never touches the ground, which makes it easier to wear: a belt secures it to the
hips and it has straps that wrap around the thighs. These are specially designed and part of the
mechanism, but an alternate version works with any footwear and touches the ground only
when in a stationary position. The user just moves into the desired pose. It will fit closely to
lower part of the body as an external body part on which maximum body forces act upon. It is
a cost effective product and any error in design may fail the structure, which creates loss. So,
these forces should be carefully analyzed during the design of structure. The best way to
predict these forces during pre-manufacturing stage is to make an analysis on the structure
with the help of software. This helps in estimating the stresses induced on the structure, which
is one of the most important criteria for evaluation of the model.

iii
List of figures

Figure 1 Schematic of chairless chair............................................................................10

Figure 2 Shoes and C-frame assembly..........................................................................22

Figure 3 Piston rod and C-frame assembly...................................................................23

Figure 4 Pneumatic cylinder components.....................................................................23

Figure 5 spray can..........................................................................................................25

Figure 6 Cutting Operation............................................................................................26

Figure 7 Welding operation...........................................................................................27

Figure 8 Drilling Operation............................................................................................29

Figure 9 Drilling Tool....................................................................................................29

Figure 10 Finishing Operation.......................................................................................30

Figure 11 Polishing Operation.......................................................................................32

Figure 12 Lathe..............................................................Error! Bookmark not defined.

Figure 13 Decision Making Processes...........................................................................33

Figure 14 Steps of Execution.........................................................................................34

Figure 15 isometric front view......................................................................................35

Figure 16 drafting..........................................................................................................36

Figure 17 Shoe...............................................................................................................36

Figure 18 Shoe holder....................................................................................................37

Figure 19 Thigh pad......................................................................................................37

Figure 20 Butt pad.........................................................................................................37

iv
Figure 21 Properties of steel C45..............................................................................40

Figure 22 cylinder dimensions......................................................................................41

Figure 23 Piston rod properties.....................................................................................43

Figure 24 Cut section of piston rod...............................................................................44

Figure 25 MS flat crossection........................................................................................47

Figure 26 flow chart......................................................................................................58

v
List of Tables

Table 1MS flat weight....................................................................................................20

Table 2 sheet metal size selection..................................................................................21

Table 3 steel grades.......................................................................................................39

Table 4 Chemical Composition.....................................................................................39

Table 5Mechanical Properties of EN C45 steel.............................................................39

Table 6 Aluminium Properties......................................................................................42

Table 7 raw material cost..............................................................................................54

Table 8 labour cost........................................................................................................54

Table 9 Final cost..........................................................................................................55

Table 10Plan of Work/Timeline.....................................................................................56

vi
 1. INTRODUCTION

Exoskeletons are defined as standalone anthropomorphic active mechanical devices

that are “worn” by an operator and work in concert with the operator’s movements.
Exoskeletons are mainly used to increase performance of able-bodied wearer. (e.g. for
military applications), and to help disabled people to retrieve some motion abilities. (such
exoskeletons are called “active orthoses” in the medical field). As we know, the normal motor
capability of legs is crucial and important for human-being’s daily life. Legs, however, are apt
to be injured in accident. And the Rehabilitation is essential for the patients to recover after
leg operation. Additionally, diseases, stoke for instance, can also result in the loss of leg
function. In order to regain the motor capability, the leg rehabilitation is a fundamental
therapeutic approach. Basically Exoskeletons are of two types:

a) Active Exoskeletons

b) Passive Exoskeletons

Active exoskeletons: They are powered by external sources like a motor, battery
powered etc. They work along with the passive exoskeletons to help in its functioning.

Passive exoskeletons: These are not powered by external power sources but work on
the basis of mechanical linkages, pneumatic and hydraulic mechanisms, spring controlled
devices etc. Since active exoskeletons pose a restriction to the amount of external energy that
can be supplied in terms of quantity, quality and time we have focused purely on passive type
of exoskeletons. Passive elements are implemented in the exoskeleton to either store or
dissipate energy with the objective of reducing the residual energy that the human would have
to expend for locomotion.

7
 1.1 Problem Statement

In factories on production lines the workers work for about 8-10 hours daily.
Generally, production line is in standing position. Due to this worker get tired physically as
well as mentally. Productivity of company gets decreased due to this. The workers face the
problem like distress to their lower limbs and other physical problems. Technology has made
tremendous development but there is technological gap between worker’s comfort and
technology. So this is an attempt to make use of technology to make worker feel comfort at
production line.

There is an insufficiency of the seat when we want to sit anywhere and anytime. It is
often troublesome to provide seating equipment for all workers in every field of aspect.
Excessive sitting is dangerous as it badly affects the body’s metabolic rate, resulting in the
risk of disease like high blood pressure, diabetes, cancer, depression, etc., Correspondingly,
excessive standing also results in worst health outcomes. In workstations, the essential
concern is to enhance productivity, but very few concerns are on the effect of work fatigue on
the worker’s body. Despite the work environment is ergonomically designed they are not
successful in soothing laborer weariness since most of the time they got to work for hours in a
specific pose.

1.2 Objective

The predominant objective is to

 Help workers to mitigate the microgravity of bones and muscles occurring due to
excessive standing

 Support injured workers to return to work faster

 Provide mechanical ergonomic device for all workers in an industry to be useful

even in cramped spaces

 Design and fabricate a low cost assistive device that allows normal movements like
walking and running

 Provide movements when we wear it too

 Allow people to sit anywhere in an industry .

8
 1.3 Scope

Numerous occupations and recreational activities require long periods of standing or

use of the legs but do not readily permit the use of seating structure on which an individual
can rest. For example, assembly line workers who must have freedom of movement from one
workstation to the other normally have no ready access to a chair or other seating support
during intermittent idle periods between work projects. Also, where seating is provided, it is
usually not readily accessible to the worker but rather is located out of the immediate work
area.

The same absence of any seating exists in numerous sporting events where the
spectator or even the participant must move from one location to the other. For example,
while observing golf tournament or other similar event, a seating structure would be desirable
but has not heretofore been practical. Also, hikers and campers having generally done without
the luxury of seating simply because of the added inconvenience or the inability of carrying a
chair in addition to other equipment. Thus, a need has arisen for a simple and lightweight
body support which is readily accessible to the user but which does not necessarily have to be
hand carried. Of course, Bonner’s patents are long expired by now, and nor should these
revelations detract from Noonee's mission in the least.

1.4 Methodology

We have to design following main component: -

1. Damper: The function of damper to carry the load of worker. We have designed it
for 100 kg load.

2. Sheet: Mild steel sheet required to give support to the worker and to fascinate the
sitting position.

3. Tie belt: Belt is used for strapping of exoskeleton to human body. Belt will be taken
as standard material available in market to wrap the model as waist and thighs.

4. Safety shoes: Shoes are the last of model, which is attached at bottom place and to
be wear at the time of working. Shoes are selected as standard size of number.

9
CONSTRUCTION

 We will buy a leather safety shoe for which we will make a C- frame, the
frame is fixed with shoes with the help of stud passed through heels of the
shoe, both ends of the stud is tightened with the help of a nut. It will hold the
shoe (shoe holder).
 Now we will make a small round box one end of which is pivoted to shoe
holder and another end is fixed to the bottom end of Piston connecting rod.
Here we will use 10 bar pressure cylinder half filled with air and half with oil
depends upon the weight of user.
 The cylinder has 20 mm bore diameter, 250 mm stroke length and is provided
with lock nuts. Now, we make leg holder which will hold the thigh and is
made by taking 1.6 mm MS sheet bent to the shape of thighs.
 Two Velcro are fixed to the thigh holder with the help of pop rivet so that it
can hold the leg. The leg holder is pivoted to square pipe and square pipe is
fixed to a cylinder.
 The cylinder pivoted with the help of square pipe to leg holder. We have used
M-6 nut bolts for all pivots. Now, as the person can sit stand and walk
comfortably.
 The "Chairless Chair" consists of two identical "chairs," one strapped to each
of the wearer's legs. It is important for the Chairless Chair to be adjusted to
each user. Just like a piece of clothing, if the chair doesn't fit, it will not feel
good. When adjusted correctly, you can comfortably relax with all your weight
on the chair. "With the lower member of the Chairless-chair strapped to the
shoe, a cylinder presses the upper member against the back of the thigh.
 As the user squats, the released compression bar pushes the leg of the chair to
a locked position, thereby supporting the body. When the user rises, the lower
member is unlocked and is retracted by a cylinder to its original position,
where it will not interfere with the user's movements.

