Design And Fabrication Of A Printing Block Machine
A printing block machine, also known as a printing press or printing equipment, is a mechanized device utilized in the reproduction of text and images onto various surfaces such as paper, fabric, or plastic. Employing intricate mechanisms, this apparatus enables the mass production of printed materials, including newspapers, books, packaging, and promotional items, thereby streamlining the dissemination of information and facilitating communication. Key components of a printing block machine typically include a plate or cylinder where the desired content is etched or engraved, ink application systems, and a pressure mechanism for transferring the inked image onto the substrate. Through precise engineering and technological advancements, modern printing block machines have significantly enhanced efficiency, accuracy, and versatility in the printing industry, catering to diverse needs ranging from commercial printing to artistic expression.
Parameters on which clear prints depends were comprehensively investigated. The study revealed that clear print depends on the impressed pressure the working temperature and the gold foil print paper life expectancy.
Also studies were he manner of dependence of these parameters on prints impressed on sheets of varied thickness. The results of these investigation were utilized in the design and fabrication of an operational manual printing machine using gold foil sheet depositor clear prints were impressed on papers during the new machine’s operation.
Title page ii
Letter of transmittal iii
Release iv
Approval page v
Dedication vi
Acknowledgement vii
Abstract viii
List of figures ix
List of tables x
List of symbols xi
Table of contents xii
CHAPTER ONE
1.1 introduction 1
1.2 literature review and data collection 2
1.3 experimental determination of pressure for prating 3
1.4 design specification 9
CHAPTER TWO
2.1 Design solutions 11
2.2 Alternative A press foot printer 11
2.3 Alternative B; crank arm (handle ) 14
2.4 Alternative C; automatic (motorized) printer 17
2.5 Comparison of alternative and choice 20
CHAPTER THREE
3.1 Design selection and analysis of parts of chosen alternative 22
3.2 Theory of design/ design calculation 24
3.3 The design of the shaft (Hollow) 26
CHAPTER FOUR
4.1 construction of prototype 28
4.2 general 28
4.3 material selection 29
4.4 sequence of construction and assembly 40
CHAPTER FIVE
5.1 Testing of prototype (test – run) 40
5.2 Evaluation of machine efficiency 40
5.3 Operator’s manual 41
5.4 Costing (cost analysis) 42
5.5 Problems Encounter 45
5.6 Conclusion 45
5.7 Recommendation 46
5.8 Reference 47
1.1 INTRODUCTION
Nigeria in recent times lays strong emphasis on mass literacy and indigenous technology. Printed matters are indispensable materials in mass literacy campaign and the trend towards indigenous technology imposes a severe clamp down on imputed engineering including printing block machinery. Thus the situation is such that make the acquisition of printing machinery from outside our boards extremely difficult.
Therefore to lessen the economic strain on the mass literacy campaign local production of printing machinery is apparently imperative. It is this fact that rendered integrative to the conception and realization of this low cost but efficient printing machine based entirely on local technology and resources.
The present machine is very useful in the printing of many items like paper backs cards etc. its design and fabrication is expected to motivate and advance the design and fabrication of other machines destined for similar purpose and based on indigenous technology and resources.
1.2 LITERATURE REVIEW AND DATA COLLECTION
There were no available books in printing in both the state and school libraries that actively dealt with printing technology. The only books available were those on the history of ‘Types’ and trade journals advertising products of foreign companies which were fund to be of little or no relevance.
However a visit to the government printing press gave us an opportunity to study the ‘types’ available and the basic operations of the giant printing (Blocking) machine with respect to the ‘Types’ from there we were able to establish;
(a) The effect of temperature on the amount of gold deposited from sheet (sharpness of print )
(b) The effect of life time on the gold foil sheet depositor.
(c) The effect of pressure on the amount of gold deposited from sheet (sharpness of print )
(d) The effect of size of ‘types’ on the sharpness of print (amount of gold deposited )
Definition:
Types : These are the characters or alphabets that forms the letters.
Print :- This is the mark or impression produced on paper due to the types. Gold foil sheet depositor :- is a thin rectangular cellophane sheet coated with gold compound.
1.3 EXPERIMENTAL DETERMINATION OF PRESSURE FOR PRINTING.
The print there must be impact force between two surfaces on e of which contains the ‘type’ and the other the paper on which print will be made. The force produces the necessary pressure for printing.
Consider alternative ‘B’ of the possible design solution. Impact force is due to the acceleration of mass of moveable plate and rail against the stationary letter box located on the element box. The pressure for printing is impact force for a constant surface area
Impact surface area the pressure varies with variation in the impact force. Similarly the impact force varies with the mass and acceleration. But the mass is constant and equal to mass of rail plus mass of moveable plate hence only the acceleration varies. Therefore in this experiment effort has been made to determine.
(a) The pressure required to print clearly on thin cellophane sheet without perforating it.
(b) The pressure required to print clearly on paper of average thickness without perforating it
(c) The pressure required to print on cardboard sheet such that very sharp prints are obtained by varying the input acceleration
Materials: very light cellophane paper, paper back of higher education exercise book ceiling sheet (card board) silver sheets,
Apparatus: Election- speed printer machine
Definition: The electronic speed printer machine is a motorized electronic motor. It has a device for varying the acceleration the current input can varied hence the heat generate and therefore the temperature varied.
Method: the acceleration is varied keeping the temperature and surface area of impact constant. Already the striking mass is constant. The following values show the accelerations at which sharpest prints were obtained without perforation of the materials after several trial. The corresponding forces and pressure are also shown.
