1.

PROJECT PLANING

Before starting every project its planning is to be done. Planning is

very important task and should be taken with great care, as the efficiency of
the whole project largely depends upon its planning while planning a project
each and every details should be worked out in anticipation and should
carefully is considered with all the relating provisions in advance. Project
planning consists of the following steps.

PROJECT CAPACITY
The capacity of the project must be decided considering the amount of
money which can be invested and availability of material and machines.

DRAWINGS
Drawing been decided for the project to be manufacture. Its detailed
drawing specification for raw material and finished products should be
decided carefully along with the specification of the machines required for
their manufacture.

MATERIAL EQUIPMENT
The list of materials required for manufacture is prepared from the
drawings. The list of is known as BILL OF MATERIALS. This passes to
the store keeper and the required materials taken from the store under
permission of store keeper operation, the necessity of operation, the person

to do the job, machine to be used to do the job are considered while planning
the operation. After considering tea above questions a best method is
developed and the best method is applied to the operation.

MACHINE LOADING
While planning proper care should be taken to find the machining
time for each operation as correct as possible. So that the arrangement for
full utilization of machine can be made machine loading programmed is also
known.

PURCHASE CONSIDERATION
It is different to manufacture all the component needed for the
equipment in the workshop it self. The decision about a particular item
whether to purchase or to manufacture is taken by planning after making
through study of relative merits demerits.

EQUIPMENT CONSIDERATION
Result obtained from PROCESS PLANNING and MACHINE
LODING helps in calculating the equipment requirement specification of
the equipment should be laid down by considering the drawing. Drawing
will also help in deciding and necessary requirement of tools, accessories.

COST CALCULATION
The cost of the project can be calculated by adding following.

Material Cost
Machining Cost
Overhead Expenses.

COMPARISION
The various items in the finished project are compared to the
standards for the further correction.

REPORT
At the end of the project work report is prepared for future references.
The report consists of all the items done the project work.

1. PNEUMATIC JACK HAMMER

A jackhammer is a pneumatic tool that combines a hammer directly with a
chisel that was invented by Charles Brady King.[1] Hand-held jackhammers
are typically powered by compressed air, but some use electric motors.
Larger jackhammers, such as rig mounted hammers used on construction
machinery, are usually hydraulically powered. They are usually used to
break up rock, pavement, and concrete. In modern terminology, a
"jackhammer" does not have the capacity to drill rock.
A jackhammer operates by driving an internal hammer up and down. The
hammer is first driven down to strike the back of the bit and then back up to
return the hammer to the original position to repeat the cycle. The bit usually
recovers from the stroke by means of a spring. The effectiveness of the
jackhammer is dependent on how much force is applied to the tool.

History
Pneumatic drills were developed in response to the needs of mining,
quarrying, excavating, and tunneling. The first "percussion drill" was made
in 1848 and patented in 1849 by Jonathan J. Couch of Philadelphia,
Pennsylvania.

[2]

In this drill, the drill bit passed through the piston of a

steam engine. The piston snagged the drill bit and hurled it against the rock
face. It was an experimental model. In 1849, Couch's assistant, Joseph W.
Fowle, filed a caveat for a percussion drill of his own design. In Fowles
drill, the drill bit was connected directly to the piston in the steam cylinder;
specifically, the drill bit was connected to the pistons crosshead. The drill

also had a mechanism for turning the drill bit around its axis between strokes
and for advancing the drill as the hole deepened. [3] By 1850 or 1851, Fowle
was using compressed air to drive his drill, making it the first true pneumatic
drill.[4]
The demand for pneumatic drills was driven especially by miners and
tunnelers because steam engines required fires in order to operate and the
ventilation in mines and tunnels was inadequate to vent the fires' fumes;
there was also no way to convey steam over long distances (e.g., from the
surface to the bottom of a mine); furthermore, mines and tunnels
occasionally contained flammable explosive gases such as methane. By
contrast, compressed air could be conveyed over long distances without loss
of its energy, and after the compressed air had been used to power
equipment, it could still serve to ventilate a mine or tunnel.
In Europe since the late 1840s, the king of Sardinia, Carlo Alberto, had been
contemplating the excavation of a 12-kilometer (7.5 mi) tunnel through
Mount Frjus in order to create a rail link between Italy and France, which
would cross his realm. [5][6] The need for a mechanical rock drill was obvious
and this sparked research on pneumatic rock drills in Europe. A Frenchman,
Cav, designed, and in 1851 patented, a rock drill that used compressed air;
however, the air had to be admitted manually to the cylinder during each
stroke, so it was not successful.[7] In 1854, in England, Thomas Bartlett made
and then patented (1855) a rock drill in which the drill bit was connected
directly to the piston of a steam engine. In 1855 Bartlett demonstrated his
drill, powered by compressed air, to officials of the Mt. Frjus tunnel
project.[8] (In 1855, a German, Schumann, invented a similar pneumatic rock
drill in Freiburg, Germany.[9]) Bartletts drill was refined by the Savoy-born

