Professional Documents
Culture Documents
INTRODUCTION
INTRODUCTION
1.1 INTRODUCTION:
The main objective of our project is to perform various machining operations using
Auto feed mechanism in drilling machine with the help of pneumatic sources. For a
developing industry the operation performed and the parts (or) components produced should
have it minimum possible production cost for it to run profitability.
In small-scale industries and automobile maintenance shops, there are frequent needs
of tightening and loosening of screws, drilling, boring, grinding ,reaming ,taping and broaching
machine.
Huge and complicated designed parts cannot be machined with the help of an ordinary
machine and further for every operation separate machine is required therefore increasing the
number of machines required and increasing the area required for them to be accommodated
and hence overall initial cost required. In our project the above complicated problems are
minimized.
By the application of pneumatics, the pneumatic cylinder with piston which is operated
by an air compressor will give the successive action to operate this machine. By this we can
achieve our industrial requirements.
1.2 AUTOMATION:
Automation is the conversion of a work process, a procedure, or equipment to
automatic rather than human operation or control. Automation does not simply transfer
human functions to machines, but involves a deep reorganization of the work process, during
which both the human and the machine functions are redefined. Early automation relied on
mechanical and electromechanical control devices; during the last 40 years, however, the
computer gradually became the leading vehicle of automation. Modern automation is usually
associated with computerization.
1.3 NEED FOR AUTOMATION:
Automation can be achieved through computers, hydraulics, pneumatics, robotics, etc.,
of these sources, pneumatics form an attractive medium for low cost automation.
The main advantage of a pneumatic system is that it is economical and simple in
construction which makes it different from other sources of automation.
Automation plays an important role in mass production. Nowadays almost all the
manufacturing process is changing to automated machines in order to deliver the products with
better quality and at a faster rate. The manufacturing operation is being automated for the
following reasons.
1.4 PNEUMATICS:
The word pneuma comes from Greek and means breather wind. The word pneumatics
is the study of air movement and its phenomena is derived from the word pneuma. Today
pneumatics is mainly understood to means the application of air as a working medium in
industry especially in driving and controlling of machines and equipment.
Pneumatics has been considered to be used to carry out simple mechanical tasks. But, in
todays world it is playing an important role by becoming one of the major sources for
automation, and the recent developments in this field has made it a useful technology in the
field of complex automated applications.
Pneumatic systems operate on a supply of compressed air which must be available in
sufficient quantity and at a pressure to suit the capacity of the system. When the pneumatic
system is being adopted for the first time, however it will indeed be necessary to deal with the
section of compressed air supply.
The key part of any pneumatic machine is supply of compressed air is by means
reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure
and delivers the air at a high pressure.
Compressor capacity is the actual quantity of air compressed and delivered. And the
volume expressed is that of the air at intake conditions namely at atmosphere pressure and
normal ambient temperature.
Which with the addition of Avogadros law later gave way to the ideal gas law. Other
important gas laws include Daltons law of partial pressures. The kinetic theory of gases,
Grahams law of effusion and root mean square velocity explains how individual molecules act
in a gas and their relation to pressure, volume, and temperature. A gas that obeys these gas
laws is known exactly as an ideal gas (or perfect gas). An ideal gas does not exist; however,
some gases follow the laws more closely than the others in given standard conditions.
The most important gas law is the ideal gas law, which states that: PV = nRT
Other gas laws, such as vander Waals equation, seek to correct the ideal gas laws to
reflect the behaviour of actual gases. Van der Waals equation alters the ideal gas law to reflect
how actual gases function using a series of calculated values called van der Waals constant
Any gas can be used in pneumatic system but air is the mostly used system now a days.
CHAPTER 2
LITERATURE REVIEW
LITERATURE REVIEW
2.1 AUTO INDEXING GEAR CUTTING ATTACHMENT FOR SHAPING MACHINE
M.V.N Srujan Manohar, S.Hari Krishna , University College of engineering, JNTU
Kakinada, A.P, INDIA(2012) :
They have been investigated to use pneumatic shaper for high production of
automatic gear cutting with auto indexing work piece. A small ratchet gear structure has
been thus devised to demonstrate the gear cutting attachment in shaping machines.
