PNEUMATIC PUNCHING MACHINE

Introduction
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. When the
pneumatic system is being adopted for the first time, however it wills indeed the
necessary to deal with the question of compressed air supply.

The key part of any facility 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
delivered the air at a high pressure.

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 WORKING PRINCIPLE

Our project works on the following three basic principles.

1. Air can flow.
2. Air can be compressed.
3. Difference in air pressure can cause movement.

The main objectives of our project is to punch object with the help of air. Initially we
press the lever manually and the force is transmitted from the lever to the cylinder
(Syringe-1) through a link. The air in the cylinder (Syringe-1) gets compressed and exerts
force through the pipe to the next cylinder (Syringe-2) where the punching tool is
connected and hence the object is punched due to air pressure.

Thus the project is easy to operate due to its simple mechanism.

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PROJECT LAYOUT

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PROJECT PICTURES

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 ADVANTAGES

 It reduces the manual work

 It reduces the production time
 Uniform application of the load gives perfect removing of the bearing.
 Damages to the bearing due to the hammering is prevented
 It occupies less floor space
 Less skilled operator is sufficient

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 LIMITATIONS

 Initial cost is high

 Cylinder stroke length is constant
 Specific Size punching operation only.
 Can work only on thin papers / sheets.

APPLICATIONS

 Pressing Operation in all industries

 Paper punching industries
 Leather washer operation in all industries.
 Sheet Metal Punching.

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 PNEUMATICS
Pneumatics is a section of technology that deals with the study and application of
pressurized gas to produce mechanical motion.

Pneumatic systems are extensively used in industry, where factories are commonly
plumbed with compressed air or compressed inert gases. This is because a centrally
located and electrically powered compressor that powers cylinders and other pneumatic
devices through solenoid valves is often able to provide motive power in a cheaper, safer,
more flexible, and more reliable way than a large number of electric motors and
actuators.

Pneumatics also has applications in dentistry, construction, mining, and other areas.

Comparison to hydraulics

Both pneumatics and hydraulics are applications of fluid power. Pneumatics uses an
easily compressible gas such as air or a suitable pure gas, while hydraulics uses relatively
incompressible liquid media such as oil. Most industrial pneumatic applications use
pressures of about 80 to 100 pounds per square inch (550 to 690 kPa). Hydraulics
applications commonly use from 1,000 to 5,000 psi (6.9 to 34 MPa), but specialized
applications may exceed 10,000 psi (69 MPa).

Advantages of pneumatics
 Simplicity of Design And Control
 Machines are easily designed using standard cylinders & other components.
Machines operate by simple ON - OFF type control.

Reliability
Pneumatic systems tend to have long operating lives and require very little maintenance.

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Because gas is compressible, the equipment is less likely to be damaged by shock. The
gas in pneumatics absorbs excessive force, whereas the fluid of hydraulics directly
transfers force.

Storage
Compressed gas can be stored, allowing the use of machines when electrical power is
lost.

Safety
 Very low chance of fire (compared to hydraulic oil).
 Machines can be designed to be overload safe.

Pneumatic logic
Pneumatic logic systems (sometimes called air logic control) are often used to control
industrial processes, consisting of primary logic units such as:
 And Units
 Or Units
 'Relay or Booster' Units
 Latching Units
 'Timer' Units
 Sorteberg relay
 Fluidics amplifiers with no moving parts other than the air itself

Pneumatic logic is a reliable and functional control method for industrial processes. In
recent years, these systems have largely been replaced by electrical control systems, due
to the smaller size and lower cost of electrical components. Pneumatic devices are still
used in processes where compressed air is the only energy source available or upgrade
cost, safety, and other considerations outweigh the advantage of modern digital control.

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 PUNCHING
Introduction
Punching is a metal forming process that uses a punch press to force a tool, called a
punch, through the workpiece to create a hole via shearing. The punch often passes
through the work into a die. A scrap slug from the hole is deposited into the die in the
process. Depending on the material being punched this slug may be recycled and reused
or discarded. Punching is often the cheapest method for creating holes in sheet metal in
medium to high production volumes. When a specially shaped punch is used to create
multiple usable parts from a sheet of material the process is known as blanking. In
forging applications the work is often punched while hot, and this is called hot punching.

Process

Punch tooling (punch and die) is often made of hardened steel or tungsten carbide. A die
is located on the opposite side of the workpiece and supports the material around the
perimeter of the hole and helps to localize the shearing forces for a cleaner edge. There is
a small amount of clearance between the punch and the die to prevent the punch from
sticking in the die and so less force is needed to make the hole. The amount of clearance
needed depends on the thickness, with thicker materials requiring more clearance, but the
clearance is always less than the thickness of the workpiece. The clearance is also
dependent on the hardness of the workpiece. The punch press forces the punch through a
workpiece, producing a hole that has a diameter equivalent to the punch, or slightly
smaller after the punch is removed. All ductile materials stretch to some extent during
punching which often causes the punch to stick in the workpiece. In this case, the punch
must be physically pulled back out of the hole while the work is supported from the
punch side, and this process is known as stripping. The hole walls will show burnished
area, rollover, and die break and must often be further processed. The slug from the hole
falls through the die into some sort of container to either dispose of the slug or recycle it.