engineer Germain Sommeiller (1815-1871) and his colleagues, Grandis and

Grattoni, by 1861.[10] Thereafter, many inventors refined the pneumatic drill.
[11]

Terminology
The word "jackhammer" is used in North American English and Australia,
while "pneumatic drill" is used colloquially elsewhere in the English
speaking world, although strictly speaking a "pneumatic drill" refers to a
pneumatically driven jackhammer.[12] In Britain, the term "jackhammer"
usually refers to electromechanical version of the tool.[citation needed]
Use
A full-sized portable jackhammer is impractical for use against walls and
steep slopes, except for a very strong man, as the user would have to both
support the weight of the tool, and push the tool back against the work after
each blow. A technique developed by experienced workmen is a two-man
team to overcome this obstacle of gravity: one man operates the hammer and
the second assists by holding the hammer either on his shoulders or cradled
in his arms. Both use their combined weight to push the bit into the
workface.

This

method

is

commonly

referred

to

as

horizontal

jackhammering.
Another method is overhead jackhammering, requiring strength conditioning
and endurance to hold a smaller jackhammer, called a rivet buster, over one's
head. To make overhead work even safer a platform can be used. One such
platform is a P.A.M. Positioner Actuator Manipulator. This unit take all the
weight and vibration from the user.

Types
Pneumatic

A compressor for running a pneumatic jackhammer

A pneumatic jackhammer, also known as a pneumatic drill or pneumatic
hammer,[13] is a jackhammer that uses compressed air as the power source.
The air supply usually comes from a portable air compressor driven by a
diesel engine. Reciprocating compressors were formerly used. The unit
comprised a reciprocating compressor driven, through a centrifugal clutch,
by a diesel engine. The engine's governor provided only two speeds:

idling, when the clutch was disengaged

maximum, when the clutch was engaged and the compressor was
running

Modern versions use rotary compressors and have more sophisticated

variable governors. The unit is usually mounted on a trailer and sometimes
includes an electrical generator to supply lights or electric power tools.
Additionally, some users of pneumatic jackhammers may use a pneumatic
lubricator which is placed in series with the air hose powering the air
hammer. This increases the life and performance of the jackhammer.
Specific lubricant in filled in the pneumatic lubricator. Furthermore, air
compressors typically incorporate moisture into the compressed air leading
to freeze-ups of the jackhammer or air hammer in cold weather.
Electromechanical

A single phase demolition breaker.

This section requires expansion.
This tool is useful where the work is light and access to a compressor is
limited or impractical. It requires a heavy duty extension cord to power the
motor instead.

Hydraulic

An excavator-mounted hydraulic jackhammer being used to break up

concrete.
A hydraulic jackhammer, much larger than portable ones, may be fitted to
mechanical excavators or backhoes and is widely used for roadwork,
quarrying and general demolition or construction groundwork. These larger
machine mounted breakers are known as Rig Mounted, or Machine Mounted
Breakers. Such tools can also be used against vertical walls (or ceilings for
that matter), since the vehicles involved are massive enough and powerful
enough to exert the forces involved without needing the help of gravity in
operating the tool. Pneumatic or hydraulic tools are particularly likely to be
used in mines where there is an explosion risk (such as underground coal
mines), since they lack any high-power electrical circuitry that might cause a
triggering spark.
Hydraulic breakers usually use a hydraulic motor driving a sealed pneumatic
hammer system, as a hydraulic hammer would develop a low strike speed
and transfer unacceptable shock loads to the pump system.

