PNEUMATIC SHEET CUTTING MACHINE

Submitted in partial fulfillment of the requirement for the award of

DIPLOMA
IN
MECHANICAL ENGINEERING
BY
Under the guidance of --------------------------------
2004-2005
DEPARTMENT OF MECHANICAL ENGINEERING
CERTIFICATE
Register number: _________________________
This is to certi! th"t the #ro$ect re#ort tit%e&
PNE'MATIC (HEET C'TTING MACHINE
submitte& b! the o%%o)ing stu&ents or the ")"r& o
the Di#%om" engineering is recor& o bon"*&e )or+
c"rrie& out b! them,
Done b!
Mr. / Ms_______________________________
In partial fl!ll"#nt $f t%# r#&ir#"#nt f$r t%# a'ar( $f
(#)r## in
Di#%om" in Mech"nic"% Engineering
During The Ye"r-./001-/0023
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He"& o De#"rtment Gui&e
C$i"*at$r# +4,+5,.
-at#:
(ubmitte& or the uni5ersit! e6"min"tion he%& on
44444444444
44444444444444444 4444444444444444
Intern"% E6"miner E6tern"%
E6"miner
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AC7NO8LEDGEMENT
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AC.N/01E-GEMENT
At this #%e"sing moment o h"5ing successu%%!
com#%ete& our #ro$ect9 )e )ish to con5e! our
sincere th"n+s "n& gr"titu&e to the m"n"gement
o our co%%ege "n& our be%o5e& ch"irm"n
2 )ho #ro5i&e& "%%
the "ci%ities to us,
8e )ou%& %i+e to e6#ress our sincere th"n+s to
our #rinci#"% 2 or
or)"r&ing us to &o our #ro$ect "n& o:ering
"&e;u"te &ur"tion in com#%eting our #ro$ect,
8e "re "%so gr"teu% to the He"& o
De#"rtment Pro, ,,2 or
her constructi5e suggestions < encour"gement
&uring our #ro$ect,
8ith &ee# sense o gr"titu&e9 )e e6ten& our
e"rnest < sincere th"n+s to our gui&e
,,9 De#"rtment
o Mech"nic"% or her +in& gui&"nce <
encour"gement &uring this #ro$ect,
8e "%so e6#ress our in&ebt th"n+s to our
TEACHING "n& NON TEACHING st":s o
MECHANICAL ENGINEERING DEPARTMENT9
,.COLLEGE NAME3,
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PNEUMATIC SHEET CUTTING
MACHINE
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CONTENT(
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CONTENTS
CHAPTER NO TITLE PAGE No.
Synopsis
1 Introduction
2 neumatic system
! "omponents and #escription
$ %or&ing principle
' #esign and drawings
( )pplications and #isad*antages
+ )d*antages
, -ist of materials
. "ost estimation
1/ "onclusion
0ibliography
hotography
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S3N/PSIS
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SYNOPSIS
1he sheet metal cutting process is a main part of the all industries2 3ormally the
sheet metal cutting machine is manually hand operated one for medium and small scale
industries2 In our pro4ect is PNEUMATIC SHEET METAL CUTTING MACHINE.
)utomation in the modern world is ine*itable2 )ny automatic machine aimed at
the economical use of man5 machine5 and material worth the most2 In our pro4ect is
solenoid *al*e is used for automation2
1he sheet metal cutting machine wor&s with the help of pneumatic double acting
cylinder2 1he piston is connected to the mo*ing cutting tool2 It is used to cut the small
si6e of sheet metal2 1he machine is portable in si6e5 so easy transportable2
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CHAPTE4-,
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INT4/-UCTI/N
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CHAPTER-1
INTRODUCTION
1his is an era of automation where it is broadly defined as replacement of manual
effort by mechanical power in all degrees of automation2 1he operation remains an
essential part of the system although with changing demands on physical input as the
degree of mechani6ation is increased2
#egrees of automation are of two types5 *i62
7ull automation2
Semi automation2
In semi automation a combination of manual effort and mechanical power is required
whereas in full automation human participation is *ery negligible2
Need For Automt!o"
)utomation can be achie*ed through computers5 hydraulics5 pneumatics5 robotics5
etc25 of these sources5 pneumatics form an attracti*e medium for low cost automation2
1he main ad*antages of all pneumatic systems are economy and simplicity2 )utomation
plays an important role in mass production2
8eduction of lab our and material cost
8eduction of o*erall cost
Increased production
Increased storage capacity
Increased safety
8eduction in fatigue
Impro*ed personnel comfort
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CHAPTE4-2
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PNEUMATIC S3STEM
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CHAPTER-#
PNEUMATIC SYSTEM
1he sub4ect of pneumatics might probably be termed as compressible fluid
mechanics2 It deals with the use of pressuri6ed gas as a source of power2 1he pressure
energy of gas is directly con*erted into force to do the required wor& with high
efficiencies of con*ersion2
1he pneumatic cylinder utili6es a low pressure fluid2 It has the ad*antage that
cylinder construction can be simplified reducing cost2 It can be used for high speed
operations2
neumatics is widely associated with low cost automation2 It generally offers the
lowest initial and operating cost and simple5 fle9ible control systems2