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Punching Characteristics
 Punching is the most cost effective process of making holes in strip or sheet metal
for average to high fabrication
 It is able to create multiple shaped holes
 Punches and dies are usually fabricated from conventional tool steel or carbides
 Creates a burnished region roll-over, and die break on sidewall of the resulting
hole.

Geometry

The workpiece is often in the form of a sheet or roll. Materials for the workpiece can
vary, commonly being metals and plastics. The punch and die themselves can have a
variety of shapes to create an array of different shaped holes in the workpiece. Multiple
punches may be used together to create a part in one step.

Equipment

Most punch presses are mechanically operated, but simple punches are often hand-
powered. Major components of this mechanical press are the frame, motor, ram, die
posts, bolster, and bed. The punch is mounted into the ram, and the die is mounted to the
bolster plate. The scrap material drops through as the workpiece is advanced for the next
hole. A large computer controlled punch press is called a computer numerical controlled
turret. It houses punches and their corresponding dies in a revolving indexed turret. These
machines use hydraulic, pneumatic, or electrical power to press the shape with enough
force to shear the metal.

Forces

The punch force required to punch a piece of sheet metal can be estimated from the
following equation:

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Where t is the sheet metal thickness, L is the total length sheared (perimeter of the shape),
and UTS is the ultimate tensile strength of the material.

Die and punch shapes affect the force during the punching process. The punch force
increases during the process as the entire thickness of the material is sheared at once. A
beveled punch helps in the shearing of thicker materials by reducing the force at the
beginning of the stroke. However, beveling a punch will disort the shape because of
lateral forces that develop. Compound dies allow multiple shaping to occur. Using
compound dies will generally slow down the process and are typically more expensive
than other dies. Progressive dies may be used in high production operations. Different
punching operations and dies may be used at different stages of the operation on the same
machine.

Cylinders
● Force = Pressure  Area
– 2” diameter piston
– Area = 3.14  12 = 3.14 in2
– Pressure = 60 psi
– 3.14 in2  60 psi = 188 lbs
– Force while extending
greater than while retracting
● Main decisions: Length and diameter
– Diameter based on required force
– Larger diameter: more force, but more air
Introduction
Components
Mechanisms
Resources

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The Three Principles

There are three scientific principles involved in each type of fluid systems. These include
the following:

1) Fluids can be compressed

2) Fluids can flow

3) Pressure differences can cause movement

“Fluids can flow” relates to my subject because for pneumatic systems to work, it needs
the compressed air to flow through something in order to do a job right.

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LIST OF COMPONENTS / ACCESSORIES USED IN THE
PROJECT
1. Punching Tools
2. Pneumatic Cylinder
3. Lever
4. Sprocket
5. Wooden Surface / Frame
6. Clamp / Dies (Male / Female)
7. Spring

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 PNEUMATIC CYLINDER

Pneumatic cylinders (sometimes known as air cylinders) are mechanical devices which
use the power of compressed gas to produce a force in a reciprocating linear motion.:85
Like hydraulic cylinders, pneumatic cylinders use the stored potential energy of a fluid, in
this case compressed air, and convert it into kinetic energy as the air expands in an
attempt to reach atmospheric pressure. This air expansion forces a piston to move in the
desired direction. The piston is a disc or cylinder, and the piston rod transfers the force it
develops to the object to be moved. :85 Engineers prefer to use pneumatics sometime
because they are quieter, cleaner, and do not require large amounts of space for fluid
storage.

Because the operating fluid is a gas, leakage from a pneumatic cylinder will not drip out
and contaminate the surroundings, making pneumatics more desirable where cleanliness
is a requirement. For example, in the mechanical puppets of the Disney Tiki Room,
pneumatics are used to prevent fluid from dripping onto people below the puppets.

Operation
General

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Once actuated, compressed air enters into the tube at one end of the piston and, hence,
imparts force on the piston. Consequently, the piston becomes displaced (moved) by the
compressed air expanding in an attempt to reach atmospheric pressure.
Compressibility of gasses

One major issue engineers come across working with pneumatic cylinders has to do with
the compressibility of a gas. Many studies have been completed on how the precision of a
pneumatic cylinder can be affected as the load acting on the cylinder tries to further
compress the gas used. Under a vertical load, a case where the cylinder takes on the full
load, the precision of the cylinder is affected the most. A study at the National Cheng
Kung University in Taiwan, concluded that the accuracy is about ± 30mm, which is still
within a satisfactory range but shows that the compressibility of air has an effect on the
system.