Health

A jackhammer with black silencer attached

The sound of the hammer blows, combined with the explosive air exhaust,
makes pneumatic jackhammers dangerously loud, emitting 100 decibels at
two meters. Sound-blocking earmuffs must be worn by the operator to
prevent a form of hearing damage of which tinnitus is the main symptom.
Most pneumatic jackhammers now have a silencer around the barrel of the
tool.
Prolonged exposure to the pronounced vibration set up by the tool can lead
to blood-circulation failures in the fingers, a condition known as white
finger. Applying athletic tape is not effective in preventing white finger but
seems to help alleviate some of its discomfort. Pneumatic drill usage can
also lead to a predisposition for development of carpal tunnel syndrome.

SELECTION OF PNEUMATICS:
Mechanization is broadly defined as the replacement of manual effort by
mechanical power.

Pneumatics is an attractive medium for low cost

mechanization particularly for sequential or repetitive operations. Many factories

and plants already have a compressed air system, which is capable of providing
both the power or energy requirements and the control system (although equally
pneumatic control systems may be economic and can be advantageously applied to
other forms of power).

The main advantages of an all-pneumatic system are usually economy and

simplicity, the latter reducing maintenance to a low level. It can also have out
standing advantages in terms of safety.

2. CLASSIFICATION OF AIR COMPRESSOR

2.1 INTRODUCTION OF THE COMPRESSOR

A gas compressor is a mechanical device that increases the pressure of a gas

by reducing its volume.
Compressors are similar to pumps, both increase the pressure on a fluid and
both can transport the fluid through a pipe. As gases are compressible, the
compressor also reduces the volume of a gas. Liquids are relatively
incompressible, so the main action of a pump is to pressurize and transport
2.2 Types of compressors
Centrifugal compressors
Diagonal or mixed-flow compressors
Axial-flow compressors
Reciprocating compressors
Rotary screw compressors
Rotary vane compressors
Scroll compressors
The main types of gas compressors are
CENTRIFUGAL COMPRESSOR
Centrifugal compressors use a rotating disk or impeller in a shaped
housing to force the gas to the rim of the impeller, increasing the velocity of
the gas. A diffuser (divergent duct) section converts the velocity energy to
pressure energy. They are primarily used for continuous, stationary service
in industries such as oil refineries, chemical and petrochemical plants and
natural gas processing plants. Their application can be from 100 horsepower

(75 kW) to thousands of horsepower. With multiple staging, they can

achieve extremely high output pressures greater than 10,000 psi (69 MPa).
Many large snow-making operations (like ski resorts) use this type of
compressor. They are also used in internal combustion engines as
superchargers and turbochargers. Centrifugal compressors are used in small
gas turbine engines or as the final compression stage of medium sized gas
turbines.
MIXED FLOW COMPRESSOR
Diagonal or mixed-flow compressors are similar to centrifugal compressors,
but have a radial and axial velocity component at the exit from the rotor. The
diffuser is often used to turn diagonal flow to the axial direction. The
diagonal compressor has a lower diameter diffuser than the equivalent
centrifugal compressor.
[edit]
Axial-flow compressors
Main article: Axial-flow compressor
AXIAL FLOW COMPRESSOR
Axial-flow compressors are dynamic rotating compressors that use arrays of
fan-like airfoils to progressively compress the working fluid. They are used
where there is a requirement for a high flow rate or a compact design.

The arrays of airfoils are set in rows, usually as pairs: one rotating and one
stationary. The rotating airfoils, also known as blades or rotors, accelerate
the fluid. The stationary airfoils, also known as a stators or vanes, decelerate
and redirect the flow direction of the fluid, preparing it for the rotor blades
of the next stage.[1] Axial compressors are almost always multi-staged, with
the cross-sectional area of the gas passage diminishing along the compressor
to maintain an optimum axial Mach number. Beyond about 5 stages or a 4:1
design pressure ratio, variable geometry is normally used to improve
operation.
Axial compressors can have high efficiencies; around 90% polytropic at
their design conditions. However, they are relatively expensive, requiring a
large number of components, tight tolerances and high quality materials.
Axial-flow compressors can be found in medium to large gas turbine
engines, in natural gas pumping stations, and within certain chemical plants.
RECIPROCATING COMPRSSOR
A motor-driven six-cylinder reciprocating compressor that can operate with
two, four or six cylinders.
Reciprocating compressors use pistons driven by a crankshaft. They can be
either stationary or portable, can be single or multi-staged, and can be driven
by electric motors or internal combustion engines. Small reciprocating
compressors from 5 to 30 horsepower (hp) are commonly seen in automotive
applications and are typically for intermittent duty. Larger reciprocating
compressors well over 1,000 hp (750 kW) are still commonly found in large