1hough pneumatic system is the study properties of air other gases5 we are
concerned with the study of air2
CHARACTERISTICS OF COMPRESSED AIR$
1he greatest ad*antage of pneumatic system is the a*ailability of wor&ing medium
free of cost and it plentiful2 "ompressed air can also be transported easily and can be
easily stored in a reser*oir2
)nother notable ad*antage is the insensiti*eness of compressed air to temperature
fluctuations2 It ensures reliable operation e*en under e9treme conditions of temperature2
"ompressed air offers no ris& of e9plosion: hence no e9pensi*e protection cost is
required2 "ompressed air is a *ery fast wor&ing medium where speed and force ar
infinitely *ariable2
CHARACTERISTICS OF PNEUMATICS$
1. Com%re&&!'!(!t)
) pneumatic fluid is compressible2 "ompressibility plays a ma4or role in the
actuation of piston5 i2e25 opening a *al*e does not mo*e the piston immediately5 rather
sufficient fluid must flow into the *olume to increase the pressure until the force
o*ercomes that on the other side2
"ompressibility is the energy storage of a fluid2 )s it is possible to store
compressed fluids and transport them5 pneumatics has the ad*antage of transportability2
)nother ad*antage of the energy storage capacity is the small compressor charging a tan&
can supply a system ha*ing high pea& loads but small a*erage loads2
#. Le*+e Se(!"+ Pro'(em&
Se*eral methods are used to minimi6e lea&age2 ;ne is to use a low operating
pressure2 )nother method to pre*ent lea&age is sealing2 <ood sliding and rotating
sealing are to obtain in pneumatics is because of low *iscosity of the fluids #iaphragms
and bellows are used to a*oid sliding seats2
,. Lo- .!&/o&!t)$
) highly encounted problem due to low *iscosity is that of sealing2 1hey pro*ide
less *iscous damping due to low *iscosity hence sliding parts wear considerably2 1his
adds the necessity for e9ternal sources of lubrication2
)nother problem is that the pneumatic cylinder should be thinner enough to
maintain a laminar flow inside2
1. Lo- De"&!t)
7luids especially gases are usually of low density2 -ow density fluids require
large mechanical wor& and more time for high pressure build up2
#. 0!de R"+e o1 Tem%erture&
1he limitations often may lead to a *iew point that the use of pneumatic
equipment is coupled with high cost2 It is pro*ed to be false5 howe*er5 since a calculation
of production cost includes not only the power cost but also all other compared with
wages5 installation cost5 and maintenance cost that they are insignificant2
,.,. AD.ANTAGES OF PNEUMATIC SYSTEM O.ER OTHER SYSTEM$
12 ;utput power of the pneumatic system can be easily controlled
22 neumatic system is not affected by o*er loading
!2 1he pneumatic system can be used at *arious wor&ing temperature
$2 )ir can be easily distributed through pipelines o*er *ery long distances
'2 neumatic enables high wor&ing speeds
(2 It is a maintenance free system
+2 neumatic enables the application of force *ery gently which is not only beneficial
to pneumatic components but also the equipment which they are installed2
,2 1he wor&ing fluid which is stored in the storage tan& can be ta&en through number
of lines which eliminates the use of indi*idual power sources say electric motor
and many other machine parts2
,.2 SPECIFICATION OF PNEUMATIC ELEMENTS$
1he *arious pneumatic elements are specified according to different standards2
1he standard *aries depending upon the manufacturers2
1. Dou'(e /t!"+ C)(!"der$
Stro&e length = '/ mm
iston #iameter = $/ mm
>a9imum ;perating ressure = 12 bar
1emperature range = 12/" to ?,/"
>aterial = )luminium alloy
Seals = olyurethane
;@ ring = 3itrile
22 So(e"o!d D!re/t!o"( Co"tro( 3(3e
%e ha*e used 'A2 solenoid *al*e as the directional control *al*e2
Boltage = 2!/ *olts
7requency = '/ C6
>a9imum ;peration ressure = 1/ bar
ort si6e = + mm
!2 F(o- /o"tro( .(3e
Te/4"!/( Dt
ort si6e D /2(!' 9 1/
E
F m
ressure D /-, 9 1/ 5 3AmF
>edia D )ir
Guantity D 1
2. Co""e/tor&
Te/4"!/( dt
>a9 wor&ing pressure D 1/ 9 1/ 5 3AmF
1emperature D /-1// H "
7luid media D )ir
>aterial D 0rass
5. Ho&e&
Te/4"!/( dte
>a9 pressure D 1/ 9 1/ 5 3AmF
;uter diameter D ( mm = ( 9 1/ I Jm
Inner diameter D !2' mm = !2' 9 1/ I Jm
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CHAPTE4-6
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C/MP/NENTS AN-
-ESC4IPTI/N
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CHAPTER-,
COMPONENTS AND DESCRIPTION
1he ma4or components of these systems are5
"ompressor
neumatic "ylinder
Solenoid Bal*e
Cose and fitting
Seals
"ontrol 1imer "ircuit
7low control *al*e
COMPRESSOR$
1he air under high pressure is gi*en by a compressor2 It is dri*en by an electric
motor2 1he compressor deli*ers air to inlet of the cylinder2 )n air compressor as the same
indicates is a machine to compress the air and to raise its pressure2 1he air compressor
suc&s air from the atmosphere5 compresses it and then deli*ers the same under a high
pressure to a storage *essel from the storage *essel it may be con*eyed by a pipeline to a
place where the supply of compressed air is required2