Fail safe mechanisms

Pneumatic systems are often found in settings where even rare and brief system failure is
unacceptable. In such situations locks can sometimes serve as a safety mechanism in case
of loss of air supply (or its pressure falling) and, thus,remedy|remedy]] or abate any
damage arising in such a situation. Due to the leakage of air from input or output reduces
the pressure and so the desired output.

Types

Although pneumatic cylinders will vary in appearance, size and function, they generally
fall into one of the specific categories shown below. However there are also numerous
other types of pneumatic cylinder available, many of which are designed to fulfill specific
and specialized functions.

Single-acting cylinder

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Single-acting cylinders (SAC) use the pressure imparted by compressed air to create a
driving force in one direction (usually out), and a spring to return to the "home" position.
More often than not, this type of cylinder has limited extension due to the space the
compressed spring takes up. Another downside to SACs is that part of the force produced
by the cylinder is lost as it tries to push against the spring. Because of those factors,
single acting cylinders are recommended for applications that require no more than
100mm of stroke length :85

Double-acting cylinders

Double-acting cylinders (DAC) use the force of air to move in both extend and retract
strokes. They have two ports to allow air in, one for outstroke and one for instroke.
Stroke length for this design is not limited, however, the piston rod is more vulnerable to
buckling and bending. Addition calculations should be performed as well. :89

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 SPROCKET

A sprocket or sprocket-wheel is a profiled wheel with teeth, cogs, or even sprockets that
mesh with a chain, track or other perforated or indented material. The name 'sprocket'
applies generally to any wheel upon which are radial projections that engage a chain
passing over it. It is distinguished from a gear in that sprockets are never meshed together
directly, and differs from a pulley in that sprockets have teeth and pulleys are smooth.

Sprockets are used in bicycles, motorcycles, cars, tracked vehicles, and other machinery
either to transmit rotary motion between two shafts where gears are unsuitable or to
impart linear motion to a track, tape etc. Perhaps the commonest form of sprocket is
found in the bicycle, in which the pedal shaft carries a large sprocket-wheel which drives
a chain which in turn drives a small sprocket on the axle of the rear wheel. Early
automobiles were also largely driven by sprocket and chain mechanism, a practice largely
copied from bicycles. Sprockets are of various designs, a maximum of efficiency being
claimed for each by its originator. Sprockets typically do not have a flange. Some
sprockets used with timing belts have flanges to keep the timing belt centered. Sprockets
and chains are also used for power transmission from one shaft to another where slippage
is not admissible, sprocket chains being used instead of belts or ropes and sprocket-
wheels instead of pulleys. They can be run at high speed and some forms of chain are so
constructed as to be noiseless even at high speed.

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 LEVER
A lever is a machine consisting of a beam or rigid rod pivoted at a fixed hinge, or
fulcrum. It is one of the six simple machines identified by Renaissance scientists. The
word comes from the French lever, "to raise", cf. a levant. A lever amplifies an input
force to provide a greater output force, which is said to provide leverage. The ratio of the
output force to the input force is the ideal mechanical advantage of the lever.

Force and levers

A lever is a beam connected to ground by a hinge, or pivot, called a fulcrum. The ideal
lever does not dissipate or store energy, which means there is no friction in the hinge or
bending in the beam. In this case, the power into the lever equals the power out, and the
ratio of output to input force is given by the ratio of the distances from the fulcrum to the
points of application of these forces. This is known as the law of the lever.

Classes of Lever
Levers are classified by the relative positions of the fulcrum and the input and output
forces. It is common to call the input force the effort and the output force the load or the
resistance. This allows the identification of three classes of levers by the relative
locations of the fulcrum, the resistance and the effort:

Class 1: Fulcrum in the middle: the effort is applied on one side of the fulcrum and the
resistance on the other side, for example, a crowbar or a pair of scissors.

Class 2: Resistance in the middle: the effort is applied on one side of the resistance and
the fulcrum is located on the other side, for example, a wheelbarrow or a nutcracker or a
bottle opener.

Class 3: Effort in the middle: the resistance is on one side of the effort and the fulcrum is
located on the other side, for example, a pair of tweezers or the human mandible.

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These cases are described by the mnemonic "fre 123" where the fulcrum is in the middle
for the 1st class lever, the resistance is in the middle for the 2nd class lever, and the effort
is in the middle for the 3rd class lever.

Law of the Lever

The lever is a movable bar that pivots on a fulcrum attached to a fixed point. The lever
operates by applying forces at different distances from the fulcrum, or pivot.