The pneumatic source of power with control accessories is used to drive the ram
or the cylinder piston to obtain the forward and return strokes. By this arrangement the
forward/reverse stroke of the pneumatic cylinder is adjustable type when compared
with the conventional machines. We desired a shaping machine which will automatically
index the job and gives automatic tool feed to the pneumatic cylinder
2.2 DESIGN & FABRICATION OF PNEUMATICALLY OPERATED PLASTIC INJECTION
MOULDING MACHINE
Poonam G. Shukla, Gaurav , P. Shukla Nagpur, India (2013) :
This project intends to use of plastic is increased now days in many industries
like automobile, packaging, medical, etc. The reason behind this is that the plastic made
things are quiet easier to manufacture, handle and reliable to use. So the plastic goods
manufacturing industries are striving hard to produce good quality products at large
scale and cheaper cost. The hydraulically operated machines solve the problem, but
they are too costlier for small scale and medium scale industries. This paper deals with
design and fabrication of pneumatically operated injection plastic moulding machine.
The manually operated machine is converted into pneumatically operated machine by
applying proper design procedure.
2.3 DESIGN AND DEVELOPMENT OF SEMI-AUTOMATIC CUTTING MACHINE FOR
YOUNG COCONUTS
Satip Rattanapaskorn , Kiattisak Roonprasang , King Mongkuts Institute of Technology
Ladkrabang, Bangkok 10520, Thailand (2008) :
The purpose of this research is to design, fabricate, test, and evaluate the
prototype of a semi-automatic young coconut fruit cutting machine. The design concept
is that fruit cutting is accomplished by pneumatic press on a young coconut sitting on a
sharp knife in a vertical plane. The machine consists of 5 main parts: 1) machine frame,
2) cutting base, 3) knife set, 4) pneumatic system, and 5) tanks receiving coconut juice
and cut fruits. The machine parts contacting edible parts of the fruit are made of foodgrade stainless steel. In operation, a young coconut is placed on the cutting base and
the pneumatic control is switched on. The coconut is automatically moved to the
pressing unit and cut in half by a knife set. The coconut juice flows down to the tank
while the cut fruits are separated and moved into the other tank.
8
CHAPTER 3
DESCRIPTION OF EQUIPMENT
10
DESCRIPTION OF EQUIPMENT
3.1 PRODUCTION OF COMPRESSED AIR:
Pneumatic systems operate on a supply of compressed air, which must be made
available in sufficient quantity and at a pressure to suit the capacity of the system.
The key part of any p neumatic system for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a certain pressure
and delivers it at a higher pressure. Compressor capacity is the actual quantity of air
compressed and delivered. And the volume expressed is that of the air at intake conditions
namely at atmosphere pressure and normal ambient temperature.
Clean condition of the suction air is one of the factors, which decides the life of a
compressor. Warm and moist suction air will result in increased precipitation of condense from
the compressed air.
Positive displacement compressors are most frequently employed for compressed
air plant and have proved highly successful for pneumatic control application.
The different types of positive compressors are:
1. Reciprocating type compressor
2. Rotary type compressor
Turbo compressors are employed where large capacity of air required at low discharge
pressures. They cannot attain pressure necessary for pneumatic control application unless built
in multistage designs and are seldom encountered in pneumatic service.
11
12
13
14
S.NO
2.
LIGHT DUTY
Aluminium stock
(Fabricated)
Brass stock
(Fabricated)
3.
Aluminium Castings
1.
MEDIUM DUTY
Aluminium stock
(Fabricated)
Brass stock
(Fabricated)
Aluminium, Brass,
iron or steel Castings.
HEAVY DUTY
Hard tensile Castings
LIGHT DUTY
MEDIUM DUTY
Plastic
Hard drawn
Aluminium tube
Hard drawn
Brass tube
2.
3.
HEAVY DUTY
Hard drawn brass tube.
Hard drawn steel tube
Brass, bronze, iron or
castings, welded steel tube
S.NO
1.
LIGHT DUTY
Aluminium Castings
MEDIUM DUTY
Aluminium Castings
Brass (Fabricated)
HEAVY DUTY
Aluminium Forgings,
Aluminium Castings.
Bronze (Fabricated)
Iron and Steel
Castings
Bronze (Fabricated)
Brass, Bronze, Iron or
Steel Castings.
2.
3.
1.
2.
LIGHT DUTY
MEDIUM DUTY
HEAVY DUTY
Aluminium
Aluminium, Brass
High Tensile
Castings
Steel Castings
Light Alloy
(Fabricated)
High Tensile
Steel Fabrication
15
S.NO
MATERIAL
FINISH
REMARKS
MILD STEEL
STAINLESS STEEL
1.
2.
3.3 VALVES:
3.3.1 SOLENOID VALVE:
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 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.
16
3.3.2.A. 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 a 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.