Since the compression of air requires some wor& to be done on it5 therefore
compressor must be dri*en by some prime mo*er2
1he compressed air is used for many purposes such as for operating pneumatic
drills5 ri*ets5 paint spraying and supercharging of internal combustion engines etc25 It is
also used in the operation of lifts5 rams5 pumps and *aricty of other de*ices in industry2
"ompressed air is suc&ed for producing ballast of air in blast furnaces and bessemer
con*erter2
C(&&!1!/t!o" o1 A!r Com%re&&or
1he air compressor may be classified in many ways but the following are
important of *iew2
12 )ccording to wor&ing
a2 8eciprocating "ompressor
b2 8otary "ompressor
22 )ccording to action
a2 Single acting compressor
b2 #ouble acting compressor
!2 )ccording to number of stages
a2 Single stage compressor
b2 >ulti stage compressor
RECIPROCATING COMPRESSOR$
1hey are a*ailable in great *ariety including special machine for unusual
requirements >a9imum compression compression ratio may be as high as 1/ per stage2
1wo stage compressors are a*ailable for compression ratios greater than eight2
1here different type of piston type reciprocating air compressor are a*ailable2
1hey are
12 Bertical
22 Cori6ontal
!2 8adial
$2
1he most commonly used one is hori6ontal air cooled type reciprocating air
compressor for a pressure range ( to 12 KgAcm72
Co"&tru/t!o"
It is similar to that of an internal combustion LI"M engine consisting of cost-iron or
aluminum body with an oil tan&5 the base piston with piston rings5 *al*es5 connecting
rods5 cran&s5 cran& shaft and bearing etc2 If the piston is mo*ing down air is suc&ed in
through the suction *al*e and a filter and is compressed in return stro&e2
;il le*el gauges5 oil filling screw and oil outlet screw etc are also important parts
of an air compressor2
1he pressure switch is connected to the dri*ing motor and is set such that it
automatically trips off5 disconnecting the electrical connection to the motor as soon as the
recei*er achie*es the desired set pressure2
1he safety *al*e is set to the same pressure limit and in case of the pressure
e9ceeds this limit5 it automatically opens and e9cess pressure is e9hausted to the
atmosphere5 thus limiting the system pressure to the desired le*el2 1he drain *al*e drains
off the condensate produced at the condenser and the recei*er piston rings are used
around the piston to ma&e it airtight2
1he first stage cylinder is called the low-pressure cylinder L-M where air is drawn
from the atmosphere and is compressed initially2 1he second cylinder is called the
second-stage cylinder5 which is of smaller diameter and it is also called high-pressure
cylinder LCM2 Cere the initially compressed air from first - cylinder is further
compressed to high pressure2
%hen air is compressed5 considerable heat is generated5 this heat must be
dissipated at least in units5 where pressure e9ceeds 2 bar2 1he main machine is cooled by
air circulation on water circulation2
C4r/ter!&t!/& o1 Dou'(e /t!"+ /om%re&&or&
7or the same sped and cylinder *olume5 air deli*ery is double that of a single
acting compressor2
1hey are mostly suitable for large capacity2
"ylinders are mostly water-cooled2
1hey are normally used for continuous and hea*y-duty wor&s2
Cigher speed of piston while reducing the si6e of the compressor may contribute
to greater wear of piston rings5 cylinder liners and pic&ings2 referable range of
piston speed ad*ocated2
7or small capacity compressor !// mAmin
7or large capacity compressor-2'mAmin
-ower discharge temperature Lmostly 2$/H" for single stage compressorsM2
1he ultimate choice of an air compressor is decided considering two main factors2
1hey areD
;ne should go for a small compressor for each machine LorM
Should one ha*e a centrali6ed compressor power houseN
1he portable answer will depend on pipe line layout5 system requirement and the
distance of the user machine from the plant2
PNEUMATIC CYLINDER$
"ylinder is a de*ice which con*erts fluid power into liner mechanical force and
motion2 1hese cylinders are widely used in industrial pneumatic systems2 1hese
cylinders are also called as linear motors and reciprocating motors pneumatic cylinders
are designed for a *ariety of ser*ices2
neumatic cylinders are designed for a *ariety of ser*ices2 neumatic cylinders
transforms the flow of pressured fluid into a push or pull of the piston rod since out
system uses double acting cylinders we shall see some details about them2
#ouble acting cylinders are in one in which fluid force can be applied to the
mo*able element in two directories2 1he force e9erted by the compressed air mo*es the
piston in two directories in a double acting cylinder2 1hey are used particularly2 1he
piston is required to perform wor& not only on the ad*ance mo*ement but also on the
return2 In principle5 the stro&e length is unlimited5 although buc&ing and bending must be
considered before we select a particular si6e of piston diameter5 rod length and stro&e
length2
1he main component of any pneumatic system is the cylinder5 which recei*ers air
