UNIVERSITY OF MAURITIUS

FACULTY OF ENGINEERING

MECHANICAL AND PRODUCTION ENGINEERING

DEPARTMENT

E443 Beng(Hons.) Mechanical Engineering (Minor:

Energy Systems)

Pneumatics and Hydraulics

MECH 3015Y

MINI PROJECT
Lecturer: Dr. Venkannah

1. Bundhun Aman kumar 1311863

2. BADULLA Muhammad Twaaha 1311150
3. NUTHOO Muhammad Ajmal 1318272

Date Submitted: 29/04/16

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Table of Contents
1.INTRODUCTION................................................................................................. 3
2.LITTERATURE REVIEW .................................................................................. 3
3.PROBLEM DESCRIPTION................................................................................ 4
4.METHODOLOGY................................................................................................ 5
5.RESULTS AND CALCULATTION ................................................................... 8
5.0 Material selection10

5.1 Calculating minimum force required for cylinder to retract12

5.2 Calculating required power by pump..13

6.DESIGN MODIFICATION OF THE GUILLOTINE .................................... 15

6.1 Design circuits...16

7.COMPONENT SPECIFICATION AND COSTING6

8.CONCLUSION...21
9.REFERENCES...22

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1. INTRODUCTION

Automation is defined as the creation and application of technology to monitor and control the
production and delivery of products and services. The importance of automation has been stressed
through its number of advantages it has brought to the manufacturing world like an increase in
production rates, in productivity rates, worker safety and product quality. Nowadays many
machines in manufacturing systems are being automated to perform basic task more efficiently
using pneumatics and hydraulics power. The use of sensors along with electrics and programmable
logic controllers can further enhance the control of the system.

2. LITTERATURE REVIEW

Sheet Metal Guillotine

A Sheet Metal guillotine is a machine which is used for shearing metals. The machine may be
foot powered, mechanically or hydraulically powered. It works by first clamping the material
with a ram. A moving blade then comes down across a fixed blade to shear the material. For
larger shears the moving blade may be set on an angle or rocked in order to shear the material
progressively from one side to the other; this angle is referred to as the shear angle. This
decreases the amount of force required, but increases the stroke. A 5 shear angle decreases the
force by about 20%. The amount of energy used is still the same. The moving blade may also be
inclined 0.5 to 2.5, this angle is called the rake angle, to keep the material from becoming
wedged between the blades, however it compromises the squareness of the edge. As far as
equipment is concerned, the machine consists of a shear table, work-holding device, upper and
lower blades, and a gauging device. The shear table is the part of the machinery that the
workpiece rests on while being sheared. The work-holding device is used to hold the workpiece
in place and keep it from moving or buckling while under stress. The upper and lower blades are
the piece of machinery that actually do the cutting, while the gauging device is used to ensure
that the workpiece is being cut where it is supposed to be. Typical workpiece materials include
aluminum, brass, bronze, and mild steel because of their outstanding shearability ratings,
however, stainless steel is not used as much due to its tendencies to work-harden. Figures 1 and 2
are examples of metal shearing guillot

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 Figure 1: Hand guillotine Figure 2: Foot powered guillotine

3. PROBLEM DESCRIPTION

The system that is being automated is a Foot Powered Sheet Metal Guillotine located in the
workshop at the University of Mauritius.
Shear Table Springs

Figure 3: Front view of foot powered metal shearing guillotine

Chopper
Foot Pedal
r

4
The foot powered metal shearing guillotine is to be redesigned so as it is hydraulically powered
and automated with the use of 3 sensors and a programmable logic controller.

The following parameters need to be identified in order to redesign the guillotine to be fully
automated:

1. Shear force required for metal shearing.

2. Pressure required to cut different metals of different dimensions.
3. Size of cylinder (including material and piston rod size) to be used for causing Chopper
to extend and retract with the calculated pressure.
4. Power required by hydraulic pump.
5. Type of Hydraulic pump to be used.
6. Size of flow pipes.