 The use 2 cylinder has 250 mm stroke length 20 mm bore diameter, and is
provided with block nuts. The leg holder which will hold the back holder and
is made by taking 16-gauge MS sheet bended to the shape of thighs. 4 Velcro

10
 laces have been fixed to the back holder with the help of pop rivets so that it
can hold the leg. The leg holder is fixing to square block and other end is fixed
to. Used M-6 nut bolts for all joint.

Figure 1 Schematic of chairless chair

FEATURES OF THE PROJECT

11
 1) A variable damper engages and supports the worker bodyweight, which is directed
downward to the shoes.

2) Any worker can use it with any footwear and touches the ground only when in
seating position.

3) The user just moves into back side mechanism is converted in chair form

4) Pneumatic cylinder is used for smooth working, which make easy to operate

5) By using Carbon-fibre or aluminium the weight of the mechanism weight can be

further minimum

1.5 Organization of Dissertation

The organization of dissertation are as follows:

Chapter 1 introduce us about the project it gives us detail about the problem statement and
clarify the objective to be done in project it also tells about the scope of the project in future
in the last part of introduction the working methodology of project is introduced and features
is described. Chapter 2 describes about the literature survey done for making the project it
tells about the various objective of the researchers about the project and what are the
conclusion they got after doing the project so we will get brief idea about that. Chapter 3 is
about design and calculation of the project here we will discuss about the construction
material used in our project every material will be described briefly in this chapter with
proper figures and the various machining operation used in our project is also described here
the CAD modelling which is done in Solidworks software is also described with proper
dimensioning and 3D view of assembly and every parts at last numerical is done with proper
formula and material properties and finally cost estimation chapter is added. In 4th chapter
experimental validation of project is done and in 5th chapter conclusion future scope
advantages application of project is shown.

12
 2. LITERATURE SURVEY
2.1 Research paper

1. Cyril Varghese (2016)

Cyril Varghese and Vedaksha Joshi has worked on the Exoskeleton Based Hydraulic
Support was successfully fabricated and it was found to be suitably safe [3]. Under fluctuating
load during walking as well as under Dead Load when the user sits/rests on it.

2. H. Zurina ,A.fatin (2015)

H. Zurina and A. Fatinhas worked on the Design and Development of Lower Body
Exoskeleton. In his paper an attempt has been made to evaluate the possibility of using the
Chairless chair that will help in increasing the energy efficiency and offer weight support
when the user feels tired rather than continuously taking on the weight. Other than that, in
term of ergonomics, and the objectives to give comfort to user has achieved by give choices
to user to choose their comfort degree level from 45° to 90°.Apart from the benefit of his
experiment it can be conclude that his design still confront with some problems that need to
fix in future so that the objective to give an ergonomic chair to user can be achieved. The
experiment testing has been conducted for our prototype to our group member with weight of
80kg and height around 170cm. From the result of experiment testing, it can be observed that
for height and weight, the Chair less chair doesn’t give any effect in lack or over measure in
its height dimension. It suits the user which prove that this chair can be wear by people from
any height range. He tester were required to use the chair while do some work, it was
observed that, he had difficulties in changing the degree level.

3. Aditya Bhalerao ,Sandesh Kambale (2016)

Aditya Bhalerao and Sandesh Kamblehave worked on Pneumatic portable chair for
employees to seat while working. By referring to human seating and walking characteristic a
leg mechanism has been conceived with as kinematic structure whose mechanical design can
be used by employees as a wearable exoskeleton. As per the Specified Design parameters the
body can suitably carry around the 100Kg of Human Body weight. In the later part to reduce
the cost, Oil was also brought in the weight sustaining mechanism thus providing better
results.

13
 4. Y. Kalyan Chakravarthy, D.Tarun, A Srinath(2014)Estimation of body segment
weights for prosthetic legs suitable to Indian amputees. Approximate height & weight of
Indian people 5 ft. 5inch to 6 ft. & weight 100 kg.
Other reviews

A mechatronic wearable posture aiding device covering associate higher support for
connecting to the thigh of someone, a lower support for connecting to the shank of the person
and a joint pivotally connecting each support, and a damper with connectors for pivotally
connecting the damper to the support [1]. The Centre of gravity of the upright human body
and the base of support. Another characterization for depicting forward and in reverse
leanings of the straight human body with the feet fixed on the ground. During the motion of
static balance steadiness of the upstanding human body depends upon the fundamental
parameters, for example, facilitates X Centre of Gravity and Y Centre of Gravity of the focal
point of gravity of the body in the upstanding position and the range R of the base of help [2].
Current methods in product plan simplifies the complicated requirements of the human higher
limb, thereby compromising the remedy and security of the injured patient. In rehabilitation
robotics, it is essential to consider the consumer desires and requirements of such a machine
early in its design phase. Them learn about established how the evaluation of person wants
participate in the sketch of a wearable robot for the rehabilitation of Filipino and Asian
patients. The effects of the find out about and dialogue later on had been translated into a list
of consumer requirements for wearable robots in neuro rehabilitation. After which,
corresponding significance scores from each the sketch engineers and their scientific
collaborators were assigned to arrive with a matrix that determines the remaining layout
priorities and specs of the device [3]. Many sufferers with spinal injuries are restricted to
wheelchairs, main to a sedentary life-style with secondary pathologies and accelerated
dependence on a career. Increasing evidence has proven that locomotor training reduces the
incidence of these secondary pathologies, but the bodily effort worried in this education is
such that there is terrible compliance. This paper reports on the control of a new “human
friendly” orthosis (exoskeleton) and diagram, powered by high strength pneumatic Muscle
Actuators (pMAs). The aggregate of a exceptionally compliant actuation system, with an
clever embedded manage mechanism which senses hip, knee, and ankle positions, velocity,
acceleration and force, produces powerful but inherently safe operation for paraplegic patients
[4]. The exoskeleton based hydraulic support being extremely light in weight causes very
little obstruction while walking and the user can easily get used to it. It was observed on

14
testing the chair while doing some work that, they had difficulties in changing the degree
level of the chair [5]. On contrary to the customary seat, it comprises of kinematic sets which
empower taking stops between constant traits at any working role alongside these lines. It is
outfitted for reducing the chance of the bodily musculoskeletal trouble considerably among
industrial workers. It pays attention on the mechanical shape and limited thing investigation
(FEA) of the instrument making use of ANSYS programming [6]. A quantitative way to deal
with examining human biomechanics, displaying standards of traditional mechanics utilizing
contextual investigations including human development. Vector variable-based math and
vector separation are utilized to portray the movement of articles and 3D movement
mechanics are treated inside and out. Graphs and programming made groupings are utilized to
show human development [7]. Wearable devices increase the efficiency of workers and
decrease the rate of fatigue [8]. The lower limit exoskeleton is a wearable automated gadget
that should empower a human to stroll with a substantial burden for a delayed timeframe
without diminishing the human's spryness. The exoskeleton is included two human legs and a
spine that gives an adaptable stacking interface. The gadget is to be structured and controlled
so that the human can lead a wide range of exercises without feeling the gadget [9]. The
design structure on how the human exoskeleton can be controlled. These types of devices
with the ergonomic background can be easily upgraded with the use of more advanced
technologies and culminating various facilities into one body and be constantly modified. It
has several major applications in a real-time scenario where it can be worn in crowded trains
or public places with space constraints [10]. By alluding to human seating and strolling
trademark a leg system has been imagined with as kinematic structure whose mechanical plan
can be utilized by representatives as a wearable exoskeleton. According to the Specified
Design parameters the body can reasonably bear the 100Kg of Human Body weight. In the
later part to decrease the cost, Oil was additionally gotten the weight continuing system hence
giving better outcomes. These sorts of gadget with ergonomically foundation can be
effectively overhauled with the utilization of further developed innovations and coming full
circle different offices into one body and be always adjusted. An essential thought of how an
exoskeleton utilizing Pneumatic or Hydraulic Cylinder can be utilized to decrease the
weariness by utilizing basic kinematic components [11]. A wearable chair in 1977 allowed
users to take a seat on two legs, which was once not obvious. But the design proposed by
them using their methodology has some de-merits as follows: it permits solely one sitting
position, irrespective to the user desire, also there is giant stress on decrease leg resulting