3.3.2.B. 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
17
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.
In any fluid power circuit, flow control valve is used to control the speed of the actuator.
The flow control can be achieved by varying the area of flow through which the air in passing.
When area is increased, more quantity of air will be sent to actuator as a result its speed
will increase. If the quantity of air entering into the actuator is reduced, the speed of the
actuator is reduced.
19
For adjustable speed via exhaust air flow control. The piston moves between air
cushions created through freely flowing supply air and restricted exhaust air. The benefit is
improved operating behaviour, even in the event of load changes
For adjustable speed via supply air flow control. The piston is moved via an air cushion
at one end, created by freely flowing exhaust air and restricted supply air. In contrast with
exhaust air restriction, there is a tendency towards a stick-slip effect.
20
With its industrial grade 3/8" chuck, this economical choice includes high quality
features for general drilling and hole sawing jobs. The planetary gear reduction balances the
load on bearings and gears for increased tool life
21
22
23
Diffuses water vapour in the piping to the outside before it liquefies, so we avoid
problems such as dried grease or ozone when using other types of dryers.
Easy mounting
3.6 CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise an
adoptee hose nipple. These types of connectors are made up of brass (or) Aluminum (or)
hardened pneumatic steel. For these type hose connectors no need of hose clamp these are
self-locking hose connectors. a Multi way four way hose connecter
The universal combination at an attractive price. Can be widely used thanks to resistant
materials. Easy to install thanks to optimised bending radii. Limited reset effect.Attractively
priced: the universal solution for metal fittings. Perfect for standard pneumatic applications in
many different fields. Wide range of variants Over 1000 types for maximum flexibility in
standard applications. Hydrolysis resistant For applications in damp environments or in contact
with water at up to 60 C. Resistant to pressure Secure connection when used with pressure
ranges of up to 14 bar. Economical for pneumatic installations in the high pressure ranges.
24
The powerful combination for applications involving pressure ranges up to 16 bar For
example, for applications with the pressure booster Robust, flexible and reliable connection for
the automotive industry. Fulfils the requirements Heat resistant For reliable compressed air
supply in high temperature ranges. Whether with 10 bar at 80 C or 6 bar at 150 C always
delivers maximum process security.Anti-static Electrically conductive tubing combined with a
solid-metal fitting Approved for the food Industry Food and Drug Administration certification
for use in the food industry:
close proximity to welding applications. Also reliable for applications in direct proximity to
welding splatter Double-sheathed tube and special fitting.
26
CHAPTER 4
DESIGN & DRAWING
OF
EQUIPMENT
27
160 mm = 0.16 m
Piston
diameter
50 mm
Piston rod
15 mm
Quantity
Seals
End cones
Piston
:
:
Cast iron
EN 8
Media
Air
Temperature :
0-80 C
Pressure
Range:
8 N/m
175 mm = 0.175 m
Piston
diameter
35 mm
Piston rod
15 mm
Quantity
Seals
End cones
Piston
:
:
Cast iron
EN 8
Media
Air
Temperature :
0-80 C
Pressure
Range:
8 N/m
29
Size
0.635 x 10 m
Part size
G 0.635 x 10 m
0-10 bar
Quantity
0.635 x 10 m
Pressure
Media
:
:
0-8 bar
Air
Quantity
30
10 bar
Temperature
0-100 C
Fluid media
Air
Material
Brass
Diameter
08 mm
Locking
Self-locking
4.1.6. Hoses:
Max pressure
10 bar
Outer diameter
8 mm = 8 x 10 m
Inner diameter
3 mm = 3 x 10 m
Material
Poly urathene
31
:
:
0.635 x 10- m
40 mm = 40 x 10 m
Drill capacity
1.5-10mm
Manual clamping
100 mm = 0.1m
Type of cylinder
Type of valve
8 bar
4.2.4 Foundation
Basement depth
Length of beam
Breadth of beam
Height of the beam
:
:
:
:
1.5ft
4.5ft
2.5ft
3.0ft
32
8bar
:
:
(3.14 D) / 4
Pressure applied x area of cylinder
( 4)(D2-d2) P ( 4)((52)(1.52))8=142.94Kg
(( 4)(D2) (P
4)(52) (
)
4)(D2) P (
4)(52)8=157.07Kg
) L)
)
(( 4)(D2-d2) (P
1.52)
)
33
((
.
lt min
) L)
(( 4)(52. lt min
CHAPTER 5
LIST OF MATERIALS
34
LIST OF MATERIALS
The material selected must posses the necessary properties for the proposed
application. The various requirements to be satisfied can be weight, surface finish, rigidity,
ability to withstand environmental attack from chemicals, service life, reliability etc.