4. METHODOLOGY

1. The following 3 materials were selected and their respective dimensions noted in table 1.

Figure 4: Metals A, B and C (in order from left to right)

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 Material Thickness/mm Width/cm

Metal A: Aluminium Alloy 2.20 5

5052
(Threadplate)

Metal B: Mild steel A55679 0.720 5

(ISO grade 300)

Metal C: Aluminium B211 0.720 5

(ASTM/ASME)

Table 1: Dimensions of the metal A, B and C

2. 3 persons each weighing 55kg, 60kg and 50kg helped in determining the required
shearing force to cut the metal. It was observed that when the person weighing 55kg
stood on the foot pedal, he was able to provide enough force to cut metal B whereas the
person weighing 50kg was unable to do so.

3. When the 2 persons weighing 55kg and 60kg stood on the 2 foot pedals, they were able
to provide enough shearing force to cut metal A.

4. The person weighing 50kg was able to provide enough shearing force to cut metal C,
however it was also observed that a much lower shearing force was required to cut metal
A, so it was assumed that about 20kg was enough to provide the required shearing force
to cut that specific metal.

5. The following equation was used to calculate that required shearing force for the 3
metals and the values obtained were tabulated in table 2:

= (1)

Where:
F: Shearing force required to cut metal
m: Mass
g: acceleration due to gravity(9.81ms-2)

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 6. The pressure required for the shearing of the three different metals were calculated from
the following equation and the values obtained were tabulated:

= (2)

Where:
: Pressure required for shearing of metals
F: Shearing force required to cut metal
A: Cross sectional area of metal being cut

7. From the 3 values obtained for Forces, the highest value is taken into consideration and
an extrapolation of the data was done by simple proportion to determine the force
required to shear 5mm thickness of any of the sample.
8. The diameter of the cylinder was determine by equating the cross sectional area of the
cylinder to the cross sectional are of the effective length of the chopper.
9. The following equation is used to calculate the power required by the hydraulic pump:

= (3)

Where:
P: Power
Q: Flow rate

10. Flow rate was calculated using the following equation:

= (4)
Where:
Q: Flow rate
A: Cross sectional area of cylinder
V: Velocity

11. Pressure that should be provided by pump was calculated using Bernoullis equation:

1 1 2 2
+ + 1 = + + 2 (5)
2 2

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Where:
1 2 : Pressure at inlet and outlet
2 and 1 : Velocity at inlet and outlet
z: Height
g: acceleration due to gravity
: Density

5. RESULTS AND CALCULATION

From Equation (1) and Eqation (2) the force and pressure required for shearing of the 3 metals
were calculated and tabulated below

Material Cross-sectional area/m2 Force/N Shear/Pa

( ) (Mg + Wchopper)
Metal A: Aluminium
Alloy 5052 1.110-4 1261.9 1.15107
(Threadplate)

Metal B: Mild steel

A55679 310-5 722.3 2.41107
(ISO grade 300)

Metal C: Aluminium
B211 310-5 280.9 9.36106
(ASTM/ASME)

Table 2: Required force and pressure for shearing

Weight of the chopper was determined by the following procedure:

The chopper is made up of cast iron (ASTM AU8 class 40 iso grade 2) having density
7150kg/m3
The volume of the chopper was calculated as follows:
= (6)

= 0.925 0.087 0.015

= 0.00121 3
Using the density formula, mass of the chopper for 0.00121m3 was found to be 8.63kg
and the weight was calculated using Equation 1 and is equal to 84.67N

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 After obtaining the pressure required to shear the 3 metals, An extrapolation of data had
to be done due to the lack of raw data using simple proportion, a new force required was
calculated for a thickness of 5mm for all the 3 metals and the values were recorded in
table 3.