15
from the response pressure imposed with the aid of the decrease bar. But the approach to
poses some ergonomic challenges, the biggest problem with such a design is ensuring that
workers can move freely and after sitting, it is in stable equilibrium [12]. The impacts of
mellow leg length imbalance on stance and step has been the wellspring of much discussion.
Numerous assessments have been communicated both for and against the requirement for
intercession to lessen the size of the disparity. Their paper underscores the requirement for
exact and dependable appraisal of leg length contrasts using a clinically utilitarian
radiographic system, and audits biomechanical ramifications of leg length disparity as
identified with the improvement of stress cracks, low back torment and osteoarthritis [13].
This is a compact starting soft cover that gives reasonable procedures to applying learning of
material science to the investigation of living frameworks and presents material in a clear way
requiring almost no foundation in physical science or science [14]. Assistive gadgets, for
example, exoskeletons are fit for giving rehabilitative improvement and autonomy to people
experiencing musculoskeletal conditions. Run of the mill gadgets utilize either dynamic help
strategies, for example, DC engines or inactive techniques, for example, springs or hole
valves or switches. Dynamic strategies require a persistent power input, while aloof
techniques are restricted by client capacity. This work presents an Active/Passive Exoskeleton
system. This gadget can latently give ceaseless help, just expecting vitality to change the
dynamic properties of the inactive state [15].

16
 3. DESIGN AND CALCULATION
3.1 Construction
Frame

The frame is usually made of mild steel. It is strong enough to withstand all types of
loads in working condition. All other parts are fitted to the frame. Frame is helping the
supporting of the various light load support. Frame shows the good aesthetic loop. every
machine should have required the good frame design. Frame material should have high
strength because frame balancing of other machine load. in ours project the frame showing
important role. Main whole project assembly ours project mounted on frame. The proper
selection of material for the different part of a machine is the main objective in the fabrication
of machine. For a design engineer it is must that he be familiar with the effect, which the
manufacturing process and heat treatment have on the properties of materials. The Choice of
material for engineering purposes depends upon the following factors:

1. Availability of the materials.

2. Suitability of materials for the working condition in service.
3. The cost of materials.
4. Physical and chemical properties of material.
5. Mechanical properties of material.

The mechanical properties of the metals are those, which are associated with the ability
of the material to resist mechanical forces and load. We shall now discuss these properties as
follows:

1. Strength: It is the ability of a material to resist the externally applied forces

2. Stress: Without breaking or yielding. The internal resistance offered by a part to an
externally applied force is called stress.
3. Stiffness: It is the ability of material to resist deformation under stresses. The modules
of elasticity of the measure of stiffness.
4. Elasticity: It is the property of a material to regain its original shape after deformation
when the external forces are removed. This property is desirable for material used in
tools and machines. It may be noted that steel is more elastic than rubber.

17
5. Plasticity: It is the property of a material, which retain the deformation produced
under load permanently. This property of material is necessary for forging, in
stamping images on coins and in ornamental work.
6. Ductility: It is the property of a material enabling it to be drawn into wire with the
application of a tensile force. A ductile material must be both strong and plastic. The
ductility is usually measured by the terms, percentage elongation and percent
reduction in area. The ductile materials commonly used in engineering practice are
mild steel, copper, aluminium, nickel, zinc, tin and lead.
7. Brittleness: It is the property of material opposite to ductile. It is the property of
breaking of a material with little permanent distortion. Brittle materials when
subjected to tensile loads snap off without giving any sensible elongation. Cast iron is
a brittle material.
8. Malleability: It is a special case of ductility, which permits material to be rolled or
hammered into thin sheets, a malleable material should be plastic but it is not essential
to be so strong. The malleable materials commonly used in engineering practice are
lead, soft steel, wrought iron, copper and aluminium.
9. Toughness: It is the property of a material to resist the fracture due to high impact
loads like hammer blows. The toughness of the material decreases when it is heated.
It is measured by the amount of absorbed after being stressed up to the point of
fracture. This property is desirable in parts subjected to shock an impact loads.
10. Resilience: It is the property of a material to absorb energy and to resist rock and
impact loads. It is measured by amount of energy absorbed per unit volume within
elastic limit. This property is essential for spring material.
11. Creep: When a part is subjected to a constant stress at high temperature for long
period of time, it will undergo a slow and permanent deformation called creep. This
property is considered in designing internal combustion engines, boilers and turbines.
12. Hardness: It is a very important property of the metals and has a wide verity of
meanings. It embraces many different properties such as resistance to wear scratching,
deformation and machinability etc. It also means the ability of the metal to cut another
metal. The hardness is usually expressed in numbers, which are dependent on the
method of making the test. The hardness of a metal may be determined by the
following test.
a) Brinell hardness test

18
 b) Rockwell hardness test
c) Vickers hardness (also called diamond pyramid) test and
d) Share scalero-scope.

The science of the metal is a specialized and although it overflows in to realms of

knowledge it tends to shut away from the general reader. The knowledge of materials and
their properties is of great significance for a design engineer. The machine elements should be
made of such a material which has properties suitable for the conditions of operations. In
addition to this a design engineer must be familiar with the manufacturing processes and the
heat treatments have on the properties of the materials. In designing the various part of the
machine, it is necessary to know how the material will function in service. For these certain
characteristics or mechanical properties mostly used in mechanical engineering practice are
commonly determined from standard tensile tests. In engineering practice, the machine parts
are subjected to various forces, which may be due to either one or more of the following.

 Energy transmitted
 Weight of machine
 Frictional resistance
 Inertia of reciprocating parts
 Change of temperature
 Lack of balance of moving parts

The selection of the materials depends upon the various types of stresses that are set up
during operation. The material selected should with stand it. Another criterion for selection of
metal depends upon the type of load because a machine part resist load more easily than a live
load and live load more easily than a shock load.

Selection of the material depends upon factor of safety, which in turn depends upon
the following factors.

 Reliabilities of properties
 Reliability of applied load
 The certainty as to exact mode of failure
 The extent of simplifying assumptions

19
  The extent of localized
 The extent of initial stresses set up during manufacturing
 The extent loss of life if failure occurs
 The extent of loss of property if failure occurs

Material used

 Mild steel

Reasons:

1. Mild steel is readily available in market.

2. It is economical to use.
3. It is available in standard sizes.
4. It has good mechanical properties i.e. it is easily machinable.
5. It has moderate factor of safety, because factor of safety results in unnecessary
wastage of material and heavy selection. Low factor of safety results in unnecessary
risk of failure.
6. It has high tensile strength.
7. Low co-efficient of thermal expansion.