The following four types of principle properties of materials decisively affect their
selection
a. Physical
b. Mechanical
c. From manufacturing point of view
d. Chemical
35
The various properties concerned from the manufacturing point of view are.
Cast ability,
weld ability,
Brazability,
Forge ability,
merchantability,
surface properties,
shrinkage,
Sometimes the demand for lowest possible manufacturing cost or surface qualities
obtainable by the application of suitable coating substances may demand the use of special
materials.
5.1.3. Quality Required:
This generally affects the manufacturing process and ultimately the material. For
example, it would never be desirable to go for casting of a less number of components which
can be fabricated much more economically by welding or hand forging the steel.
36
Some materials may be scarce or in short supply. It then becomes obligatory for the
designer to use some other material which though may not be a perfect substitute for the
material designed.
The delivery of materials and the delivery date of product should also be kept in mind.
5.1.5. Space Consideration:
Sometimes high strength materials have to be selected because the forces involved
are high and the space limitations are there.
5.1.6. Cost:
37
DESCRIPTION
DOUBLE ACTING PNEUMATIC
CYLINDER
QUANTITY
MATERIAL
Aluminium
HOSE COLLAR
PNEUMATIC MOTOR
4 WAY CONNECTOR
PU TUBES
VICES
10
COLUMN SUPPORT
11
AIR COMPRESSOR
12
Brass
13
H.S.S
14
15
BOARING BIT
16
GRINDING WHEEL
17
TAP SET
18
19
8
1
1
15mtr
1
2
1
1
Aluminium
Brass
M.S
PU
Polyurethane
Iron
M.S
Al
M.S
1
1
1
1
30
38
C.I
H.S.S
ABR:SI
H.S.S
H.S.S
Iron
CHAPTER 6
COST ESTIMATION
39
COST ESTIMATION
6.1 COST ESTIMATION
SNO
DESCRIPTION
DOUBLE ACTING
PNEUMATIC CYLINDER
SINGLE PASS SOLENOID
VSLVE
QUANTITY
MATERIAL
RATE
AMOUNT
AL
2000.00
2000.00
AL
1600.00
1600.00
1800.00
1800.00
1950.00
1950.00
HOSE COLLAR
125.00
1000.00
PNEUMATIC MOTOR
2000.00
2000.00
4 WAY CONNECTOR
PU
60.00
60.00
PU TUBES
PU
30.00
300.00
FRAME STAND
M.S
600.00
600.00
10
PLATES
M.S
100.00
200.00
11
COLUMN SUPPORT
M.S
200.00
200.00
12
AIR COMPRESSOR
13
14
REAMING BIT
15
16
BOARING BIT
17
GRINDING WHEEL
18
TAP SET
19
1
2
TOTAL
LABOUR CHARGES
MACHINING CHARGES
GRAND TOTAL
AL
AL
BRASS
M.S
1
10MTR
1
2
1
1
2
1
1
1
1
1
1
40
BRASS
250.00
500.00
H.S.S
200.00
200.00
H.S.S
450.00
450.00
H.S.S
1500.00
1500.00
ABR:SI
350.00
350.00
H.S.S
2500.00
2500.00
H.S.S
180.00
180.00
17390.00
4500.00
3450.00
25340.00
CHAPTER 7
FABRICTION
41
FABRICATION
7.1 METHOD OF FABRICATION:
The stand (or) base carries the whole machine. The whole machine is installed on the
foundation .A circular column having length of 90cm about one third part of its length is in the
foundation the remains part is above the foundation, from the upper end of the vertical
column 50cm is machined by performing turning operation, a bush with having length 7.5cm is
machined and slides over the machining parts of rod.
The horizontal rod is slider over the, vertical column by means of bush. A double acting
cylinder is connected to horizontal column by using clamp for feeding of the machine.
A Pneumatic motor with chuck is connected to the horizontal column normally. A 5/2
way solenoid value is connected to control the double acting cylinder to upward &downward
motion.
A single acting cylinder and a movable jaw is fixed to the base of the machine it will act
as a work holding device
By changing toll bits from the chuck for performing different opertions
42
43
CHAPTER 8
WORKING PRINCIPLE
44
WORKING PRINCIPLE
45
v straight shank: this type has a cylindrical shank and is held in a chuck;
v taper shank: his type is held directly in the drilling machine spindle.