industrial and petroleum applications. Discharge pressures can range from

low pressure to very high pressure (>6000 psi or 41.4 MPa). In certain
applications,

such

as

air

compression,

multi-stage

double-acting

compressors are said to be the most efficient compressors available, and are
typically larger, noisier, and more costly than comparable rotary units.[6]
Another type of reciprocating compressor is the swash plate compressor,
which uses pistons which are moved by a swash plate mounted on a shaft.

ROTARY SCREW COMPRESSOR

Rotary screw compressors use two meshed rotating positive-displacement
helical screws to force the gas into a smaller space. These are usually used
for continuous operation in commercial and industrial applications and may
be either stationary or portable. Their application can be from 3 horsepower
(2.2 kW) to over 1,200 horsepower (890 kW) and from low pressure to very
high pressure (>1200 psi or 8.3 MPa).
ROTARY VANE COMPRESSOR
Rotary vane compressors consist of a rotor with a number of blades inserted
in radial slots in the rotor. The rotor is mounted offset in a larger housing
which can be circular or a more complex shape. As the rotor turns, blades
slide in and out of the slots keeping contact with the outer wall of the
housing.[1] Thus, a series of decreasing volumes is created by the rotating
blades. Rotary Vane compressors are, with piston compressors one of the
oldest of compressor technologies.

With suitable port connections, the devices may be either a compressor or a

vacuum pump. They can be either stationary or portable, can be single or
multi-staged, and can be driven by electric motors or internal combustion
engines. Dry vane machines are used at relatively low pressures (e.g., 2 bar)
for bulk material movement whilst oil-injected machines have the necessary
volumetric efficiency to achieve pressures up to about 13 bar in a single
stage. A rotary vane compressor is well suited to electric motor drive and is
significantly quieter in operation than the equivalent piston compressor.

SCROLL COMPRESSOR
Mechanism of a scroll pump
A scroll compressor, also known as scroll pump and scroll vacuum pump,
uses two interleaved spiral-like vanes to pump or compress fluids such as
liquids and gases. The vane geometry may be involutes, Archimedean spiral,
or hybrid curves. They operate more smoothly, quietly, and reliably than
other types of compressors in the lower volume range
Often, one of the scrolls is fixed, while the other orbits eccentrically without
rotating, thereby trapping and pumping or compressing pockets of fluid or
gas between the scrolls.
This type of compressor was used as the supercharger on Volkswagen G60
and G40 engines in the early 1990's.

3. INTRODUCTION OF PEUMATIC YLINDER

Pneumatic cylinders are the devices for converting the air pressure into
linear mechanical force and motion. They are basically used for single

purpose applications such as clamping, tilting, bending, turning and many

other applications.
The Pneumatic power is converted to straight line reciprocating motion by
pneumatic cylinders. The various industrial applications for which air
cylinders are used can be divided duty wise into the groups. They are light
duty, medium duty and heavy duty but according to the operating principle
air cylinders can be sub divided as 1.single-acting, 2.Double- acting
cylinders. Since our project is based on single acting cylinder we shall see
deep about it.
In a single-acting cylinder, compressed air is fed only in one side hence, this
cylinder can produce work only in one direction the return movement of the
piston is affected by a builtin spring or by application of an external force
the spring is designed to return the piston to its initial position with a
sufficiently high speed.

4. PNEUMATIC COMPONENTS
SELECTION OF PNEUMATICS

Mechanization is broadly defined as the replacement of manual effort

by mechanical power. Pneumatics is an attractive medium for low cost
mechanization particularly for sequential or repetitive operation.