under pressure and the pressuri6ed air helps to mo*e the piston to and fro2 1he force
acting on the piston will be equal to the product of the pressure of air and the area of the
cylinder2
1he amount of air deli*ered into the cylinder into the cylinder decides the rate of
doing wor&2 ) cylinder is a hollow circular section with the top and bottom flange
pro*ided to pre*ent the lea&age of air2
1he compressed air is used to actuate the piston2 In order to mo*e the piston to
and fro5 the air is supplied to the top and bottom of the cylinder alternati*ely2
"ylinder is mainly classified into two types namely5
Single acting cylinder2
#ouble acting cylinder2
In single acting cylinder5 using the spring pro*ided around the piston rod attains
the return stro&e5 but it is not efficient2 So5 the double acting cylinder is used in which
the return stro&e is attained using compressed air2
Dou'(e A/t!"+ C)(!"der
In this the force e9erted by the compressed air mo*es the piston in two directions2
1hey are used partially when the piston is required to perform wor& not only on the
ad*ance mo*ement but also on the return stro&e2 1his principle5 the stro&e length is
unlimited5 although buc&ing and bending must be considered before selecting the
particular si6e of piston diameter5 rod length and stro&e length2
1he different parts of double acting cylinder areD
12 0arrel
22 iston rod
!2 1op "o*er
$2 0ottom "o*er
'2 %iper "o*er
(2 8etaining ring
+2 iston
,2 iston guide
.2 0earing "ap
1/2 O;@ ring for piston guide
112 Ce9agonal soc&et head screw
122 "hec& nut
1he double acting cylinder is made up of cast aluminium2 1he inner and outer
surface of the cylinder should be machined accurately2 1he internal diameter of the
cylinder should be accurate in order to pro*ide a smooth surface for the pac&ing2 1he
appearance of the outer diameter should be good2
1he outer most part of the bottom and top co*er contains internal threads for
inserting bolts to clamp the cylinder2
In case of double acting cylinder a force is de*eloped in both the directions2 1he
mo*ing member inside the cylinder is nothing but a piston which is found to be mo*ing
forward and bac&ward due to high-pressure air2 1he cylinder top and lower plate are
flanged together by means of bolts and nuts2 1he bottom of the cylinder is also flanged
with end co*ers for the mo*ement of the piston in reciprocating manner2
1he bottom end co*er has a bore in center whose diameter is slightly larger than
piston rod diameter2 1he force during the return stro&e is less compared to that of the
forward stro&e because in the former5 the piston rod co*ers some area so that the air
cannot concentrate in the piston rod area2
2.2.1. Prt& o1 P"eumt!/ C)(!"der
P!&to"
1he piston is a cylindrical member of certain length which reciprocates inside the
cylinder2 1he diameter of the piston is slightly less than that of the cylinder bore diameter
and it is fitted to the top of the piston rod2 It is one of the important part which con*erts
the pressure energy into mechanical power2
1he piston is equipped with a ring suitably proportioned and it is relati*ely soft
rubber which is capable of pro*iding good sealing with low friction at the operating
pressure2 1he purpose of piston is to pro*ide means of con*eying the pressure of air
inside the cylinder to the piston of the oil cylinder2
<enerally piston is made up of
)luminium alloy-light and medium wor&2
0rass or bron6e or "I-Cea*y duty2
1he piston is double acting type2 1he piston mo*es forward when the high-
pressure air is turned from the right side of cylinder2 1he piston mo*es bac&ward when
high pressure acts on the piston from the left side of the cylinder2 1he piston should be as
strong and rigid as possible2
1he efficiency and economy of the machine primarily depends on the wor&ing of
the piston2 It must operate in the cylinder with a minimum of friction and should be able
to withstand the high compressor force de*eloped in the cylinder and also the shoc& load
during operation2
1he piston should posses the following qualities2
a2 1he mo*ement of the piston not creates much noise2
b2 It should be frictionless2
c2 It should withstand high pressure2
P!&to" Rod
1he piston rod is circular in cross section2 It connects piston with piston of other
cylinder2 1he piston rod is made of mild steel ground and polished2 ) high finish is
essential on the outer rod surface to minimi6e wear on the rod seals2 1he piston rod is
connected to the piston by mechanical fastening2 1he piston and the piston rod can be
separated if necessary2
;ne end of the piston rod is connected to the bottom of the piston2 1he other end
of the piston rod is connected to the other piston rod by means of coupling2 1he piston
transmits the wor&ing force to the oil cylinder through the piston rod2 1he piston rod is
designed to withstand the high compressi*e force2 It should a*oid bending and withstand
shoc& loads caused by the cutting force2 1he piston mo*es inside the rod seal fi9ed in the
bottom co*er plate of the cylinder2 1he sealing arrangements pre*ent the lea&age of air
from the bottom of the cylinder while the rod reciprocates through it2
