Research Article / Research Project / Literature Review

Ministry of Higher Education
Egyptian Academy for Engineering & Advanced Technology (EAEAT)

Affiliated by Ministry of Military Production
Research Article / Research Project / Literature Review

In fulfillment of the requirements of
Department mechatronics
Academic Year 2019/2020
Course name Design of Mechatronics
Course code MEC 353
Title: -
Automated Punching Machine
By:
Name Edu mail ID

1 Magdy Mohamed m.mohammed2016153@eaeat academy.edu.eg 2016153
2 Karim tarek k.tarek2016147@eaeat-academy.edu.eg 2016147
3 Ahmed Mokhtar a.mohammed2016039@eaeat-academy.edu.eg 2016039
4 Mohamed ahmed m.ahmed2016159@eaeat-academy.edu.eg 2016159
Approved by:
Examiners committee Signature

Ministry of Higher Education Electronics and Mechatronics Department
Egyptian Academy for Engineering & Advanced Technology Final Research Report
Research objectives
Designing and discussing the idea of automating punching machine to reduce the job
setting, marking and punching times, and to reduce the labour cost by providing
automatic job feeding and punching machine by different ideas and choose one to be
the main idea of research.
1|Page
Abstract
By using the conventional punching machines, the time for job setting, marking and
punching operations is more and in addition to more labour cost. With Geneva based
punching machine the time for job setting, marking and punching operations is
reduced and labour cost is reduced too, in this research we have discussed the autoroll
punching machine with Geneva based mechanism, this is used to present automation
in industries, and this idea is suitable for starting mass production of punched jobs.
2|Page
Table of contents
Divide your research into sections or subjects; mention each section first page at this
table
Subject / section Page
3|Page
List of Figures
Figure I.D Description Page
Introduction
 background to the topic
In any conventional punching machine, there’s many old methods to apply the
punching operations to the work pieces, but these machines was very old and
going bad.
And by looking to the work done to these pieces it wasn’t done by the most
critical way but it has types of errors that make the operating cost so high
regardless the payroll payed to the workers and operarting time for machines
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and needed material costs for lubricating and to compensate the tune that is
wasted in this conventional operations.
 brief review of current knowledge
In any conventional punching machine, the work piece is to be marked before
punching operation and setting the aligning of the work piece with the punching
tool. When the job is manually feeded for every punch hole.
 Khnowledge gap
In this previous discussed operations done to the work piece it is clearly
observed that we waste material, time and money to make simple operations
like punching so in this research we discuss how to fill this gap to get the best
results with least efforts and cost.
 Literature review
By searching we found that automating these processes like automatic feeding
and punchine, will help us to save effort, money and labour to redirecting it to
more important operations and projects.
Literature Review
Today every mission in this world has Its technical progress has made it faster and
faster but This development also demands enormous investments and Spending,
every industry wants to produce high productivity Rate to keep product quality and
standard weak Average cost but we still use a separate machine for Separate
operations. This absorbs time and power
Punching machine is one of the devices of theory in Paper cutting industry & metal
sheeting industry. It's Mainly used for cutting strings, as the name suggests. And
we are going to make a "PUNCHING" machine INDUSTRIES "so it should be
multipurpose & Used for card and paper cutting.
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In manual punching machine, the job is to be marked before punching operation.
This whole process takes longer to make. And series of punching operations
So we needed to upgrade to new automated punching machines.
This initiative would have an exceptionally successful potential scope Since we

combine two machining operations, including Metal perforation and feeding in a
single tube. In the end it reduces power consumption and takes up less Floor field,
and portable as well. Compared to individuals Machining operations This blend of
different operations Ultimately, reduces the overall budget into a single machine
6|Page
Methodology
CONSTRUCTION
This project consists of
1) VDC Motor with built in speed reduction gear box
2) Chain drive mechanism
3) Job feeding rollers
4) Main shaft with Plummer block support
5) Geneva wheel mechanism
6) Crank wheel
7) Punching tool.
8) Bolts & Screws
WORKING PRINCIPLE
Paper punching machine is designed with mechanical arrangement in