Drills are normally made of HSS but carbide-tipped drills, and drills with mechanically
attached carbide inserts are commonly used in many operations, especially on CNC drilling
machines
47
C.TAPPING OPERATION:
These are straight flute general purpose tools which can be used for both machine or
hand tapping. They are generally the most economical tool for use on production runs, but are
best on materials that produce chips, or where the swarf breaks readily. Where deep holes are
to be tapped, in materials which produce stringy swarf, other types of taps may be needed,
especially for coarse threads. Hand taps can be supplied in sets of three; bottom, second and
taper leads, or individually.
8.C.1BOTTOM TAPS:
It has a chamfer (lead) of 12 threads, the angle of the lead being around 18 degrees
per side. They are used to produce threads close to the bottom of blind holes.
48
8.C.3THIRD TAPS:
It has a lead of 7-10 threads at 5 degrees per side. The taper lead distributes the
cutting force over a large area, and the taper shape helps the thread to start. They can
therefore be used to start a thread prior to use of second or bottom leads, or for through
holes.
E.BROACHING OPERATION:
Broaching is a machining process for removal of a layer of material of desired width
and depth usually in one stroke by a slender rod or bar type cutter having a series of cutting
edges with gradually increased protrusion as indicated in Fig. 4.10.1. In shaping, attaining full
depth requires a number of strokes to remove the material in thin layers step by step by
gradually infeeding the single point tool .
Whereas, broaching enables remove the whole material in one stroke only by the
gradually rising teeth of the cutter called broach. The amount of tooth rise between the
successive teeth of the broach is equivalent to the in feed given in shaping.
50
F.GRINDING OPERATION:
Grinding is a material removal and surface generation process used to shape and finish
components made of metals and other materials. The precision and surface finish obtained
through grinding can be up to ten times better than with either turning or milling.
Grinding employs an abrasive product, usually a rotating wheel brought into controlled
contact with a work surface. The grinding wheel is composed of abrasive grains held together
in a binder. These abrasive grains act as cutting tools, removing tiny chips of material from the
work As these abrasive grains wear and become dull, the added resistance leads to fracture of
the grains or weakening of their bond. The dull pieces break away, revealing sharp new grains
that continue cutting.
51
CHAPTER 9
MERITS AND DEMERTIES
53
9.1MERITS
It reduces the manual work.
Quick in operation
Accuracy is more
Low cost machine
In a single machine no.of operations are performed, like, drilling ,taping, reaming
,grinding etc.,
Consumption of electric power is less when compare with manual machines
Cost for reaming all machines are optimized
Floor space for reaming machines are reduced
Low cost automation, man power for performing operations are reduced
Work holding device is also automatic
9.2 DEMERITS
Tool changing foe every operation is manual
noise in operation
constant pressure maintenance is required for thought operation
connections are may be leak
pressure drop occur in the pipelines
54
CHAPTER 10
APPLICATIONS
55
10.APPLICATIONS
Applications :
Used in automobile workshops for drilling carburettor holes
Used in small scale industries
It can be used as machine with fixed mounting and as a portable
machine because it is flexible to move
In welding shop for grinding
For performing the operations in huge numbers which cannot be done in ordinary
machines, Since its portable.
In such places where frequent change in operation is required
It will used in where no.of operations are performed
56
CHAPTER 11
CONCLUSION
57
CONCLUSION
11.1 CONCLUSION:
The project carried out by us made an impressing task in the field of small scale
industries and automobile maintenance shops. It is very usefully for the workers to carry out
a number of operations in a single machine. Automation can be possible for large scale
industries but not for small scale industries so we adopt low cost automation and medium
of actuation is also is freely available.
This project has also reduced the cost involved in the concern. Project has been
designed to perform the entire requirement task which has also been provided.
58
CHAPTER 12
REFERANCES
59
REFERANCE
12.1 REFERANCE
Auto indexing gear cutting attachment for shaping machine by M.v.n srujan
manohar, S.hari Krishna (2012)
Design & fabrication of pneumatically operated plastic injection moulding machine
By Poonam g. Shukla, gaurav , p. Shukla (2013)
Design and development of semi-automatic cutting machine for young
coconuts Satip rattanapaskorn , kiattisak roonprasang (2008)
Pneumatic auto feed punching and riveting machine A.s. Aditya polapragada, k. Sri
varsha (2012)
Pneumatic hand book by R.H.WARRNING
Festo catalogues
Janatics catalogues
Strength of materials by R.S KHURMI
60