C)(!"der Co3er P(te&
1he cylinder should be enclosed to get the applied pressure from the compressor
and act on the pinion2 1he cylinder is thus closed by the co*er plates on both the ends
such that there is no lea&age of air2 )n inlet port is pro*ided on the top co*er plate and an
outlet ports on the bottom co*er plate2 1here is also a hole drilled for the mo*ement of
the piston2
1he cylinder co*er plate protects the cylinder from dust and other particle and
maintains the same pressure that is ta&en from the compressor2 1he flange has to hold the
piston in both of its e9treme positions2 1he piston hits the top plat during the return
stro&e and hits the bottom plate during end of forward stro&e2 So the co*er plates must
be strong enough to withstand the load2
C)(!"der Mou"t!"+ P(te&$
It is attached to the cylinder co*er plates and also to the carriage with the help of
O-@ bends and bolts2
CONTROL .AL.E$
Barious types of control *al*es are used to regulate5 control and monitor the air
energy for control of direction pressure5 flow5 etc2
neumatic energy is regulated and controlled by pneumatic *al*es2 7unctionally
*al*es are di*ided into four ma4or groups2
#irection "ontrol
7low "ontrol
In our pro4ect electrically actuated solenoid operated 'A2 #" *al*es are used2
Solenoid is another name for an electromagnet2 #irection control *al*es are *ery
often actuated by electromagnets2 )n electromagnet is a temporary magnet2 ) magnetic
force is de*eloped in an electromagnet when electrical current passes through it and force
drops down as soon as it is de energi6ed2
1his electromagnet is commonly termed as solenoid2 1he proper wor&ing of a
solenoid operated *al*e depends on the reliability of the electromagnets2
It ensures
Guic& and sure action
-ong life2
Pasy maintenance2
-ess wastage of energy2
So(e"o!d .(3e
1he directional *al*e is one of the important parts of a pneumatic system2
"ommonly &nown as #"B5 this *al*e is used to control the direction of air flow in the
pneumatic system2 1he directional *al*e does this by changing the position of its internal
mo*able parts2
1his *al*e was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of using a
solenoid *al*e2 ) solenoid is an electrical de*ice that con*erts electrical energy into
straight line motion and force2 1hese are also used to operate a mechanical operation
which in turn operates the *al*e mechanism2
Solenoids may be push type or pull type2 1he push type solenoid is one in which
the plunger is pushed when the solenoid is energi6ed electrically2 1he pull type solenoid
is one is which the plunger is pulled when the solenoid is energi6ed2
1he name of the parts of the solenoid should be learned so that they can be
recogni6ed when called upon to ma&e repairs5 to do ser*ice wor& or to install them2

2.5.1. Prt& o1 So(e"o!d .(3e
1. Co!(
1he solenoid coil is made of copper wire2 1he layers of wire are separated by
insulating layer2 1he entire solenoid coil is co*ered with an *arnish that is not affected by
sol*ents5 moisture5 cutting oil or often fluids2 "oils are rated in *arious *oltages such as
11' *olts )"5 2!/ *olts )"5 $(/ *olts )"5 '+' Bolts )"5 ( Bolts #"5 12 Bolts #"5 2$
Bolts #"5 11' Bolts #" Q 2!/ Bolts #"2 1hey are designed for such frequencies as '/
C6 to (/ C62
#. Frme
1he solenoid frame ser*es se*eral purposes2 Since it is made of laminated sheets5
it is magneti6ed when the current passes through the coil2 1he magneti6ed coil attract the
metal plunger to mo*e2 1he frame has pro*isions for attaching the mounting2 1hey are
usually bolted or welded to the frame2 1he frame has pro*isions for recei*ers5 the
plunger2 1he wear strips are mounted to the solenoid frame5 and are made of materials
such as metal or impregnated less fiber cloth2
,. So(e"o!d P(u"+er
1he Solenoid plunger is the mo*er mechanism of the solenoid2 1he plunger is
made of steel laminations which are ri*eted together under high pressure5 so that there
will be no mo*ement of the lamination with respect to one another2 )t the top of the
plunger a pin hole is placed for ma&ing a connection to some de*ice2 1he solenoid
plunger is mo*ed by a magnetic force in one direction and is usually returned by spring
action2
Solenoid operated *al*es are usually pro*ided with co*er o*er either the solenoid
or the entire *al*e2 1his protects the solenoid from dirt and other foreign matter5 and
protects the actuator2 In many applications it is necessary to use e9plosion proof
solenoids2
2.5.#. 0or*!"+ o1 So(e"o!d .(3e
1he solenoid *al*e has ' openings2 1his ensure easy e9hausting of 'A2 *al*e2 1he
spool of the 'A2 *al*e slide inside the main bore according to spool position: the ports get
connected and disconnected2 1he wor&ing principle is as follows2
Po&!t!o"-1
%hen the spool is actuated towards outer direction port O@ gets connected to O0@
and OS@ remains closed while O)@ gets connected to O8@
Po!&!t!o"-#
%hen the spool is pushed in the inner direction port O@ and O)@ gets connected to
each other and O0@ to OS@ while port O8@ remains closed2
HOUSE AND FITINGS$