which movements are controlled by using Geneva mechanism. paper
punching machine consists of two sections. One section is automatic
feeding mechanism and the second section is conversion of rotary motion
into linear reciprocating motion of punching tool. The first section
consists of Geneva wheel disc keyed to shaft at one end and the other end
is connected with chain sprocket wheel. This Geneva wheel shaft is
supported on nylon bushes. This sprocket wheel transmit the rotary
motion from the Geneva wheel to the feeding rollers through a chain drive. Hence when the Geneva
wheel is rotated, the paper also moved for punching operation.
The second section consists of a DC electric motor, a nylon bush, a crank wheel with a pin, a
connecting rod and a punching tool. The second section is used to convert the rotary movement of
the forearm wheel into a reciprocating movement of the punching tool. The rotor shaft is attached to
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the crank wheel at one end and the other end is connected to the DC motor. This column is supported
on a nylon bush. The punch tool slice is replaced by connecting the crank wheel through the
connecting rod. Paper is automatically fed through the rotation of the Geneva wheel.
When the engine is running, the camera drive disc is rotated. The linear rail attached to the drive of
the cam drive with deviation from the center is retracted to the punching machine. The punching
machine consists of a punch head, when the linear bar is moved
down it presses the head of the hole. The boring head consists of
boring tools that punch the paper in the required way. The cam drive
disk has a pin attached to it, plugs into the Geneva wheel aperture
and turns the Geneva wheel. For each drive disk spin, the Geneva
wheel spins 1/4 of the spindle. The Geneva wheel shaft is attached to
a sprocket. When the Geneva wheel spins, the sprocket also rotates
which in turn spools attached to the other sprocket. The two cog
wheels are connected by a cylindrical chain. With the help of
cylinders, the paper moves forward and is perforated.
FEATURES OF AUTOMATED PUNCHING MACHINE

1. It is small in size
2. It can be move
3. The electric power consumption is lower
4. It can be used in our workshop
5. It is simple to build
6. Low cost
7. Less weight and easy to handle
8. It reduces the man power
SAFETY,CARE AND MAINTENANCE

Before using the device, some points should be noted for safety purposes,
Before starting the process, check the following items
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(1) Check the proper operation mechanism, and Treat carefully while you work.
(2) Check the alignment of chain drives, task feed rollers and loader in the unit.
(3) Do not insert any material or object between during the punching process.
(4) Check the chain drive lubrication in the unit.
Principal of dc motor
We need a power supply circuit to convert 220 AC volt to 12 v DC that we need to
feed our motor.
The ac voltage is connected to a transformer, usually 220V, which steps the voltage
down to the level of the desired dc output. A diode rectifier then provides a rectified
full-wave voltage, which is initially filtered through a simple condenser filter to
produce a dc voltage.
Motor calculation:
 12V (DC) O/p
 The consumed electric power of the motor (Pin) = I x
V = 1.5 x 12 = 18 W
 Angular speed (ωout) = 2 x π x rpm / 60
 The o/p mechanical power of motor = T x ωout Watts
The Torque of the motor (Tin) = Eb x Ia x 60 / 2 x π x N
 Efficiency of motor = Pout / Pin
 Input angular speed (ωin) = 2 x π x rpm / 60
 equation for Gear pair = Tout / Tin = ωout / ωin
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Sheet metal design
S.NO. PART MATERIAL

1 Geneva wheel Mild steel
2 Roller Steel
3 Shaft Mild steel
4 Columns and base Aluminum and mild steel
5 Sprockets Cast iron
6 Bolts & Screws Steel
Reslut & Discussion
Result
O/p torque from dc motor
Equation of gear pear :
Tout/Tin = ωout / ωin
Tin in motor = 9.55 x 1.5 x 60 / 2 x 3.14 x 1020