Many

factories and plants already have a compressed air system, which is capable
of providing both the power or energy requirements and the control system
(although equally pneumatic control system may be economic and can be
advantageously applied to other forms of power).
The main advantages of an all- pneumatic system are usually
economy and simplicity, the latter reducing maintenance to a low level. It
can also have out standing advantages in terms of safety.
The single acting pneumatic cylinder consists of the following
components to the requirements of complete operation of the machine.
1. piston
2. cylinder
3. Ram
4. End plate
5. Return spring
6. Nipple

4.1 COMPONENT DESCRIPTION

Cylinder

An air cylinder is an operating device in which the state input

energy of compressed air i.e., pneumatic power is converted into mechanical
output power by reducing the pressure of air to that of atmosphere
Ram
It is an output device when the pressure inside the cylinder
exceeds the limit the ram actuates. This actuation is used for the operation.
End plate
End plates are connected to both the ends of the cylinder. Pressure
acts mainly on both the end plates. It is made up of ms plate.
Nipple
Air from the compressor is passed through the nipple in to the
cylinder it is made up of mild steel
Stud and nut
It is used to connect two plates or some members of the setup.
Here stud and nut are used to connect the plates
Spring
Open coil spring is used in this system.
Piston
It is the main component which is placed inside the cylinder. It is
used to force the ram in and out by the action of compressed air.

CYLINDER:

The cylinder is a single acting cylinder one, which means that the air
pressure operates alternatively (forward and backward).

The air from the

compressor is passed through the regulator which control the pressure to

required amount by adjusting its knob. A pressure gauge is attached to the
regulator for showing the line pressure.
Then the compressed air is passed though the directional control valve
for supplying the air alternatively to either sides of the cylinder. Two hoses
take the output of the directional control valve and they are attached to two
ends of the cylinder by means of connectors. One of the output from the
directional control valve is taken to the flow control valve from taken to the
cylinder.
Pneumatic cylinder
An air cylinder is an operative device in which the state input energy
of compressed air i.e. pneumatic power is converted in to mechanical output
power, by reducing the pressure of the air to that of the atmosphere.
SOLENOID VALVE WITH CONTROL UNIT:

The directional valve is one of the important parts of a pneumatic system.

Commonly known as DCV, this valve is used to control the direction of air flow in

the pneumatic system. The directional valve does this by changing the position of
its internal movable parts.

This valve 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 valve. A solenoid is an electrical device that converts
electrical energy into straight line motion and force. These are also used to
operate a mechanical operation which in turn operates the valve mechanism.
Solenoids may be push type or pull type. The push type solenoid is one in which
the plunger is pushed when the solenoid is energized electrically. The pull type
solenoid is one is which the plunger is pulled when the solenoid is energized.

The name of the parts of the solenoid should be learned so that they can be
recognized when called upon to make repairs, to do service work or to install
them.

Parts of a Solenoid Valve

1. Coil

The solenoid coil is made of copper wire. The layers of wire are separated
by insulating layer. The entire solenoid coil is covered with an varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in
various voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC,
6 Volts DC, 12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are
designed for such frequencies as 50 Hz to 60 Hz.

2. Frame
The solenoid frame serves several purposes. Since it is made of laminated
sheets, it is magnetized when the current passes through the coil. The magnetized
coil attracts the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted or welded to the frame. The frame has
provisions for receivers, the plunger. The wear strips are mounted to the solenoid
frame, and are made of materials such as metal or impregnated less fiber cloth.

3. Solenoid Plunger

The Solenoid plunger is the mover mechanism of the solenoid.

The

plunger is made of steel laminations which are riveted together under high

pressure, so that there will be no movement of the lamination with respect to one
another. At the top of the plunger a pin hole is placed for making a connection to
some device. The solenoid plunger is moved by a magnetic force in one direction
and is usually returned by spring action. Solenoid operated valves are usually
provided with cover over either the solenoid or the entire valve. This protects the
solenoid from dirt and other foreign matter, and protects the actuator. In many
applications it is necessary to use explosion proof solenoids.

