Design and fabrication of pneumatic press for various attachments

3. DESIGN AND DEVELOPMENT OF PNEUMATIC

Nowadays the world is focusing on automation to sustain in competitive environment Each
and every work of human is reduced by a machine. Proses are one of the most commonly used
machine tools in industry for the forming of different materials In the past. for the pressing
tasks in industry. mechanical presses were more frequently used, but now a days pneumatic
presses take precedence due to their numerous advantages, such as: full force throughout the
stroke, moving parts that operate with good lubrication, stroke that can be fully adjustable which
contributes to the flexibility of application, built in overload protection, can be made for very
large force capacities, silent operation and more compact. Hence a pneumatic press is a machine
that makes use of the air pressure for operations.

A pneumatic press derives its primary mechanical action (such as shearing, punching.
bending, forming, drawing. extruding. assembly. or other action) from a pressure source by
means of compressed air. Such presses arc used in variety of purposes. A pneumatic system
is a system that uses compressed air to transmit and control energy. Pneumatic systems are used
in controlling train doors, automatic production lines, and mechanical clamps.

This project is study about the design and development of pneumatic press. for us the main
objective of our project is to implement the pneumatic press machine in small scale industries,
workshops. Pneumatic press machine consist of double acting cylinder, direction control
valve, hoses, motor. compressor. base frame structure, punching tool, punching die. shearing
blade, shearing attachment, stamp holder. The main advantage of our project is the small size
pans are easily pressed.

3.1 Material Selection

 Design and fabrication of pneumatic press for various attachments

To prepare any machine part, the type of material should he properly selected considering
design safety The selection of material for engineering application is given by the following
factors,
1) Availability of materials
2) Suitability of the material t'or the requiml components.
3) Cost of the materials.

The base frame is basically made up of mild steel. The reasons for the selection are Mild steel
is readily available in market.
1] It is economical to use and is available in standard sizes.
2] It has good mechanical properties i.e. it is easily machinable.

3] It has moderate factor of safety, because factor of safety results in unnecessary

wastage of material and heavy selection, low factor of safety results in unnecessary risk of
failure.
4] It has high tensile strength, Low coefficient of thermal expansion. The materials of the
sheets to be cut are taken as aluminium and plastic as they are replacing many metals in the
present scenario because of their distinguished properties and features.

Mild steel composition

Mild steel contains -

Carbon 0.16 to 0.18 % (maximum 0.25 is allowable)
Manganese 0.70 to 0.90 %

Silicon maximum 0.40 %

Sulphur maximum 0.04 %

Phosphorous maximum 0.04 %

3.2 General Concepts on Design and Development of Pneumatic Systems

 Design and fabrication of pneumatic press for various attachments

3.2.1 Development of Pneumatic System

The solution to a control problem is worked out according to a system with documentation
playing an important role in communicating the final result. The circuit diagrams are drawn
using standard symbols and labeling. Comprehensive documentation is required including
most of the following the methodical design of a circuit diagram in accordance with
prescribed rules and instructions.

In pneumatic application one cylinder is used. The activation of the limit switch of cylinder
will provide set or reset signal to the final control valves for further controlling the
movement of cylinder. The limit switch have to be arranged in the proper location with the
help of motion diagram. In order to develop control cylinder applications, it is necessary to
draw the motion diagram to understand the actuation of signal input switches-limit switches
and sensors. 'The status of the cylinder displacement
and actuation of set and reset signals at 3/2 spool
operated directional control valve is shown by functional diagram.
1

Fig. 3.0 Pneumatic circuit diagram

1.3,1 Pneumatic
 Design and fabrication of pneumatic press for various attachments

Fig. 3.1 Pneumatic cylinder

Many industrial applications require linear motion during their operating sequence.
One Of the simplest and cost effective ways to accomplish that is with a pneumatic
cylinder. An actuator is a device that translates a source of static power into useful
output motion. It can also be used to apply a force. Actuators are typically
mechanical devices that take
energy and convert it into some kind of motion. That motion can be in many form
such as bl.king, clamping and ejecting Pneumatic actuators are mechanical devices
that use compressed air acting on a piston inside the cylinder to move a load along
linear path

Unlike the ir hydraulic

al te rna ti ve s. th e operating f lui d in a p ne um at ic cy li nd er i s s im pl y O. so leakage doesn't drip and contaminate surrounding areas.

Unlike their hydraulic alternatives. the operating fluid in a pneumatic cylinder is simply
O. so leakage doesn't drip and contaminate surrounding areas.