It is pro*ided for the passage of compressed air from the compressor outlet to the
operating *al*e2
1wo separate pipes also connect the operating *al*e with the wor&ing cylinder
pressure drop through and air line depends on the flow rate5 pipe diameter5 pipe length
and pipe geometry2 It can be determined directly for straight pipes of any gi*en length2
) small chaining bore si6e can ha*e mar&ed effect on pressure drop5 where as e*en
doubling the pipe length5 will only result in doubling the pressure drop2
ressure drop through bends and fittings can only be determined by empirical
tests5 since it is specific to the internal geometry in*ol*ed2 8igid pipes howe*er are less
manipulated through remain form of bends with arrangements increase and *ariable air
ha*e to flow and the flow itself may be of fluctuating or pulsating nature2 In this case it
is thus normally based on practical recommendation2
SEALS$
Seal is an important component of a pneumatic system and is used to pre*ent the
air lea&age through the 4oint2
1his pro4ect passes the static seal which are used to pre*ent the lea&age through
the stationary surface2
>aterial of the seal is 1eflon tape2 1eflon has the following properties
%ithstand the system pressure and temperature without any damage2
8esist the wear and abrasion2
8eco*er from deformation2
8esists the ad*erse effects such as deterioration and shrin&ing
caused by the system air2
Seals are de*ices for closing gaps to pre*ent lea&age or ma&e pressure 4oints and
also to pre*ent the entry of air and dirt from outside into the system2 1he material of seal
must be compatible with the fluid medium2 It is a circular ring made of synthetic rubber2
It is used for pro*iding tight sealing between the piston and the cylinder wall2 It pre*ents
air lea&age from the top and bottom of the cylinder2
Seals for air cylinder and *al*es are not normally called upon to seal pressure
higher than about 2 bars2 Since the fluid to be seated is a gas5 Lin our case airM rubbing
speeds tends to be high and the seal the seal may ha*e to be operated under dry
conditions with minimal lubrication2
CONTROL TIMER CIRCUIT$
Need 1or T!mer C!r/u!t$
>ain purpose to timer circuit is to actuate the solenoid *al*e at regular inter*al of
time to achie*e proper lubrication at the desired inter*al2
ELECTRONIC CONTROL TIMING UNIT$-
2 6
7 IC
555
8 ,
# 1
18
,
2917
#
12
2
1, 6
Cere the ''' I" has been used as a multi *ibrator2 1he output of I" ''' is fed to
the input pin Lpin no 1$M of "# $/1+ continues counting2
1he output of the I" becomes a*ailable at pin 3os2 !5 2 and $2 1he output pulse of
any one of output pin triggers Luts ;3M the 1riac and current starts flowing across the
load connected2 1his process continues on other pins at different time inter*als and the
cycle continues2 1he frequency inter*al L1imeM of the cycle can be ad4usted by the pre-set
loo& connected to pin ( of ''' 1imer I"2


2A-#,9. : ,
27;
L1
TRIAC : ,
1N2997 : ,
L#
19;
L,
199=F 1N2997 : 2
1N2997
1999=F

#,9<=.
1 ,


2 +
IC
NE 555
! (
$ '

#,9. A<C I<P
IC 555 TIMER
1he I" SP A 3P ''' monolithic circuit is a highly stable controller capable of
producing accurate time delays or oscillations2 )dditional terminals are pro*ided for
triggering or resetting if desired2 In the timing operations5 the time is precisely controlled
by one e9ternal resistor and a capacitor5 by the operation as an oscillator5 the free running
frequency and the duty cycle are both accurately contributed with the e9ternal 8"
constants2
PIN DIAGRAM$
GROUND SUPPLY >.//?
TRIGGER DISCHARGE
OUTPUT THERSOLD
RESET CONTROL
PIN NO$ 1
It is ground terminal2
PIN NO$ #
1he trigger *oltage to the lower comparator is applied2 It has constant *oltage
that is atleast one third of the supply *oltage5 when trigger *oltage falls below this le*el
the flip-flop changes its state and output becomes high2
PIN NO$ ,
It is the output
terminal5 in low state output is equal to
6ero and when at higher state output is
equal to Bcc2
PIN NO$ 2
It controls the flip
flop directly2 It turns the de*ice to its
original position when reset pin is
connected to ground the output is
appro9imately equal to 6ero2 %hen reset is not used it is connected to Bcc2
PIN NO$ 5
It is the control *oltage terminal2 It is connected to ground through a capacitor of /2/1
R72 )ny e9ternal *oltage at pinD ' will change both the threshold *oltage and the trigger
*oltage reference le*el2
PIN NO$ 8
1hreshold *oltage of upper comparator is applied from this terminal2 1he resistor 8t
connected to Bcc and pinD ( is grounded by an e9ternal capacitor2 1he output is high
capacitor charges by resistor 8t2 %hen the capacitor changes to the threshold le*el5 the
output becomes low2
PIN NO$ 7
It is the discharge pin for e9ternal capacitor2 Usually pinD + is connected with pinD (
directly to by a resistor2 %hen the output becomes low then the e9ternal capacitor
discharges by internal discharge transistor remains at cut-off and the e9ternal capacitor
charges to Bcc2
PIN NO$ 6
It is the positi*e supply terminal2 ) dc *oltage from ?' to ? 1' can be applied2
T4e !m%ort"t 1eture& o1 IC555 /" 'e &ummr!@ed & 1o((o-&.