Material Thickness/mm Area/m2 Force/N Pressure/Pa

Metal A:
Aluminium Alloy 5 2.510-4 2868 11.47106
5052
(Threadplate)
Metal B: Mild
steel A55679 5 2.510-4 5016 20.06106
(ISO grade 300)

Metal C:
Aluminium B211 5 2.510-4 1951 7.80106
(ASTM/ASME)

Table 3: Shearing 5 mm thickness

Extrapolation of data:
Sample A
2.2 mm 1261.9 N
1261.9
5 mm 5 =2868 N
2.2

Sample B
0.72 mm 722.3 N
722.3
5 mm 0.72 5 =5016N

Sample C
0.72 mm 280.9 N
280.9
5 mm 0.72 5 =1951 N

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From table 3 it can be observed that the critical shearing force is equal to 5016N and all component
selection was based on that critical value.

5016N

Chopper

5cm

Considering an effective mean length of 20cm, we assume that we have a distributed load of 5016N
over the 20cm
5016N 5016N 5016N 5016N 5016N

20cm

The area of the chopper is calculated and is equal to 3.110-3m2 (Area = 1.5 10-2 20 10-2)

Determining the Diameter of the cylinder:

= .

D = 6.18 mm
5.0 Material selection

Specifications of the cylinder.

1. Cylinder tube

It should be strong enough to be able to withstand the pressure of the system.

Corrosion resistant
Lightweight
High tensile strength

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Based on the above information the material chosen for the cylinder tube is Aluminium 6061-T6.
It has a tensile strength of 310MPa, is lightweight, corrosion resistant and is affordable.

2. Piston rod.
High yield strength
Lightweight
Tough

Regarding the piston rod, the material selected is Stainless steel 204 Chromium electroplated
which has a compressive strength of 600MPa.

3. Flow Pipe.
Flexible
High tensile strength

Plastic coated stainless steel 304 with a diameter equal to the inlet of the input of the cylinder
would be appropriate given the pressure is less than the tensile strength of the pipe. Hexagonal nut
of size M10 must be used for fixing the pipe to the cylinder, the DCV and the the pump.
Pressure at outlet of pump is then calculated by applying Bernoulli Equation (5) with the following
parameters:

Company SMC PNEUMATICS

Model JIS standard compact cylinder
Series CHKDB 63 100M
Features 2 Reed auto switches of 24 V DC
Action Double acting
Normal pressure 10MPa
Max allowable pressure 13MPa
Min allowable pressure 0.3MPa
Piston speed 0.1 m/s
Rod End Thread Male thread
Bore Diameter 63mm
Rod Diameter 35.5mm
Theoretical output 31170N
Stroke 100mm
Mass 3844g
Cylinder mounting Hexagonal socket head cap screws CJISB1176
strength class 10.9
Tightening torque 40Nm
Inlet and outlet Diameter 10mm
Table 4: Selecting the appropirate cylinder from the market.

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5.1 Calculating minimum force required for cylinder to retract

= 0.015 0.087 0.2( )

= 2.61 102 3

Density of chopper = Density of cast iron 40 ISO Grade

= 7150 /3

=
= 7150 2.61 102
= 1.87

Weight of chopper is then found to be 18.3 N

The mass of piston rod made up of stainless steel is calculated from the following parameters:
Density of piston rod made up of stainless steel 304 = 7900 kg/m3
The volume of the piston rod is calculated as follows:
(35 102 )2
= 0.1
4

= 989 105

=
= 989 105 7900
= 0.78

The weight of the piston rod equal to 7.67N

Regarding the hydraulic fluid we opted for the hydraulic oil ISO 68 having viscosity of 68
centistokes at 40 and density 865kg/m3

Density/kgm-3 Volume/m3 Mass/kg Weight/N

-2
Chopper 7150 2.61 10 1.87 18.3
5
Piston rod 7900 989 10 0.78 7.67
-4
Hydraulic oil 865 3.11 10 0.27 2.64
Table 4: Density, volume, mass and weight

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The minimum force required for cylinder to retract will be equal to:

= + +
= 18.3 + 7.67 + 2.64
= 28.61N

5.2 Calculating required power by pump

The following values were used for calculating the power required by the hydraulic pump:

The inlet velocity to the cylinder is 0.1ms-1 according to the cylinders description by the
company.
The diameter of the bore for the cylinder is 63mm.