= 0.1341 N-m
(ωout) = 2 x π x rpm / 60 = 2 x 3.14 x 1020 / 60
= 106.8 rad/sec
(ωin ) = 2 x π x rpm / 60 = 2 x 3.14 x 51 / 60

= 5.34 rad/s
10 | P a g e
Tout / 0.1341 = 106.8 / 5.34
Tout = 6.282 N-m
Power required to punch
 (p) = 2πNT/60 W
 Torque input to the cam drive (Tin) = 6.22 N-m
 The o/p torque to drive = Tin(√2 cosθ –1)
= 6.22 (√2 cos0 – 1) = 2.57 N-m
 Power required to punch = 2 x π x N x T / 60
=2x3.14x51x2.57/60
= 13.72 W
Punching made in paper
Hole diameter = 5.5 mm
Thickness of paper = 5 mm
Ultimate shear stress of paper =500Kpa
Area under shear stress= π x d x t mm2
Force required to punch
F = A x τ Newton
= ( π x 5.5 x 0.5) x500
11 | P a g e
=4.315 N
Discussion
Paper punching is based on paper feeding through the cylinder that is operated by the
Geneva mechanism so that it is not indirectly. From the Geneva hatch play a role in
feeding the amount of paper.
Different types of punching machines are used for material punching and it is also one
of the automatic feeding and punching functions that are now operated by Geneva
mechanism.
At the end,
This machine has more advantages for other types of punching machines because it is
more easy to operate the automatic feeding arrangement for convenient function and
also less time consumption.
Conclusions
In this paper we discussed and explained the design and the control methodology of
the automated punching machine. this machine used in any process need punching on
paper and G.I sheet and some types of metal sheets with more accurate than a
conventional punching machine. this machine is worked by DC motor connected to
Geneva mechanism and rollers and chine drivers. the purpose of using the machine is
12 | P a g e
easy to use and can use it in many purposes. And by using this machine we can
overcome on many problems which we face on the other conventional punching
machine like long time, low finishing quality and labor cost.
References
Includes a list of references that helped you in your research
13 | P a g e
14 | P a g e

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Ministry of Higher Education

Egyptian Academy for Engineering & Advanced Technology (EAEAT)

Research Article / Research Project / Literature Review

Name Edu mail ID

Examiners committee Signature

Subject / section Page

Figure I.D Description Page

In manual punching machine, the job is to be marked before punching operation.

This whole process takes longer to make. And series of punching operations

So we needed to upgrade to new automated punching machines.

This initiative would have an exceptionally successful potential scope Since we

1) VDC Motor with built in speed reduction gear box

2) Chain drive mechanism

3) Job feeding rollers

4) Main shaft with Plummer block support

5) Geneva wheel mechanism

8) Bolts & Screws

Paper punching machine is designed with mechanical arrangement in

FEATURES OF AUTOMATED PUNCHING MACHINE

3. The electric power consumption is lower

4. It can be used in our workshop

7. Less weight and easy to handle

8. It reduces the man power

SAFETY,CARE AND MAINTENANCE

Before starting the process, check the following items

(4) Check the chain drive lubrication in the unit.

Sheet metal design

S.NO. PART MATERIAL

Reslut & Discussion

O/p torque from dc motor

Equation of gear pear :

Tout/Tin = ωout / ωin

Tin in motor = 9.55 x 1.5 x 60 / 2 x 3.14 x 1020

(ωout) = 2 x π x rpm / 60 = 2 x 3.14 x 1020 / 60

(ωin ) = 2 x π x rpm / 60 = 2 x 3.14 x 51 / 60

Tout / 0.1341 = 106.8 / 5.34

Tout = 6.282 N-m

Power required to punch

Punching made in paper

Hole diameter = 5.5 mm

Ultimate shear stress of paper =500Kpa

Area under shear stress= π x d x t mm2

Force required to punch

= ( π x 5.5 x 0.5) x500

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