TABLE 1
Material Accel. For sharpest print without perforation Mass (m) Force (ma) Pressure (ma/a)
Cellophane paper 0.07mls 2 35kg 2.45N 2.45
0.0972 = 25.24 n/m2
Paper back of higher education note book 0.76 mls2 35kg 26.6N 26.6 = 273.N/M2
0.0972
Ceiling sheet
Cardboard 2.3 mls2 35kg 80.8n 80.8 = 831 N/m2
0.0.972
operating temperature 1550c (fixed)
0.0972 = area of foolscap sheet (fixed)
for the heating coil, the heat dissipated given by H. = 12 Rt where 1 = current passing in ampere R = resistance of coil in ohms and t = duration time in seconds. It varies directly with temperature which is the measurement of heat hence the determination of:
TABLE 11
EFFECT F TEMP. ON SHARPNESS OF PRINT
Temp
(0 c) Cellophane paper Paper back of higher Edu. Book Ceiling sheet cardboard Acceleration (m/s2) Pressure (N/m2
25 No print No print No print 0.07 25.2
50 Slight deposit No print No print 0.07 25.2
155 Sharp print No print No print 0.07 25.2
200 No print 0.07 25.2
250 Shrinks Non – clear print No print slight deposit 0.07 25.2
25 Slight deposit No print No print 0.76 273
50 Clear print Slight print No print 0.76 273
155 Perforation Sharp print No print 0.76 273
200 Burns / shrins Slight groove Slight deposit 273
250 Increased burns Deeper grooves Non- clear print 0.76 273
25 Fairly clear print Slight deposit Slight deposit 2.3 831.2
50 Perforation Clear print Non-clear print 2.3 831.2
155 Burns/ shrinks Sharp print with very deep groove Sharp print 2.3 831.2
200 Increased burns Perforation begins Grooving begins 2.3 831.2
250 Increased burns Deeper perforations Deeper groove 2.3 831.2
OBSERVATION:
From tables 1 and 11 it can be observed that
(a) The sharpness of print varies directly with the acceleration and hence the operating pressure.
(b) The sharpness of print varies directly with temp.
(c) No matter how high the pressure applied at room temp.250c) a sharp print can never be obtained before and even after grooving and consequent perforation occurs.
(d) By increasing acceleration and decreasing tem. Or vice- versa sharpness of prints can be altered provided the temp. Variation does not require a fall below 1550c.
CONCLUSION:
Sharpness of print depends on pressure and on temp (from about 1500c upwards).
(a) EFFECT OF LIFE TIME ON GOLDEN FOIL DEPOSITION
Gold foil sheet as already defined is a very thin rectangular cellophane sheet coated with golden compound chemical such that temperature and pressure can be regulate its deposition on paper. Form the time of production (coating of gold on cellophane) the coherency of gold deposit decreases with time until a times when the layers of the compound starts peeling off from the sheet by itself. Hence sharpness of print depends on life time of coating. This fact was established after observing different life golden sheets used under same temperature and pressure.
(b) THE EFFECT OF SIZE OF TYPES ON THE SHARPNESS OF PRINT.
Since pressure = force / Area the same force applied ‘types’ having smaller surface area exerts greater pressure in direct proportion to the ratios of their surface area.
1.4 DESIGN SPECIFICATION
The printing (blocking) machine to be designed must be able to:
1.4.1 produce sharp print on paper from gold coated sheet
1.4.2 require small effort for operation
1.4.3 resist failure of excessive effort should be applied.
1.4.4 Be easily operated by anybody
1.4.5 Produce as many per unit time as possible.
1.4.6 Must be relatively cheap in every respect
1.4.7 Should be compact and portable
1.4.8 Should nut be too heavy – can easily be moved from one location to another
1.4.9 Position of operator in use should be convenient not tiring
1.4.10 Should be durable
1.4.11 should have replaceable parts – using bolts, screws and other forms of assembly rather than welding. Also using components whose forming / manufacturing process is less complex so the user can easily replace damaged parts.
1.4.12 Manufacture ability – can be manufactured within the limits of available materials and processes in the school workshop and neighboring establishments.
Printing Block Machine:
A printing block machine, also known as a letterpress or block printing machine, is a device used for printing text and images on paper or other surfaces. It is a traditional printing technology that was widely used before the advent of modern digital printing methods.
Here’s an overview of how a printing block machine works:
- Printing Block Preparation: The process begins with the creation of printing blocks. These blocks can be made from various materials such as wood, metal, or linoleum. Text and images are typically engraved or carved into these blocks in reverse, so that they will appear correctly when printed.
- Ink Application: Ink is applied to the printing blocks. In traditional letterpress printing, ink is often applied manually using rollers or ink pads. The ink adheres to the raised portions of the printing blocks.
- Paper Feeding: Sheets of paper or other printing substrates are fed into the machine. The paper is usually fed one sheet at a time, and it’s positioned to meet the printing blocks.
- Printing: The paper and inked printing blocks are pressed together with significant force. The ink from the blocks is transferred onto the paper, creating the printed image or text. This process can be repeated as many times as needed to produce multiple copies of the same content.
- Drying: The printed sheets are typically left to dry, as the ink can take some time to set and dry completely.
- Collection: Once the ink is dry, the printed sheets are collected and can be further processed or distributed.
Printing block machines were widely used for centuries and played a crucial role in the dissemination of written information, including books, newspapers, and other printed materials. While they have largely been replaced by more modern printing technologies like offset printing and digital printing, letterpress and block printing still have niche applications today, often valued for their distinctive and artisanal qualities.
In recent years, there has been a resurgence of interest in letterpress printing as a form of artistic expression and for producing unique, high-quality printed materials, such as wedding invitations, art prints, and fine press books. Modern printing block machines often combine traditional craftsmanship with contemporary design and technology to cater to this demand.