Flow at inlet of cylinder is calculated using Equation (4) diameter of cylinder is taken to be 63mm
and inlet velocity to be equal to 0.1ms-1 and the flow rate was found to be 3.1110-4 m3s-1

The following parameters were used when calculating velocity at outlet of pump:
Diameter of hose is taken to be 10mm because inlet and outlet of cylinder has diameter of
10 mm.
Using equation 4, the flow is 3.1110-4 m3s-1 and therefore Velocity at inlet is calculated.

The velocity is then calculated based on the above theories and using Equation (4) and is equal to
3.96ms-1
P2 was obtained by considering the critical shear force of 5016N and the area of the chopper:

5016
2 =
5 102 1.5 102

2 = 6.88
Using the Bernoullis Equation:
2 : 6.688 MPa
2 and 1 : 0.1ms-1 and 3.96ms-1
Z1 and Z2: 0m and 0.5m (the cylinder is located 50cm above the pump)
g: 9.81ms-2
: 865 kg/m3
6.688 106 3.962
1 = ( + + 0.5) 865 9.81
865 9.81 2 9.81

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 1 = 6.69

The pressure provided at outlet of pump is found to be 6.69MPa

Power required by hydraulic pump is then obtained by using Equation (3) and is found to be 3hp
(assuming 100% pump efficiency).

= 6.69 106 3.11 104

Power of pump = 2080.59 3 hp

Company Waukesha
Features On/Off Push Buttons
Power Rating 3 HP
Mode of Operation Positive Displacement
Voltage 230/460 VAC
Inlet/Outlet 2" inlet & outlet
Materials Stainless Steel Belt Cover and Carbon Steel Base
Pipe Adapter 5 cm to 1 cm
Size 55
Maximum Pressure 300 bar
Maximum Speed 1750 RPM
Size Length: 27 in Width: 13 in Height: 9 in.
Pump Mounting Foot Bracket Kit
Table 5: Selecting the appropriate pump from the market.

Calculating Volume of fluid required

According to the design of the system, the cylinder will be located 0.5m above the pump therefore
the total length of the pipe carrying the hydraulic oil be equal to 1m.

The cylinder stroke is equal to 100mm and the cylinder bore diameter is equal to 63mm

The total volume of hydraulic oil required is obtained via the following equation:

= (1 1 ) + (2 2 )
Where:
1 : Area of pipe
2 : Area of cylinder
L1: Length of pipe
L2: length of Cylinder

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From the above equation the total volume of fluid required is found to be 0.385 litres

Note: Volume of oil in DCV is not taken into consideration, therefore a total amount of 0.8-1 litres
of oil would be suitable for the system.

6. DESIGN MODIFICATION OF THE GUILLOTINE

Flow pipes
Push button

Guard

Clamp

Cylinder

Chopper

Hydraulic pump
+ 4/2 solenoid Figure 5: Back-view of the modified guillotine
actuated

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The following modifications were made to the guillotine:
The dimensions of the chopper were considerably reduced to a mean effective length of
20cm and its width to 1.5cm.
The cylinder is located 50cm above the hydraulic pump.
A guard of length 40cm and width 15cm has been installed for safety purposes.
The stroke of the cylinder is 100mm.
A push button and an emergency stop has been installed to the modified system.

6.1 DESIGN CIRCUITS

B3

Figure 6: Hydraulic system.

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The circuit consists of 2 limit switches B1and B3 and a pressure switch B2.
A 4/2 double solenoid actuated valve is used for extension and retraction of cylinder.
Initially the cylinder is in retracted position and the guard must be open.
Guard must be closed for system to operate as a safety measure.
A flow control is used to control return flow in the hydraulic system

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Figure 7: PLC circuit of guillotine system

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 Figure 8: PLC flow chart
There must be 3 conditions for the system to start. Start Push button PB1 must be pressed,
cylinder must be in retracted position (at limit switch B1) and guard(G) must be closed. If
everything is normal, cylinder extends until piston rod reaches limit switch (B2) and retracts
immediately. However, if piston rod is blocked, a pressure builds up, when the pressure reaches
above 7MPa, pressure switch B3 closes, activates a buzzer, a lamp and an ON delay timer.
Cylinder retracts when timer has an accumulated value of 5 seconds.
Note: The circuit was carried out using the Festo micro Analog built PLC