Properties of Mild Steel:

M.S. has a carbon content from 0.15% to 0.30%. They are easily wieldable thus can be
hardened only. They are similar to wrought iron in properties. Both ultimate tensile and
compressive strength of these steel increases with increasing carbon content. They can be
easily gas welded or electric or arc welded. With increase in the carbon percentage weld
ability decreases. Mild steel serve the purpose and was hence was selected because of the
above purpose

MS FLAT:

MS Flats are generally used in Industrial gratings, various fabrication works & domestically,
it is used in grills outside window. Representation of M.S. Flats is done by the Width (W) &

20
the Thickness (T) of the Flat. For example: When we say 25 X 5 FLAT, it means Width =
25mm & Thickness = 5mm. The weight of flat bar is easily calculated. Simply multiply the
appropriate alloy density by the length, width, and thickness of the required part For taking
weight of each components

Cross-Sectional size of link used is 18x4 mm

Figure 2 Mild steel flat

Representation of M.S. Flats is done by the Width (W) & the Thickness (T) of the Flat.
Weight (Kg/mtr)

Table 1 MS flat weight

Size (mm) Weight (kg/ft) Weight (Kg/mtr)

12 x 3 0.086 0.282

12 x 5 0.143 0.470

18 x 4 0.180 0.585

20 x 3 0.143 0.470

20 x 5 0.241 0.790

20 x 6 0.287 0.942

25 x 3 0.183 0.600

25 x 5 0.305 1.000

25 x 6 0.365 1.197

25 x 8 0.470 1.550

25 x 10 0.609 1.998

21
 MS SHEET METAL:

These mild steel sheets confirm to various standards like ANSI, API, MSS, BS, DIN,
JIS & IS standards. We can provide these mild steel sheets and mild steel sheets in different
grades, thickness, length and weight as per the requirements. Sheet metal is metal formed by
an industrial process into thin, flat pieces. Sheet metal is one of the fundamental forms used in
metalworking, and it can be cut and bent into a variety of shapes. Countless everyday objects
are fabricated from sheet metal. Thicknesses can vary significantly; extremely thin sheets are
considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are considered plate steel or
"structural steel".

Sheet metal is available in flat pieces or coiled strips. The coils are formed by running
a continuous sheet of metal through a roll slitter.

In most of the world, sheet metal thickness is consistently specified in millimeters. In

the US, the thickness of sheet metal is commonly specified by a traditional, non-linear
measure known as its gauge.

Table 2 sheet metal size selection

22
 Guage Thickness mm Weight kg/sq.m

8 4 31.4

9 3.55 27.9

10 3.15 24.75

11 2.8 22

12 2.5 19

13 2.25 17.6

14 2 15.7

15 1.8 14.15

16 1.6 12.55

17 1.4 11

18 1.25 9.8

19 1.12 8.8

20 1 7.85

21 0.9 7.05

22 0.8 6.3

24 0.63 4.95

26 0.5 3.9

28 0.4 3.15

We will buy a leather safety shoe for which we will make a C- frame, the frame is
fixed with shoes with the help of stud passed through heels of the shoe, both end of stud is
tightened with the help of nut. It will hold the shoe (shoe holder).

23
 Figure 3 Shoes and C-frame assembly

Now we will make a small square box one end of which is pivoted to shoe holder and
another end is fixed to the bottom end of Piston connecting rod.

Figure 4 Piston rod and C-frame assembly

Here we will use 10 bar pressure cylinder half filled with air and half with oil, depends
upon the weight of user. The cylinder has 25 mm bore diameter, 250 mm stroke length and is
provided with two flow control valves.

24
 Figure 5 Pneumatic cylinder components

Now, we make leg holder which will hold the thigh and is made by taking 1.6 mm MS
sheet bended to the shape of thighs. Two nylon laces are fixed to the thigh holder with the
help of pop rivet so that it can hold the leg. The leg holder is pivoted to square block and
square block is fixed to cylinder.

The cylinder pivoted with the help of this component to leg holder. We have used M-6
nut bolts for all pivots.

Now, as the person can sit stand and walk comfortably. The "Chairless Chair" consists
of two identical "chairs," one strapped to each of the wearer's legs. It is important for the
Chairless Chair to be adjusted to each user. Just like a piece of clothing, if the chair doesn't fit,
it will not feel good. When adjusted correctly, you can comfortably relax with all your weight
on the chair.

"With the lower member of the chair strapped to the calf, a cylinder presses the upper
member against the back of the thigh. As the user squats, the released compression bar pushes
the leg of the chair to a locked position, thereby supporting the body. When the user rises, the
lower member is unlocked and is retracted by a cylinder to its original position, where it will
not interfere with the user's movements."

25
 Spray paint can:

Spray paint, also known as aerosol paint, is paint that's stored in a pressurized
container and dispensed using a valve to release a mixture of paint and a propellant, usually
pressurized gas or compressed air. The result is a fine, even mist that is easily applied to a
variety of surfaces. Spray painting is one of three primary methods for paint application
besides using a paintbrush or a roller, and is generally quicker, cleaner, and easier to achieve a
uniform coat.

Spray paint started becoming a steadfast friend to do-it-yourselfers when American

artist Francis Davis Millet developed an oil and lead mixture that could be sprayed to speed
up preparations for the Chicago World's Fair. But it was Edward Seymour who thought to use
an aerosol spray to dispense paint. In 1949, he demonstrated a new aluminum paint designed
for finishing radiators on a large scale quickly. Aerosol spray cans had been around since
Norwegian engineer Eric Rotheim invented the first one in 1931, and Seymour was simply
piggybacking on this innovation as a way to showcase his own product [source: Harris]. But
he was so intrigued by this new method of paint delivery that he directed his company,
Seymour of Sycamore, to dedicate considerable resources to exploring its potential [source:
Seymour of Sycamore].

Figure 6 spray can

Around the same time Seymour was working on his contributions to spray paint,
Krylon and Crown Holdings Inc. were each developing new can designs that eventually gave
rise to the metal cylinders we use today [source: Sattler]. They were smaller, lighter, cleaner

26
and applied an even coat faster than a brush or roller could, making those small paint projects
around the house a lot more manageable. And once the manufacturing industry discovered its
benefits, spray paint went from a resourceful and useful invention to a full-blown industrial
boon.

Today, spray paint comes in enamels, stains, flats and glossies, and there are varieties
designed for virtually any surface, including wood, metal, glass, plastic and masonry. In other
words, if it can be painted, there's probably a spray paint that can do the job.

The various machining operations conducted after material selection are as follows:

PROCESS SHEET:

Following operations were while fabricate the project

Cutting: -

Cutting is the separation or opening of a physical object, into two or more portions, through
the application of an acutely directed force.

Implements commonly used for cutting are the knife and saw, or in medicine and science the
scalpel and microtome. However, any sufficiently sharp object is capable of cutting if it has a
hardness sufficiently larger than the object being cut, and if it is applied with sufficient force.
Even liquids can be used to cut things when applied with sufficient force (see water jet
cutter).

The material as our required size. The machine used for this operation is power chop saw. A
power chop saw, also known as a drop saw, is a power tool used to make a quick, accurate
crosscut in a work piece at a selected angle. Common uses include framing operations and the
cutting of moulding. Most chop saws are relatively small and portable, with common blade
sizes ranging from eight to twelve inches.

27
 Figure 7 Cutting Operation

The chop saw makes cuts by pulling a spinning circular saw blade down onto a work piece in
a short, controlled motion. The work piece is typically held against a fence, which provides a
precise cutting angle between the plane of the blade and the plane of the longest work piece
edge. In standard position, this angle is fixed at 90°. A primary distinguishing feature of the
mitre saw is the mitre index that allows the angle of the blade to be changed relative to the
fence. While most mitre saws enable precise one-degree incremental changes to the mitre
index, many also provide "stops" that allow the miter index to be quickly set to common
angles (such as 15°, 22.5°, 30°, and 45°).