Types of pneumatic cylinders:

Diaphragm cylinders. rod less cylinders, telescoping cylinders and through-rod cylinders.
 Design and fabrication of pneumatic press for various attachments

t his project we used double acting cylinder. Double-acting cylinders have an air port at
ea ch end and move the piston forward and back by alternating the pon that receives the
high pressure air. In a typical application, the actuator body is connected to a support
frame and the end of the rod is connected to a machine element that is to be moved. An
on-off control valve is used to direct compressed air into the extended port while opening
the Retract port to atmosphere. The difference in pressure on the two sides of the piston
results in a force equal to the pressure differential multiplied by the surface area of the
piston.

Fig 3.2 Compressor

 Design and fabrication of pneumatic press for various attachments

Fig 3.3. Classification of compressor

Applications:

 To supply high-pressure clean air to fill gas cylinders.

 To supply moderate-pressure clean air to a submerged surface supplied diver.

 To supply moderate-pressure clean air for driving some office and school building pneumatic
HVAC control system valves.
 To supply a large amount of moderate-pressure air to power pneumatic tools, suet as
jackhammers.

 For filling tires.

 To produce large volumes of moderate-pressure air for large-scale industria Processes (such as
oxidation for petroleum coking or cement plant bag holm purge systems).

33.3 Direction Control Valve

 Design and fabrication of pneumatic press for various attachments

Fig. 3.4 Directional control valv.

Directional control valves are one of the most fundamental parts in hydraulic machinery as well
and pneumatic machinery. They allow fluid flow into different paths from one or more sources.
They usually consist of a spool inside a cylinder which is mechanically or electrically contmlled.
The movement of the spool restricts or permits the flow, thus it controls the fluid flow.

Spool-type valves are available in 2-way 2-position, 3-way 2-position, 4-way 2-position, and 4-
way 3 position configurations. In this project we use 3 way 2 position direction control valve.
For all these valves the spools are pressure balanced and are held in position by a spring when
de-energized. When the solenoid coil is energized, magnetic force overcomes the spring and
shifts the spool. As the spool moves, flow forces, also awn as Bernoulli fortes, act on the spool
and can prevent proper operation.

3.3.4 Pressure Gauge

 Design and fabrication of pneumatic press for various attachments

Fig. 3.5 Pressure gauge

A pressure gauge is a fluid intensity measurement device. Pressure gauges are required

for the set-up and tuning of fluid power machines, and are indispensable in

troubleshooting them. Without pressure gauges, fluid power systems would be both

unpredictable and unreliable. Gauges help to ensure there arc no leaks or pressure

changes that could affect the operating condition of the pneumatic system.

Pneumatic and compressed air systems are also rise with gauges, as pressure is also

measured in many locations throughout the system. Pressure is measured at the

receiver(s), as well as at every FRL or stand-alone regulator in the system.

Sometimes pressure is measured at pneumatic actuators as well. Typically, pneumatic

pressure gauges are rated for not much more than 300 psi, although typical systems run

around 100 psi.

3.3.5 Air Supply Pipe

 Design and fabrication of pneumatic press for various attachments

Fig. 3.6 Air Supply Pipe

A compressed air system transfers more in the form of air pressure. A ctnice somewhere else
in a workshop can use the energy the compressor creates. The component that connects
everything together in a compressed air system is the capmg. The basics of compressed an pipe
work are simple. We just need to attach a compressor to an end-use device via a pipe.
Because of the following reasons, in this project we used plastic pipes:
I. They do not corrode. so you don't have to worry about rust dropping imo your air flow. This,
its tuns, induces the risk of obstructions.
2. The interior surface is smooth and never deteriorates. which encourages laminar flow.

3. The pipes are lightweight and easy to transport and fit.

4. Cutting through plastic pipes is quick and simple and requires basic tools
5. Plastic pipes can be glued together. which is less costly and quicker than welding metal.
Design and fabrication of pneumatic press for various attachments

Fig no.3.8 Base

 Design and fabrication of pneumatic press for various attachments

The following table summarizes the procedure development of punching tool Table 3.2
Manufacturing process for punching tool.
 Design and fabrication of pneumatic press for various attachments

SR. NO. OPERATION TOOL) JIG/ FIXTURE SPEED/ FEED/ D.O.C.

200 RPM
— Cutting Machine Hacksaw

2• 600 RPM
Facing Facing Tool

3. 600 RPM
Turning Turning Tool

4. 900 RPM
Step Turning Turning Tool

5• 1200 RPM
Finishing Finishing Tool

800 RPM
• Drilling Drill Bit

7 Tap Manually
Threading

8. 1500 RPM
Grinding Grinding wheel

9 Manually.

Inspection Vernier Caliper

Design and fabrication of pneumatic press for various attachments
Design and fabrication of pneumatic press for various attachments
Design and fabrication of pneumatic press for various attachments
Design and fabrication of pneumatic press for various attachments