12 1iming range from microseconds to hours2
22 >ono-stable and )stable operation is possible through I"'''2
!2 1he duty cycle can be ad4usted according to our necessity2
$2 It has the ability to operate from a wide range of supply Boltage2
IC 555 SPECIFICATION
Supply Boltage LBccM = $2' to 1'B
Supply "urrent LBcc='BA2M = ! to (m)
Supply "urrent LBcc=2'BA2M = 1/ to 1'm)
;utput "urrent = 2//m) Lma9imumM
ower dissipation = (//mw
FLO0 CONTROL .AL.E$
7low "ontrol Bal*es are fitted to all the distribution tubes2 1his *al*e is made of
brass2 0oth the ends ha*e stepped surface to insert hoses2 ) handle is pro*ided to control
the flow of oil in e*ery *al*e2
>? Te/4"!/( Dt$
Si6e D S
ressure D / to 1/ &g A cm2
>edia D )ir
> ' ? Pur%o&e$
1his *al*e is used to speed up the piston mo*ement and also it acts as an one way
restriction *al*e which means that the air can pass through only one way and it can@t
return bac&2
0y using this *al*e the time consumption is reduced because of the faster
mo*ement of the piston2
---------------------------------------------------------------------------------------
CHAPTE4-4
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
0/4.ING P4INCIP1E
---------------------------------------------------------------------------------------
CHAPTER-2
0OR;ING PRINCIPLE
1he compressed air from the compressor is used as the force medium for this
operation2 1here are pneumatic double acting cylinders5 solenoid *al*e: flow control
*al*e and timer unit used 21he arm from the compressor enters to the floe control Bal*e2
1he controlled air from the flow control *al*e enters to the solenoid *al*e2 1he
function of solenoid *al*es all of air correct time inter*al2 1he 'A2 solenoid *al*e is used2
In one position air enter to the cylinder and pusses the piston5 so that the cutting stro&e is
obtained2
1he ne9t position air enters to the other side of cylinder and pusses the piston
return bac&5 so that the releasing stro&e is obtained2 1he speed of the cutting and releasing
stro&e is *aried by the timer control unit circuit2

---------------------------------------------------------------------------------------
CHAPTE4-5
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
-ESIGN AN- -4A0INGS
---------------------------------------------------------------------------------------
CHAPTER-5
DESIGN AND DRA0INGS
PNEUMATIC CYLINDER
De&!+" o1 P!&to" rod$
-oad due to air ressure2
#iameter of the iston LdM = $/ mm
ressure acting LpM = ( &gfAcm7
>aterial used for rod = " $'
Tield stress L8
y
M = !( &gfAmm7
)ssuming factor of safety = 2
7orce acting on the rod LM = ressure 9 )rea
= p 9 L9d7 A $M
= ( 9 UL 9 9 $7 : A $ V
= +!2!( Kgf
#esign StressL8
y
M = 8y A 7/ S
= !( A 2 = 1, KgfAmm7
= A L9 d7 A $ M
; d = < $ p A 9 W 8
y
X
= < $ 9 +'2!( A U9 9 1,V
= < '2!! = 22! mm
; >inimum diameter of rod required for the load = 22! mm
%e assume diameter of the rod = 1' mm
De&!+" o1 /)(!"der t4!/*"e&&$
>aterial used = "ast iron
)ssuming internal diameter of the cylinder = $/ mm
Ultimate tensile stress = 2'/ 3Amm7 = 2'// gfAmm7
%or&ing Stress = Ultimate tensile stress A factor of safety
)ssuming factor of safety = $
%or&ing stress L f
t
M = 2'// A $ = (2' KgfAcm7
)ccording to O-)>PS PGU)1I;3@
>inimum thic&ness of cylinder L t M = ri U< Lf
t
? pM A Lf
t
p M -1 V
%here5
ri = inner radius of cylinder in cm2
f
t
= %or&ing stress LKgfAcm7M
p = %or&ing pressure in KgfAcm7
; Substituting *alues we get5
t = 22/ U < L(2' ? (M A L (2' (M -1V
t = /2/1. cm = /21. mm
%e assume thic&ness of cylinder = 22' mm
Inner diameter of barrel = $/ mm
;uter diameter of barrel = $/ ? 2t
= $/ ? L 2 9 22' M = $' mm
De&!+" o1 P!&to" rod$
D!meter o1 P!&to" Rod$
7orce of piston 8od LM = ressure 9 area = p 9 9/4 Ld7M
= ( 9 L9 A $M 9 L$M7
= +!2!( Kgf
)lso5 force on piston rod LM = L9A$M Ld
p
M7 9 f
t
= LYA$M 9 LdpM7 9 (2'
+!2!( = LYA$M 9 LdpM7 9 (2'
; dp7 = +!2!( 9 L$AYM 9 L1A(2'M
= /21'
dp = /2!, cm = !2, mm
0y standardi6ing dp = 1' mm
Le"+t4 o1 %!&to" rod$
)pproach stro&e = 1(/ mm
-ength of threads = 2 9 2/ = $/mm
P9tra length due to front co*er = 12 mm
P9tra length of accommodate head = 2/ mm
1otal length of the piston rod = 1(/ ? $/ ? 12 ? 2/
= 2!2 mm
0y standardi6ing5 length of the piston rod = 2!/ mm
---------------------------------------------------------------------------------------
CHAPTE4-+
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
APP1ICATI/NS =
-ISA->ANTAGES
---------------------------------------------------------------------------------------
CHAPTER-8
APPLICATIONS AND DISAD.ANTAGES
APPLICATIONS$-
1his machine is *ery useful for small scale industries
1his machine is used to cut the roller sheet metal
)ll Industrial )pplication
DISAD.ANTAGES$-
%hile wor&ing5 the compressed air produces noise therefore a silencer may
be used2
Cigh torque can not be obtained
-oad carrying capacity of this unit is not *ery high2LZ'/ 3M
---------------------------------------------------------------------------------------
CHAPTE4-?