Welding: -
Welding is a ((fabrication or sculptural ((process that joins materials, usually metals or
thermoplastics, by using high heat to melt the parts together and allowing them to cool
causing fusion. Welding is distinct from lower temperature metal-joining techniques such as
brazing and soldering, which do not melt the base metal.

In addition to melting the base metal, a filler material is typically added to the joint to form a
pool of molten material (the weld pool) that cools to form a joint that, based on weld
configuration (butt, full penetration, fillet, etc.), can be stronger than the base material (parent
metal). Pressure may also be used in conjunction with heat, or by itself, to produce a weld.
Welding also requires a form of shield to protect the filler metals or melted metals from being
contaminated or oxidized.

28
 Square pipes of different lengths to make frame. The machine used for this operation is
electric arc welding. Electrical arc welding is the procedure used to join two metal parts,
taking advantage of the heat developed by the electric arc that forms between an electrode
(metal filler) and the material to be welded. The welding arc may be powered by an
alternating current generator machine (welder). This welding machine is basically a single-
phase static transformer Suitable for melting RUTILE (sliding) acid electrodes. Alkaline
electrodes may also be melted by alternating current.

Figure 8 Welding operation

The welding current is continuously regulated (magnetic dispersion) by turning the hand
wheel on the outside of the machine, which makes it possible to select the current value,
indicated on a special graded scale, with the utmost precision. To prevent the service
capacities from being exceeded, all of our machines are fitted with an automatic overload
protection which cuts of the power supply (intermittent use) in the event of an overload. The
operator must then wait for a few minutes before returning to work. This welding machine
must be used only for the purpose described in this manual. Read the entire contents of this
manual before installing, using or servicing the equipment, paying special attention to the
chapter on safety precautions. Contact your distributor if you do not fully understand these
instructions. The time required for this operation is 120 minutes.

Drilling: -

Drilling is a cutting process that uses a drill bit to cut a hole of circular ((cross-section in solid
materials. The drill bit is usually a rotary ((cutting tool, often multi-point. The bit is pressed
against the work-piece and rotated at rates from hundreds to thousands of revolutions per

29
minute. This forces the cutting edge against the work-piece, cutting off chips (swarf) from the
hole as it is drilled.

In ((rock drilling, the hole is usually not made through a circular cutting motion, though the
bit is usually rotated. Instead, the hole is usually made by hammering a drill bit into the hole
with quickly repeated short movements. The hammering action can be performed from
outside the hole ((top-hammer drill) or within the hole (down-the-hole drill, DTH). Drills used
for horizontal drilling are called drifter drills.

In rare cases, specially-shaped bits are used to cut holes of non-circular cross-section; a
((square cross-section is possible.

Figure 9 Drilling Operation

Drilled holes are characterized by their sharp edge on the entrance side and the presence of
((burrs on the exit side (unless they have been removed). Also, the inside of the hole usually
has helical feed marks.

Drilling may affect the mechanical properties of the work piece by creating low residual
stresses around the hole opening and a very thin layer of highly ((stressed and disturbed
material on the newly formed surface. This causes the work piece to become more susceptible
to corrosion and crack propagation at the stressed surface. A finish operation may be done to
avoid these detrimental conditions.

For ((fluted drill bits, any chips are removed via the flutes. Chips may form long spirals or
small flakes, depending on the material, and process parameters. The type of chips formed

30
can be an indicator of the machinability of the material, with long chips suggesting good
material machinability.

Figure 10 Drilling Tool

Finishing: -

Finishing is a broad range of industrial processes that alter the surface of a manufactured item
to achieve a certain property. Finishing processes may be employed to: improve appearance,
adhesion or wettability, solder ability, corrosion resistance, tarnish resistance, chemical
resistance, wear resistance, hardness, modify electrical conductivity, remove burrs and other
surface flaws, and control the surface friction. In limited cases some of these techniques can
be used to restore original dimensions to salvage or repair an item.

An unfinished surface is often called mill finish.

The edges with grinder using grinding wheel. The machine used for this operation is
hand grinder. An angle grinder, also known as a side grinder or disc grinder, is a handheld
power tool used for cutting, grinding and polishing. Angle grinders can be powered by an
electric motor, petrol engine or compressed air.

The motor drives a geared head at a right-angle on which is mounted an abrasive disc
or a thinner cut-off disc, either of which can be replaced when worn. Angle grinders typically
have an adjustable guard and a side-handle for two-handed operation. Certain angle grinders,
depending on their speed range, can be used as sanders, employing a sanding disc with a
backing pad or disc. The backing system is typically made of hard plastic, phenolic resin, or

31
medium-hard rubber depending on the amount of flexibility desired. The time required for
this operation is 20 minutes.

Figure 11 Finishing Operation

Polishing: -

Polishing is the process of creating a smooth and shiny surface by rubbing it or using a
chemical action, leaving a surface with a significant specular reflection (still limited by the
index of refraction of the material according to the Fresnel equations.) In some materials
(such as metals, glasses, black or transparent stones), polishing is also able to reduce diffuse
reflection to minimal values. When an unpolished surface is magnified thousands of times, it
usually looks like mountains and valleys. By repeated abrasion, those "mountains" are worn
down until they are flat or just small "hills." The process of polishing with abrasives starts
with coarse ones and graduates to fine ones.

The welded joints with hand grinder using grinding wheel. The machine used for this
operation is hand grinder. With refinement, grinding becomes polishing, either in preparing
metal surfaces for subsequent buffing or in the actual preparation of a surface finish, such as a
No. 4 polish in which the grit lines are clearly visible. Generally speaking, those operations
which serve mainly to remove metal rapidly are considered as grinding, while those in which
the emphasis is centered on attaining smoothness are classified as polishing. Grinding
employs the coarser grits as a rule while most polishing operations are conducted with grits of
80 and finer. If polishing is required, start with as fine a grit as possible to reduce finishing
steps. There is a wide range of grinding and polishing tools on the market and advice is

32
available from ASSDA members to assist in particular applications. Polishing operations are
conducted with the abrasive mounted either on made-up shaped wheels or belts which provide
a resilient backing. The base material may be in either a smooth rolled or a previously ground
condition. If the former, the starting grit size may be selected in a range of 80 to 100. If the
latter, the initial grit should be one of sufficient coarseness to remove or smooth out any
residual cutting lines or other surface imperfections left over from grinding. In either case, the
treatment with the initial grit should be continued until a good, clean, uniform, blemish-free
surface texture is obtained. The initial grit size to use on a pre-ground surface may be set at
about 20 numbers finer than the last grit used in grinding, and changed, if necessary, after
inspection. Upon completion of the initial stage of polishing, wheels or belts are changed to
provide finer grits. Polishing speeds are generally somewhat higher than those used in
grinding. A typical speed for wheel operation is 2500 meters per minute. The time required
for this operation is 20 minutes.

Figure 12 Polishing Operation

Safety Precautions:

The following points should be considered for the safe operation of machine

and to avoid accidents: -

 All the parts of the machine should be checked to be in perfect alignment.

 All the nuts and bolts should be perfectly tightened.
 The operating switch should be located at convenient distance from the operator so as
to control the machine easily.

33
 The inspection and maintenance of the machine should be done from time to time.

34
 3.2 Decision Making Process

No methodology is available for material and method selection except decision

making in multi attribute environment. Material selection is vital and crucial activity in any
industry nowadays. This substantially reduces the risk of wrong material or method selection.

State the Problem

Identify the Alternatives

Evaluate the Alternatives

Make a Decision

Figure 13 Decision Making Processes

35
 3.3 Project Pan

Following fig explains the steps for experiment. The process flow mentioned above
will be considered to meet the goal of research work.

Literature Survey

Reference data collection, Study and Problem

Statement

Modeling of Chairless chair

Calculations

Experimental readings

Obtained the Results and Specify the Suitable

Solutions

Figure 14 Steps of Execution

36
 3.4 Cad drawing
Procedure

 The entire model has been designed with the help of designing software solid works.
 With the help of colour feature the colours are given to the entire model.