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8. COMPONENT SPECIFICATION AND COSTING

Product Specifications Approximate Price/ Rs

Waukesha 3 HP Size 55 3 HP 33 000
Positive Displacement Pump 2" inlet & outlet
230/460 VAC
3 Phase

Gates 1/4" 4M3K Hydraulic 1/4" diameter 500

Hose 40" length
3000 psi
Chief WX Welded Cylinder: 2.5" Bore x 40" 8800
207422 Stroke
Chrome Plated Rod

Festo Analogue Input PLC Permissible voltage 5000

range: 2227V DC
4 analogue voltage
inputs: Range: -10 V
+10 V (max. 30 V),
input resistance: 200
k
4 analogue current
inputs: Range: 0 20
mA (max. -4 +24
mA), input voltage:
max. 30 V
2 analogue outputs:
Voltage: -10 +10 V,
short-circuit-proof,
max. 30 V, fuse-
protected, current:
max. 20 mA
47300
Table 6: Cost analysis.

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9. CONCLUSION

The Circuit was tested in the RS logic software using plc model micro logic built
analog and it is working as planned.
The system will have an estimated cost of Rs 47 300 plus labour cost which we believe is in the
university budget taking into consideration that the existing guillotine in the workshop lab is old
and is partly defective so the system redesigning using automation is a good solution without
having to buy a new one which will be far for costly.
Pump rating = 3 hp = 2.238 kW
In Mauritius, the industrial tariff for industrial energy consumption is about Rs 3.54/ kWh
according the CEB.
The stroke of the cylinder in 100mm and its speed it 100 mm/s means it can perform a cut in a
total of 2 seconds. Assuming we take 7 seconds to place and remove the workpiece from the
guillotine, in 1 hour 3600/9 = 400 pieces can be cut off.
Therefore, energy consumption in 1 hour = 2.238 x 3.54 = Rs 7.92
And cost per workpiece = 7.92/400 = 0.019 2 cents per workpiece.
Safety aspects such as the Pressure relief valve in the power pack was included in case there is
high pressure. Also the pressure switch B3 prevents the pressure building up too high, it also
prevents damage of workpiece and the chopper. Moreover, a guard needs to be close for system
to starts, this prevents any kind of injury to the user.

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10. REFERENCES
eBay. 2016. Gates 1 4" ID 4M3K 3000psi Hydraulic Hose 40" Length 1 2" Male Fittings New |
eBay [ONLINE]
Available at: http://www.ebay.com/itm/Gates-1-4-ID-4M3K-3000PSI-Hydraulic-Hose-40-
Length-1-2-Male-Fittings-NEW-
/171685045277?hash=item27f939e41d%3Ag%3Am20AAOSwstxU4lRx.
[Accessed 28 April 2016].
Connection unit, analogue - Process models/Components PLC, Electronics - Automation
technology/PLC - Equipment sets - Festo Didactic. 2016. [ONLINE]
Available at: http://www.festo-didactic.com/ie-en/equipment-sets/automation-technology-
plc/process-models-components-plc,electronics/connection-
unit,analogue.htm?fbid=aWUuZW4uNTU1LjE3LjE4LjYxNy43NDQ4&basket=add&vid=9925.
[Accessed 28 April 2016].

hand metal cutting shears from China manufacturer - NANTONG JUGAO MACHINERY CO
LTD. 2016. hand metal cutting shears from China manufacturer. [ONLINE]
Available at: http://jugao.en.hisupplier.com/product-997256-hand-metal-cutting-shears.html.
[Accessed 28 April 2016].

Treadle Guillotine Shear Gives More Than Precision Cutting. 2016. Treadle Guillotine Shear
Gives More Than Precision Cutting. [ONLINE]
Available at: http://www.shearing-machine.com/shearing-machine/treadle-guilltine.html.
[Accessed 28 April 2016]

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