Assuming the lever does not dissipate or store energy, the power into the lever must equal
the power out of the lever. As the lever rotates around the fulcrum, points farther from
this pivot move faster than points closer to the pivot. Therefore a force applied to a point
farther from the pivot must be less than the force located at a point closer in, because
power is the product of force and velocity.

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 SPRINGS
DEFINITION FOR SPRING:
Springs are elastic bodies (generally metal) that can be twisted, pulled, or stretched by
some force. They can return to their original shape when the force is released. In other
words it is also termed as a resilient member.
CLASSIFICATION OF SPRINGS:
Based on the shape behavior obtained by some applied force, springs are classified into
the following ways:
SPRINGS

HELICAL SPRINGS LEAF SPRINGS

SPIRAL SPRINGS

TENSION HELICAL TORSION SPRING

SPRING
COMPRESSION HELICAL
SPRING

I. HELICAL SPRINGS:
DEFINITON:
It is made of wire coiled in the form of helix.
CROSS-SECTION:
Circular, square or rectangular
CLASSIFICATION:
1) Open coil springs (or) Compression helical springs
2) Closed coil springs (or) Tension helical springs
1) HELICAL TENSION SPRINGS:
CHARACTERISTICS:

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 Figure1 shows a helical tension spring. It has some means of transferring
the load from the support to the body by means of some arrangement.

 It stretches apart to create load.

 The gap between the successive coils is small.

 The wire is coiled in a sequence that the turn is at right angles to the axis
of the spring.

 The spring is loaded along the axis.

 By applying load the spring elongates in action as it mainly depends upon

the end hooks as shown in figure2.

FIGURE.TENSION HELICAL SPRING

FIGURE.TYPES OF END HOOKS OF A HELICAL EXTENSION

SPRING

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APPLICATIONS:
1) Garage door assemblies

2) Vise-grip pilers

3) carburetors

2) HELICAL COMPRESSION SPRINGS:

CHARACTERISTICS:
 The gap between the successive coils is larger.

 It is made of round wire and wrapped in cylindrical shape with a constant

pitch between the coils.

 By applying the load the spring contracts in action.

 There are mainly four forms of compression springs as shown in figure3..

They are as follows:

1) Plain end
2) Plain and ground end
3) Squared end
4) Squared and ground end
Among the four types, the plain end type is less expensive to manufacture.
It tends to bow sideways when applying a compressive load.
FIGURE.COMPRESSION HELICAL SPRING

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APPLICATIONS:
1) Ball point pens

2) Pogo sticks

3) Valve assemblies in engines

3) TORSION SPRINGS:
CHARACTERISTICS:
 It is also a form of helical spring, but it rotates about an axis to create load.

 It releases the load in an arc around the axis as shown in figure4.

 Mainly used for torque transmission

 The ends of the spring are attached to other application objects, so that if
the object rotates around the center of the spring, it tends to push the
spring to retrieve its normal position.

FIGURE.TORSION SPRING
APPLICATIONS:
 Mouse tracks

 Rocker switches

 Door hinges

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  Clipboards

 Automobile starters

4) SPIRAL SPRINGS:
CHARACTERISTICS:
 It is made of a band of steel wrapped around itself a number of times to
create a geometric shape as shown in figure5.

 Its inner end is attached to an arbor and outer end is attached to a retaining
drum.

 It has a few rotations and also contains a thicker band of steel.

 It releases power when it unwinds.

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 PUNCHING TOOLS / ACCESSORIES

A punch is a hard metal rod with a shaped tip at one end and a blunt butt end at the other,
which is usually struck by a hammer. Most woodworkers prefer to use a ball-peen
hammer for using punches. Punches are used to drive objects, such as nails, or to form an
impression of the tip on a workpiece. Decorative punches may also be used to create a
pattern or even form an image.

Punches and dies are necessities in a metal shop. They will help to make work more
efficient in the realm of modular home construction to auto body repair and restoration.
Whether in need of a punch for a variety of metal work tasks or for more specific needs
in auto body shops, variety of punches and dies, that are capable of punching through a
variety of metals.

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 CONCLUSION
Our team has made this project with utmost dedication which will help common people.
This project has been made for the first time and this the pneumatic punching machine
can easily punch the papers, metals, plastics etc. Initially we press the lever manually and
the force is transmitted from the lever to the cylinder (Syringe-1) through a link. The air
in the cylinder (Syringe-1) gets compressed and exerts force through the pipe to the next
cylinder (Syringe-2) where the punching tool is connected and hence the object is
punched due to air pressure.

Thus the project is easy to operate due to its simple mechanism.

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 REFERENCES
 www.engineering.world.edu/me
 www.blown-film-machine.com/mechanical-type-pneumatic-type-manual-
punchingmachine.htm
 www.howstuffworks.com
 www.100projects.org
 www.technocrats.com/projects/mechanical-project/
 www.students360.in

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