Figure- Cad model of the assembled project is designed on Solidworks 2022 software

SOLID MODELING
The entire model has been designed with the help of designing software solid works.

Figure 15 isometric front view

37
Figure 16 drafting

Figure 17 Shoe

38
Figure 18 Shoe holder

Figure 19 Thigh pad

Figure 20 Butt pad

39
 3.5 Calculations
EN 10083 C45 steel carbon steel

C45 steel sheet Physio-chemical testing items for products of the plant include tensile test,
hardness test ,impact test ,flattening test ,and chemical composition analysis, etc .C20,C45
steel pipes are manufactured by cold drawn process.

C45 is a medium carbon steel is used when greater strength and hardness is desired than in the
"as rolled" condition. Extreme size accuracy, straightness and concentricity combine to
minimize wear in high-speed applications. Turned, ground and polished.

Soft Annealing

Heat to 680-710oC, cool slowly in furnace. This will produce a maximum Brinell hardness of
207.

Normalizing
Normalizing temperature: 840-880oC/air.

Hardening
Harden from a temperature of 820-860oC followed by water or oil quenching.

Tempering
Tempering temperature: 550-660oC/air.

C45 steel plate, EN 10083 C45 steel plate, under EN 10083 standard, we can regard C45 steel
plate as high carbon steel.

C45 steel plate is one mainly of high carbon steel, EN 10083 C45 steel plate is for quenching
and tempering. Technical delivery conditions for non-alloy steels, these steels are for general
engineering purposes

Comparison of steel grades

JIS G 4051 S 45 C

C45 DIN 17200 C 45

EN 10083-2 NFA 33-101 AF65-C 45

40
 Number:1.0503 UNI 7846 C 45

BS 970 070 M 46

UNE 36011 C 45 k

SAE J 403-AISI 1042/1045

Table 3 steel grades

Chemical Composition of EN C45 steel

Grade C(%)mi Si(%)min- Mn(%)mi P(%)ma S(%)ma Cr(%)mi

n-max max n-max x x n-max

C45 0.42- 0.15-0.35 0.50-0.80 0.025 0.025 0.20-

0.50 0.40

Table 4 Chemical Composition

Mechanical Properties of EN C45 steel

Grad Condition Yield Tensil Elon Hardn Quenc Benda- Nominal

e Streng e - ess hing Thickness,t
bility
th Streng
gatio HRC Tempe 1.95mm≤t≤
th
R°(M n rature 10.0mm
pa) Rm
A5( (℃) Roll Ann
(Mpa) %) ed eale
d

Rolled 460 750 18 58 820 Min.reco- 2.0 1.0×t

mmended
Annealed 330 540 30 55 860 ×t
Bending
C45 Water- 2270
radius
quenched
1980
(≤90°)
Oil
quenched

Table 5Mechanical Properties of EN C45 steel

41
Properties of steel C45 (1.0503) Properties of steel C45 (1.0503)

Weld ability: Due to the medium-high carbon content it can be welded with some
precautions.
Hardenability: It has a low hardenability in water or oil; fit for surface hardening that gives
this steel grade a high hardness of the hardened shell.

Figure 21 Properties of steel C45

Why Mild Steel C-45 is selected in our project.

1. Easily available in all sections.

2. Welding ability
3. Machinability
4. Cuttingability
5. Cheapest in all other metals.

42
Material = C 45 (mild steel)

Take fos 2

σt = σb = 540/fos = 270 N/mm 2

σs = 0.5 σt

= 0.5 x 270

= 135 N/mm2

DESIGN

o Area x Pressure = Force Output

F=PXA

Consider the weight of human sitting on chair = 100 kg. = 981 N

981 = P x π r2

P = 981/ π 102

P = 3.12 N/mm2

Figure 22 cylinder dimensions

43
 1. DESIGN OF CYLINDER: -

Now for thickness of cylinder wall of cylinder,

Hoops law

We have, t = pd/2 σtensile where p = internal pressure= 3.12N/mm 2, & d = diameter of

cylinder=20 mm selected, σtensile = permissible stress.

Table 6 Aluminium Properties

Material Yield Ultimate

strength (MPa) tensile strength
(MPa)

Aluminium 241 300

alloy 6061-T6

We have ultimate stress for cylinder material σultimate = 300 N/mm2 aluminium alloy

Considering factor of safety as 4.

We get permissible stress = ultimate stress/factor of safety

 σtensile=300/4

σ tensile = 75 N/mm2

Inputting this value in the thickness formula,

We get, t = 3.12 x 20/2 x 75

= 62.4/150= 0.416 mm.

t = 0.5 mm (say)

44
 but standard available cylinder in the market is 3 mm thick, so our design is safe.

Outer Dia. of cylinder = 20 + (2 x 3) = 26 mm

The minimum outside diameter of cylinder is 26 mm

2. Load of person on piston rod, so it may fail under bending.

AISI 4140 Alloy Steel (UNS G41400)

Introduction Alloy steels are designated by AISI four-digit numbers. They comprise
different kinds of steels having composition exceeding the limitations of B, C, Mn, Mo, Ni,
Si, Cr, and Va set for carbon steels. AISI 4140 alloy steel is chromium, molybdenum,
manganese containing low alloy steel. It has high fatigue strength, abrasion and impact
resistance, toughness, and torsional strength. The following datasheet gives an overview of
AISI 4140 alloy steel. Chemical Composition The following table shows the chemical
composition of AISI 4140 alloy steel

Mechanical Properties

The following table outlines the mechanical properties of AISI 4140 alloy steel.

Properties Metric I

45
 m

Figure 23 Piston rod properties

M = WL/4 = 981 × 250/4

= 61312.5 N-mm

10mm

Z= π/32 x d3 Figure 24 Cut section of piston rod

Z= π/32 x 10 3

Z= 98.174 mmᶟ

σb (induced)= M/Z = 61312.5/98.174 = 624.5 N/mm²

As induced bending stress is less then allowable bending stress i.e., 655 N/mm 2 design
is safe.

46
 3. Design of bolt for sheer stress failure: -

Bolt is to be fastened tightly also it will take load due to rotation. Stress for C-45 steel.
Standard nominal diameter of bolt is 9.31 mm. From table in design data book, diameter
corresponding to M10 bolt is 8 mm

Figure 25 Nut bolt

Let us check how much load bolt can sustain -

P =? N is the value of force

Stress = load/area

P
σ=
A

π
A= d2
4

π 2
A= 8 = 49.98
4

P=135 x 49.984

P = 6747.84 N = 687 kg

The calculated load is much higher than any applied load, hence our design is safe.

47
 4. Design of bolt for sheer stress failure: -

Bolt is to be fastened tightly also it will take load due to rotation. Stress for C-45 steel.
Standard nominal diameter of bolt is 5.5 mm. From table in design data book, diameter
corresponding to M-6 bolt is 6 mm

Figure 26 Nut bolt

Let us check how much load bolt can sustain -

P =? N is the value of force

Stress = load/area

P
σ=
A

π
A= d2
4

π
A= 5.52 = 23.75 mm2
4

P=135 x 23.75

P = 3207.36 N = 326.78 kg

48
The calculated load is much higher than any applied load, hence our design is safe.

5. Design of MS flat used for making mechanism

t = thickness of arm in mm.

W = maximum force applied by human = 981 N

Bending moment = W x L

M = 981x 25 = 24525 N-mm

And section modulus = Z = 1/6 bh2

Z = 1/6 x 4x182

Z = 1/6 x 1296

Figure 27 MS flat cross-section

Z = 216 mm3.