WORKING OF 3/2 SINGLE ACTING SOLENOID (OR) CUT OFF VALVE:

The control valve is used to control the flow direction is called cut off
valve or solenoid valve. This solenoid cut off valve is controlled by the emergency
push button. The 3/2 Single acting solenoid valve is having one inlet port, one
outlet port and one exhaust port. The solenoid valve consists of electromagnetic
coil, stem and spring. The air enters to the pneumatic single acting solenoid valve
when the push button is in ON position.

4.2 TYPES OF CYLINDERS

1. SINGLE ACTING
Air pushes the piston in one direction and the piston is returned by
means of an external means.
2. DOUBLE ACTING CYLINDER
The force exerted by the compression spring moves the piston in both the
direction.

3. CUSHION END CYLINDER

Cushion is used in the end position to prevent sudden damaging impacts.
4. TANDEM CYLINDER
Here two cylinders are arranged in series so that the force obtained from
the cylinder is almost double.
5. DUAL LINER CYLINDER (3-POSITION)
Similar to the tandem cylinder, but the piston and the rod assemblies of a
dual actuator are not fastened together like tandem cylinder.
6. DOUBLE -ROD CYLINDER (THROUGH ROD CYLINDRE)
It has piston rod extending from both the ends of the cylinders. It
produces equal force and speed on both sides of the cylinder.

7. TELESCOPIC CYLINDER
It is a two stage double acting telescopic cylinder.
8. TURN CYLINDER (ROTARY CYLINDER)
It has a piston rod having rack and pinion arrangement in such a manner
that liner movement of the piston rod ,the worm wheel rotates at
45,90,180.

5. CONSTRUCTION AND WORKING OF PNEUMATIC

CYLINDER

CONSTRUCTION
Generally a single acting cylinder mainly consists
of following parts such as end plate, piston, cylinder, return spring, ram and
nipple. The spring is placed inside the cylinder and it covers the ram. The piston
is placed upon the spring. The end plates are fitted on both sides of the cylinder

by four cover screws or tie rods. Ram is fixed to the piston and it moves along the
piston. The nipple is found outside the cylinder.
Working
In pneumatic cylinder air is being compressed by the compressor and it is fed
into the cylinder through the nipple using dc valve. This compressed air moves
the piston in one direction against the spring force. The maximum pressure
applied inside the cylinder is 10-12bar.The piston is connected by a ram, the ram
moves along with the piston when the compressed air moves the piston. This
makes a linear movement of the ram. In single acting cylinder the stroke is
limited to the compressed length of the spring. When the compressed air entering
the cylinder is less the piston comes to its original position by the action of spring
force. The moving ram performs many operations such as slotting, punching etc.

6. BORING OPERATION OF PNEUMATIC CYLINDER

FORMING

Boring is the operation of enlarging a hole. The single point cutting

tool is used for a boring operation. Generally a single point tool bit is
mounted in the boring bar of suitable diameter commensurate with the
diameter to be bored. The over hang of the tool is to be made as small as
possible to reduce the chatter which is very common in boring. The work
piece were a hole is already existing is mounted on the table of a horizontal

boring machine. The table of a horizontal boring machine has accurate guide
ways to move the table into perpendicular direction.

HONING
Honing is a low abrading process whish uses bonded abrasive Sticks
for removing stock from metallic surfaces. However, it can also be Used for
external cylindrical surfaces as well as flat surfaces. It is most Commonly
used for internal surface. Those is an operation performed as The final
operation to correct the errors that have occurred from the previous
Machining operation. The advantages of honing are.
(a) Correction of geometrical accuracy
(1) Out of roundness
(2) Taper
(3) Axial distortion
(b) Dimensional accuracy

7. INTRODUCTION OF THE STRUCTURE

Structural steel is steel construction material, a profile, formed with a

specific shape or cross section and certain standards of chemical
composition and strength. Structural steel shape, size, composition, strength,
storage, etc, is regulated in most industrialized countries.
Structural steel members, such as I-beams, have high second moments of
area, which allow them to be very stiff in respect to their cross-sectional
area.
A steel I-beam, in this case used to support wood beams in a house.
Structural steel in construction: A primed steel beam is holding up the floor
above, which consists of a metal deck (Q-Deck), upon which a concrete slab
has been poured.
Steel beam through-penetration with incomplete fireproofing.
Metal deck and OWSJ (Open Web Steel Joist), receiving first coat of spray
fireproofing plaster, made of polystyrene leavened gypsum. Contents
1 Common structural shapes
2 Standards
2.1 Standard structural steels
2.2 Standard structural steels
2.2.1 Carbon steels
2.2.2 High strength low alloy steels