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
A->ANTAGES
---------------------------------------------------------------------------------------
CHAPTER-7
AD.ANTAGES

1he pneumatic is more efficient in the technical field
Guic& response is achie*ed
Simple in construction
Pasy to maintain and repair
"ost of the unit is less when compared to other machine
3o fire ha6ard problem due to o*er loading
"omparati*ely the operation cost is less
1he operation of cutting is faster because the medium used to operate is air
"ontinuous operation is possible without stopping
---------------------------------------------------------------------------------------
CHAPTE4-@
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
1IST /A MATE4IA1S
---------------------------------------------------------------------------------------
CHAPTER-6
LIST OF MATERIALS
S(.
No.
De&/r!%t!o" At). MATERIAL
/12
/22
/!2
/$2
/'2
/(2
/+2
/,2
.
1/2
112
122
#ouble acting cylinder
Solenoid Bal*e
1imer
7low "ontrol Bal*es
Coses
%ire
Stand
0ase 0oard
Cose "ollar
8educer
7i9ed cutting plate
>o*ing "utting late
1 3o2
1 3o2
1 3o2
1 3o2
2 >
2>
1 3o2
1 3o2
( 3;2
1 3;2
1 3;2
1 3;2
P3,
)-U2
P-P"18;3I"
)-U2
;-TU8P1P3P
-
>S
>S
08)SS2
08)SS
S2S
S2S
---------------------------------------------------------------------------------------
CHAPTE4-B
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
C/ST ESTIMATI/N
---------------------------------------------------------------------------------------
CHAPTER-=
COST ESTIMATION
1. MATERIAL COST$
S(.
No.
De&/r!%t!o" At). MATERIAL COST >RS?
/12
/22
/!2
/$2
/'2
/(2
/+2
/,2
.
1/2
112
122
#ouble acting cylinder
Solenoid Bal*e
1imer
7low "ontrol Bal*es
Coses
%ire
Stand
0ase 0oard
Cose "ollar
8educer
7i9ed cutting plate
>o*ing "utting late
1 3o2
1 3o2
1 3o2
1 3o2
2 >
2>
1 3o2
1 3o2
( 3;2
1 3;2
1 3;2
1 3;2
P3,
)-U2
P-P"18;3I"
)-U2
;-TU8P1P3P
-
>S
>S
08)SS2
08)SS
S2S
S2S
TOTAL B
#. LACOUR COST
-)1CP5 #8I--I3<5 %P-#I3<5 <8I3#I3<5 ;%P8 C)"KS)%5 <)S "U11I3<D
"ost =
,. O.ERHEAD CHARGES
1he o*erhead charges are arri*ed by >anufacturing cost
>anufacturing "ost = >aterial "ost ? -abour cost
=
=
;*erhead "harges = 2/[ of the manufacturing cost
=
TOTAL COST
1otal cost = >aterial "ost ? -abour cost ? ;*erhead "harges
=
=
1otal cost for this pro4ect =
---------------------------------------------------------------------------------------
CHAPTE4-,0
---------------------------------------------------------------------------------------
---------------------------------------------------------------------------------------
C/NC1USI/N
---------------------------------------------------------------------------------------
CHAPTER-19
CONCLUSION
1his pro4ect wor& has pro*ided us an e9cellent opportunity and e9perience5 to use
our limited &nowledge2 %e gained a lot of practical &nowledge regarding5 planning5
designing drawing5 purchasing5 computing and machining while doing this pro4ect wor&2
%e feel that the pro4ect wor& is a good solution to bridge the gates between institution
industries2
%e are proud that we ha*e completed the wor& with the limited time successfully2
1he machine is wor&ing with satisfactory conditions2 %e are able to understand the
difficulties in maintaining the tolerances and also quality2 %e ha*e done to our ability
and s&ill ma&ing ma9imum use of a*ailable facilities2
In conclusion remar&s of our pro4ect wor&5 let us add a few more lines about our
impression pro4ect wor&2
1he chief ad*antage of our system is that5 it cutting speed is *aried2 1he fast
operation is done by the timer unit2 1his pro4ect is a low cost automation pro4ect2
---------------------------------------------------------------------------------------
CIC1I/G4APH3
---------------------------------------------------------------------------------------
CICLIOGRAPHY
12 ) 1e9t 0oo& of >achine #esign----82S2Khurmi Q \2K2<upta5 Purasia ublishing
Couse *t2 -td25 1..+2
22 0uild Tour ;wn #igital "loc&s----8upendra K2 Sharma5 1ata >c<raw Cill
ublications2 1...2
!2 7luid ower with )pplications----)ntony Psposito*5 1ata >c <raw Cill
ublications5 1..,2
$2 7PS1; "ontrol 1echnical #ata 0oo&----7PS1; "ontrol *t2 -td25 1..,2
'2 -inear Integrated "ircuits----#2 8oy "houdhury5 Shail \ain5 3ew )ge
International L*tM -td ublishers5 1...2
(2 2S2<2#esign #ata 0oo&5 7aculty of >echanical Pngg: 2S2<21ech25 >AS #B
rinters5 2///2
+2 neumatic "ontrol System----Stroll Q 0ernaud5 1ata >c <raw Cill ublications5
1...2
,2 neumatic System---->a4umdhar5 3ew )ge India International LM -td
ublishers5 1..+2
.2 Strength of >aterials----S2 8amamurtham Q 82 3arayanan5 #hanpat 8ai
ublishing "orporation5 1..,2
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PH/T/G4APH3
---------------------------------------------------------------------------------------