Now using the relation,

σ bending =M/Z

σ bending = 24525/ 216 = 113.45 N/mm2

49
 Induced stress is less then allowable so design is safe

6. Design of transverse fillet welded joint: -

Checking the strength of the welded joints for safety

The transverse fillet weld welds the side plate and the edge stiffness plates,

The maximum load which the plate can carry for transverse fillet weld is

P = 0.707 x S x L x σt

Where, S = size of weld, L = contact length = 25mm

The tensile force along with the friction is 981 N

Hence, 981 = 0.707 x 3.4 x 10 x σt induced

Hence let us find the safe value of ‘σt’

981

Therefore σt = -------------------

0.707 x 3.4 x 25

σ induced =
t 16.32 N/mm2

Since the calculated value of the tensile load is very smaller then, the permissible value

as σt =21 N/mm2. Hence welded joint is safe.

50
 3.6 COST ESTIMATION
Cost estimation may be defined as the process of forecasting the expenses that must
be incurred to manufacture a product. These expenses take into a consideration all expenditure
involved in a design and manufacturing with all related services facilities such as pattern making,
tool, making as well as a portion of the general administrative and selling costs.

PURPOSE OF COST ESTIMATING:

1. To determine the selling price of a product for a quotation or contract so as to ensure a

reasonable profit to the company.
2. Check the quotation supplied by vendors.
3. Determine the most economical process or material to manufacture the product.
4. To determine standards of production performance that may be used to control the cost.
BASICALLY, THE BUDGET ESTIMATION IS OF TWO TYRES:

1. material cost
2. Machining cost
MATERIAL COST ESTIMATION:

Material cost estimation gives the total amount required to collect the raw material which has to
be processed or fabricated to desired size and functioning of the components.

These materials are divided into two categories.

1. Material for fabrication:

In this the material in obtained in raw condition and is manufactured or processed to finished size
for proper functioning of the component.

1. Standard purchased parts:

This includes the parts which was readily available in the market like Allen screws etc. A list is
forecast by the estimation stating the quality, size and standard parts, the weight of raw material
and cost per kg. For the fabricated parts.

MACHINING COST ESTIMATION:

This cost estimation is an attempt to forecast the total expenses that may include to manufacture
apart from material cost. Cost estimation of manufactured parts can be considered as judgment on

51
and after careful consideration which includes labour, material and factory services required to
produce the required part.

PROCEDURE FOR CALCULATION OF MATERIAL COST:

The general procedure for calculation of material cost estimation is

1. After designing a project, a bill of material is prepared which is divided into two
categories.
a. Fabricated components
b. Standard purchased components
2. The rates of all standard items are taken and added up.
3. Cost of raw material purchased taken and added up.
LABOUR COST:

It is the cost of remuneration (wages, salaries, commission, bonus etc.) of the employees of a
concern or enterprise.

Labour cost is classifying as:

a. Direct labour cost

b. Indirect labour cost
Direct labour cost:

The direct labour cost is the cost of labour that can be identified directly with the manufacture
of the product and allocated to cost centres or cost units. The direct labour is one who counters
the direct material into saleable product; the wages etc. of such employees constitute direct labour
cost. Direct labour cost may be apportioned to the unit cost of job or either on the basis of time
spend by a worker on the job or as a price for some physical measurement of product.

Indirect labour cost:

It is that labour cost which cannot be allocated but which can be apportioned to or absorbed by
cost centres or cost units. This is the cost of labour that doesn’t alters the construction,
confirmation, composition or condition of direct material but is necessary for the progressive
movement and handling of product to the point of dispatch e.g. maintenance, men, helpers,
machine setters, supervisors and foremen etc.

52
 EXPENSES
The expenses are also mainly divided into direct and indirect labour expenses.

1) Direct expenses

The expenses which can be directly cragged on cost of particular product are called direct
expenses.

2) indirect expenses

The expenses that cannot be charged directly on the cost of particular product are called indirect
expenses

PROCEDURE OF COSTING

Actual expenditure incurred in various departments for costing collects different items. The
expenditure is categorized under the following main heads. All the expenses made by an industry
may be group into various components of cost.

The various components of cost are under:

It should be noted that it is cumulative as shown. This system is used in most of modern
industries irrespective of their size. It is because this type of classification is very helpful in
analysing cost compounds according to modern management techniques.

(a) Prime cost

it is also referred as direct cost and is comprised of the direct material cost, direct labour cost and
direct expenses incurred on the manufacturing of product.

Prime cost =Direct material cost + Direct labour cost + Direct expenses

(b) Factory cost

it is also referred as works cost and is comprised works overhead.

Factory cost = Prime cost + Factory over head

(c) Office cost

it is also referred as production cost of manufacturing; cost is comprised of factory cost and
administrative over heads or office on cost.

Office cost = Factory cost + Administrative over heads

53
 (d) Total cost
it is also referred as ultimate cost or gross cost and is comprised of the Office cost and selling and
distribution overhead

total cost = Office cost + Selling and distribution overhead

(e) Selling price

When profit or loss of organization is added / subtracted to the total cost of the product we get
selling price.

selling price = Total cost + Profit or loss

(f) Market price

it is also referred as catalogue price or list price some percentage of discounts is always allowed
to the distributors, when this discount to the distribution is added to the selling price, we get
market price.

market price = Selling price + Discount to the distributors

Machines & equipment’s required

Required machine tools

 Lathe machine
 Welding machine
 Hacksaw machine
 Grinding machine
 Drilling machine
 Slotting machine
Required tools /equipment’s
 Hacksaw blade
 Spanner set
 Hammer
 Drill bit
 Fasteners
 Welding electrodes
 Centre punch

54
  Measure tape
 Chisel
 Single point cutting tool
 Steel rule
 Rough, smooth file
Required fixture
 Bench vice
 Anvil
 C-clamp
 Drill machine vice
Other requirement
 Lubricating oil
 Cutting fluid
 Coolant
 Paint

The total labour cost is calculated on the basis of wages paid to the labour for 8 hours per day.

Cost estimation is done as under

Cost of project = (A) material cost + (B) Machining cost + (C) labour cost

(A) Material cost is calculated as under: -

i) Raw material cost

ii) Finished product cost

i) Raw material cost: -

It includes the material in the form of the Material supplied by the “Steel authority of India
limited” and ‘Indian aluminium co.,’ as the round bars, angles, square rods, plates along with the
strip material form. We have to search for the suitable available material as per the requirement of
designed safe values. We have searched the material as follows: -

Hence the cost of the raw material is as follows: -

55
 RAW MATERIAL & STANDARD MATERIAL
Table 7 raw material cost

SR NO PART NAME MAT QTY COST

CYLINDER 20 BORE 250 5000
1 STD 2
STROKE
PAD 800
2 MS 2

BELT 600
3 NY 4

SHOE 1500
4 LE 2

PIVOT JOINT 700

5 MS 2

SHOE HOLDER 300

6 MS 2

POP RIVIT 50
7 MS 24

NUT BOLT M-6 199

8 MS 0.5 KG

SQUARE PIPE 300

9 MS 3 KG

MS FLAT BARS 60
10 MS 1 KG

LOCK NUT 40
11 MS 2

1000
12 MISSILINIOUS - -

10679
TOTAL

B) DIRECT LABOUR COST: -

Table 8 labour cost

RATE /
SR. NO. OPERATION HOURS AMOUNT
LABOUR

1. Drilling 7 100 700

56
 2. Welding 16 175 2800

3. Grinding 3 60 180

4. Cutting 8 40 320

5. Assembly 2 100 200

6. Painting 2 100 200

TOTAL 38/-

INDIRECT COST

Transportation cost = 500/-

Coolant & lubricant = 100/-

Drawing cost = 500/-

Project report cost = 2000/-

TOTAL INDIRECT COST = 2100/-

TOTAL COST
Raw Material Cost + STD Parts Cost + Direct Labour Cost +Indirect Cost