2.2.3 Corrosion resistant high strength low alloy steels

2.2.4 Quenched and tempered alloy steels
3 Steel vs. concrete
4 Thermal properties
5 Fireproofing of structural steel

COMMON STRUCTURAL SHAPES

In most developed countries, the shapes available are set out in

published standards, although a number of specialist and proprietary cross
sections are also available.
I-beam (I-shaped cross-section - in Britain these include Universal Beams
(UB) and Universal Columns (UC); in Europe it includes the IPE, HE, HL,
HD and other sections; in the US it includes Wide Flange (WF) and H
sections)
Z-Shape (half a flange in opposite directions)
HSS-Shape (Hollow structural section also known as SHS (structural hollow
section) and including square, rectangular, circular (pipe) and elliptical cross
sections)
Angle (L-shaped cross-section)
Channel ( [-shaped cross-section)
Tee (T-shaped cross-section)
Rail profile (asymmetrical I-beam)

Railway rail
Vignoles rail
Flanged T rail
Grooved rail
Bar a piece of metal, rectangular cross sectioned (flat) and long, but not so
wide so as to be called a sheet.
Rod, a round or square and long piece of metal or wood, see also rebar and
dowel.
Plate, sheet metal thicker than 6 mm or 1/4 in.
Open web steel joist
While many sections are made by hot or cold rolling, others are made by
welding together flat or bent plates (for example, the largest circular hollow
sections are made from flat plate bent into a circle and seam-welded).
Standard structural steels
Most steels used throughout Europe are specified to comply with the
European standard EN 10025. However, many national standards also
remain in force.
Typical grades are described as 'S275J2' or 'S355K2W'. In these examples,
'S' denotes structural rather than engineering steel; 275 or 355 denotes the
yield strength in newtons per square millimetre or the equivalent
megapascals; J2 or K2 denotes the materials toughness by reference to
Charpy impact test values; and the 'W' denotes weathering steel. Further
letters can be used to designate normalized steel ('N' or 'NL'); quenched and

tempered steel ('Q' or 'QL'); and thermo mechanically rolled steel ('M' or
'ML').
The normal yield strength grades available are 195, 235, 275, 355, 420, and
460, although some grades are more commonly used than others e.g. in the
UK, almost all structural steel is grades S275 and S355. Higher grades are
available in quenched and tempered material (500, 550, 620, 690, 890 and
960 - although grades above 690 receive little if any use in construction at
present).
]
Thermal properties
The properties of steel vary widely, depending on its alloying elements.
The austenizing temperature, the temperature where a steel transforms to an
austenite crystal structure, for steel starts at 900C for pure iron, then, as
more carbon is added, the temperature falls to a minimum 724C for eutectic
steel (steel with only .83% by weight of carbon in it). As 2.1% carbon (by
mass) is approached, the austenizing temperature climbs back up, to 1130C.
Similarly, the melting point of steel changes based on the alloy.
The lowest temperature at which a plain carbon steel can begin to melt, its
solidus, is 1130 C. Steel never turns into a liquid below this temperature.
Pure Iron ('Steel' with 0% Carbon) starts to melt at 1492 C (2720 F), and is
completely liquid upon reaching 1539 C (2802 F). Steel with 2.1% Carbon
by weight begins melting at 1130 C (2066 F), and is completely molten
upon reaching 1315 C (2400 F). 'Steel' with more than 2.1% Carbon is no

longer Steel, but is known as Cast iron. http://www.msm.cam.ac.uk/phasetrans/images/FeC.gif

]
Fireproofing of structural steel
In order for a fireproofing product to qualify for a certification listing of
structural steel, through a fire test, the critical temperature is set by the
national standard, which governs the test. In Japan, this is below 400C. In
China, Europe and North America, it is set at ca. 540C. The time it takes for
the steel element that is being tested to reach the temperature set by the
national standard determines the duration of the fire-resistance rating.
Care must be taken to ensure that thermal expansion of structural elements
does not damage fire-resistance rated wall and floor assemblies. Penetrants
in a firewalls and ferrous cable trays in organic firestops should be installed
in accordance with an appropriate certification listing that complies with the
local building code.