Total cost of project is done in table

Table 9 Final cost

TOTAL COST AMOUNT

A 10679

B 4400

C 2100

Total cost of project 17179

57
 3.7 Plan of execution:
Table 10Plan of Work/Timeline

Months/
Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May
Activity
A

Activities
 A= Topic finalization
 B= Literature Review
 C= Formulation of Problem
 D= Parametric analysis
 E=Development of CAD models of system
 F= Purchasing of components
 G= Manufacturing
 H= Assembly and Testing
 I= Results and Conclusion
 J= Report Writing

58
 3.8 PROJECT FLOW CHART

From the flow chart, this project started with the objective of the project. The objective of the
project must follow the title. The objective must fulfill the title Then follow up with design
review about folding table and then study a lot of investigation about folding table. This is
including study about several of stage, type of stage, types of material which suitable to make
a stage. These tasks have been done through study on internet, books and others resources.
After all information had been collected and gathered, the project continued with the design
process. All the knowledge and lessons had been applied to make a suitable design for the
project. After several design sketched, design consideration has been made and one of the
designs have been chosen by using Pugh’s concept selection. The solid modeling and
engineering drawing by using solid works software the fabrication process progress use
drawing as a reference. The process consist fabrication to all parts that have been designed by
the dimension using various type of manufacturing process. The manufacturing process
includes welding, drilling, bending, cutting and etc. During the fabrication process, if there
have error occur, such as fabrication error, so the process need to modification the process
need to go back to the previous step and the process flow again, until no error occur the
process can have been continued smoothly until the final product finished. Then, the draft
report needs to be submitted to the supervisor for double checking if there had an error.

59
 LITERATURE
SURVEY

PROBLEM
DEFINATION

OBJEECTIVE

DESIGN OF
PHYSICAL MODEL

MATERIAL
SELECTION AND

OPTIMIZATION

FABRICATION

CONFIRMATIO
N TEST

CONCLUSION

Figure 28 flow chart

60
 4. EXPERIMENTAL VALIDATION

 At high load the system failure was not form. The system was comfortable for
the people using it. The cost of the system is decrees due to adequate material
and strengthens to the system. The maximum stress and deflection within
limit.
 The chair is designed in such a way that worker can walk and stand easily.
When adjusted height of chair, you can fill comfortably relax with all worker
weight. Belt of Chairless chair wrap around thighs without any difficulty.
 After designing, the final manufacturing of chair less chair by modelled part
 model and all the parts are then assembled the specific weight and high for
chair less chair is 5 ft. to 5’5’’ regular size and 100 kg weight.
 When in full-scale production, the EBHS will be available in three sizes,
I. From 5ft to 5‟5”: Regular Size
II. From 5‟5” to 6ft: Large Size
III. From 6ft to 6‟5”: Extra Large Size

61
 5. CONCLUDING REMARK
5.1 Conclusion

In this project design and fabrication of Chairless chair has been done. The main goal
of our project was to give the comfort to workers, who work on production line for hours.

Also, to make the model at least cost, that has been achieved. The work started with
designing of model and procurement of required material. Finally, fabricated Chairless Chair
at workshop. The model is working satisfactorily. This concept was new and the data
available was also limited. There is some future modification possible.

5.2 Scope of future work

The basic operation of this machine to reduce fatigue by sustaining the weight of the
wearer in a similar fashion as that by a regular chair as your leg weakness progresses due to
increasing in your age, your health care team may recommend equipment known as
ambulation aids and bracing to help you with walking. Other devices can help give you
needed support as the muscles in your neck and arms weaken. There may be a use of such
exoskeletons which can give more effect than braces and ambulation aids. The specific aid or
device that's best for you depends on the extent of the weakness and your willingness to use
such a device. Using such instruments for walking climbing, doing work is safe and you’re
confident that you won’t fall. For some, this means having an attendant or using an assistive
device when walking short distances. Such instruments are going to bring more flexibility,
mobility and most importantly the confidence Apart from in medical therapy and military
sector, active or hoses or exoskeletons offer other applications, for example as a power
booster during assembly work in production. They act here as a strength support device to
prevent signs of fatigue that occur especially when performing repetitive actions.

5.3 Advantages

1. The movements of the worker are copied by the exoskeleton, i.e., the limbs of the
human and the exoskeleton is aligned during motion.

2. No external power source required.

3. Heavy objects can be lifted for long period of time.

62
 4. Increases efficiency of operator.

5. Robust in design, requires less space, can be assembled & disassembled easily.

5.4 Disadvantages

1. Distinction of intended from unintended movements is often difficult and results in

systems with many

different kinds of sensors and complex signal processing.

2. But the cooperation and function allocation, man-machine information exchange,

real-time motion planning

and safety control are the difficulties faced by building such a control strategy.

3. Free body motions are restrained.

4. May require costly materials like carbon-fibre, aluminium.

5.5 Applications

 With the growth of technology, many companies like Audi have optimized
factory floor plans designed to maximize efficiency, with little room, literally
or figuratively, for chairs. The Chairless chair effectively lets employees carry
a seat with them at all times. This enables them to take micro-breaks of 3 to 10
seconds while working thereby reducing muscle fatigue.
 This invisible chair would prove helpful to hunters, farmers, surgeons, retail
workers, etc. i.e. anyone who needs to stand for long hours at stretch.
 This Chairless chair would be helpful to the elderly as they need rest a while
after walking some distance.
 Chairless chair can be developed further to suit the needs of the handicap, by
acting as a walking assistance.
 Once into mass production, an organisation can completely give up the usage
of conventional chairs and make use of Chairless chair to save floor space and
maximize efficiency.
 Commuters standing in a crowded train or metro to relax themselves without
occupying much space can use it.

63
 Used my military and trekkers while trekking difficult terrains.

64
 6. REFERENCES

[1] H.Zurina, A.Fatin “The design and development of the lower body Exoskeleton”, 2nd
Integrated design project conference (IDPC) 2015.

[2] Cyril Varghese, “Design and fabrication of exoskeleton based on hydraulic support”,
International journal of advanced research (2016), volume4, Issue 3, 22-28.

[3] Y. Kalian chakravarthy, D.Tarun, A.Srinath, “Estimation of body segment weights for
prosthetic legs suitable to Indian amputees”, International journal of applied engineering
research, ISSN 0973- 4562 volume9, no 20(2014) pp. 7543-7462.

[4] Aditya Bhalero, sandesh kamble “pneu portable chair”, Journal of scientific research,
volume:

[5] DeyuanMeng, Guoliang Tao, et.al., “Modeling of a Pneumatic System for High Accuracy
Position Control”, International Conference on Fluid Power and Mechatronics, pp.: 505-510,
ISBN: 978-1-4244-8452-2.

[6]Harris T.A., Rolling Bearing Analysis, John Wiley, 1966 [7] Thierauf, Spiegel,
Exoskeleton based chair, Johns Hopkins Univ. Press, Baltimore, 1983.

[8] Von Wagner, Houlden, Analysis of Hydraulic Cylinders under Load, Ph.D. Thesis, Univ.
of Melbourne, 1995.

[9] Hillier, A.and Cooper, System modeling of Chairless Chair, Philadelphia : L.A.Saunders,
1998

[10]Dean L.O., Article on eccentric loading on pivot supports, VDI Zeitschrift VDI, 69
(1925) 24-28.

[11]Bedford J.E., Form in Engineering Design, Oxford, 1954.

[12]Woolman J. and R.A. Mottram, The Mechanical and Physical Properties of British
Standard EN Steels, (Three Volumes), The British Iron and Steel Research Association,
Pergamon Press, 1968

65
 Websites

 https://www.audi-mediaservices.com

 www.wired.com/2015/03/exoskeleton-acts-like-wearable-chair/

 noonee.com/.../8.../17-first-chairless-chair-user-trials-completed-with-au...

 robohub.org/noonee-testing-chairless-chair.

 nextbigfuture.com/2015/03/lower-body-exoskeleton.

 www.technology.org/2015/02/.../audi-to-use-chairless-chairs.

66