8.PROCESS CHART
PART NAME

MACHINING OPERATION

Cylinder bore

Boring, hack sawing, Reaming.

Pneumatic Cylinder

Turning, Grooving, Drilling,

Tapping.

Ram

Turning, Facing, Thread forming.

End plate / Gas cutting

Drilling.

Grinding, Shaping, grooving,

Stud

Turning, Threading.

Guide `

Facing, chamfering, welding.

9. DESIGN ASPECTS

PROPERTIES OF MILD STEEL:

Physical property
density-7860kg/m
melting point-1427C
thermal conductivity-63w/mk
CARBON CONTENT
Low corrosion or mild steel-0.15% to 0.45% of carbon
MECHANICAL PROPERTY
elasticity
ductility
toughness
weld ability
In our design screwed spindles have a main part hence the calculations are
concentrated on it.

10. MATERIALS USED

NAME OF THE COMPONENTS

MATERIALS

Cylinder
Piston
Ram
Spring
Nipple
End plate

M.S rod
M.S with chromium
M.S rod
M.S
M.S rod
M.S plate

11. COST ESTIMATION

S.NO

COMPONENT

QUANTITY

Pneumatic
cylinder
3/2 Direction
control valve
Pneumatic
accessories
Structure work
Machining cost

MATERIAL
USED
M.S

750

450

M.S

1450

2
3
4

COST(RS)
2800

TOTAL 5450

Total material cost =5450

Assembly cost =150
Total cost of the project=5600

12. ADVANTAGE

1. It does not require current carrying cables.

2. No extra skill is required for operating this system.
3. Easier maintenance
4. Operation is very smooth and in this system we can get more output
by applying less effort.
5. Simple construction of pneumatic elements and easy handling.
6. Comparatively cheaper in cost then the other systems.
7. Compared to hydraulic and mechanical Punching machine pneumatic
Punching machine is economical
8. Efficient Hammer action.

LIMITATION
1. Stroke length is fixed
2. Even a bit of leakage may result in power loss
3. The max pressure is used in the cylinder is (6-12bar)

13. APPLICATIONS
A hammer drill is well suited for drilling hole in msonary or stone. It is also
used to drill holes in concrete footings to pin concrete wall farms to drill
holes in concrete floors to pin wall framing.

14. WORKING PRINCIPLES OF THE PNEUMATIC HAMMER

A Pneumatic hammer machine is used for blow and drilling for any
hard surface.. The pneumatic hammer machine is ideal for job fixers and
general engineering applications. They are smooth operating systems for
both vertical and horizontal operations. The fixing capacity of Pneumatic
ram fixers varies as per the strength, power and performance. They are
suited for various types of fixing and forming applications. Before operating
the hammering machine, first insert the required fixing job in the bed to the
release valve turn the operating handle clock wise until release valve.
After the job is fixed on the base the pneumatic source is executed. At once
the system will function aswellas hammering action will performed.

15. LINE DIAGRAM OF THE PNEUMATIC HAMMER

PUNCHING MACHINE

CONCLUSION:
This report deals with the design and fabrication of pneumatic
hammer machine and it is attached with the line diagram with design . The
pneumatic system can be found in almost all industries /fields. However
some of the industrial application is punching, clamping, materials handling,
hammering throughout the project period we gained knowledge on all type
of machining Process and pneumatic system is controlled. We have done to
our ability and skill making maximum use of available facilities.

BIBLOGRAPHY
GUPTA J.K and KHURUMI R.S (1981) Text book of Machine
Design, S.Chand & comp and.
Parr. ANDREW (2003) Hydraulic & Pneumatics Butterworth
Heimann Ltd
Dr.D.K.AGGARVAL & Dr.P.C SHARMA(2004) machine design,
S.K.Kataria and sons
MAJUMDAR.S.R Pneumatic systems, Tata mcgraw-hills company
ltd.
SRINIVASAN.R(2004) Hydraulic & pneumatic controls, vijay
Nicole imprints private ltd.