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A PROJECT REPORT ON

FABRICATION OF PNEMATIC SHEET CUTTING MACHINE


Submitted in partial fulfillment of the requirement for the award of degree of
BACHELOR OF TECHNOLOGY
IN
MECHANICAL ENGINEERING
Submitted by

SK.AZGAR 13JD5A0306
E.ANIL 12JD1A0311
P.VASU 12JD1A0344
M.SAI RAMESH 12JD1A0323
M.SAI MANIKANTA 12JD1A0330

Under the guidance of


Mr. U.RAJESH(ASST PROF)

DEPARTMENT OF MECHANICAL ENGINEERING


ELURU COLLEGE OF ENGINEERING AND TECHNOLOGY
DUGGIRALA, ELURU
ELURU COLLEGE OF ENGINEERING AND TECHNOLOGY
ELURU
DEPARTMENT OF MECHANICAL ENGINEERING

Certificate
This is to certify that this project work entitled

FABRICATION OF PNEMATIC SHEET CUTTING MACHINE


Is the bonafide work of Mr. SK.AZGAR

Bearing pin no 13JD5A0306 of that year done 2014-15 with her batch mates
submitted in partial fulfillment of the requirement for the along award of B-
TECH in Mechanical Engineering of Jawaharlal Nehru Technological University
KAKINADA, during the academic session 2012-2016

Project guide head of the department

External examiner
ACKNOWLEDGEMENT

We express our sincere thanks to our principal Sri. P BALA KRISHNA


PRASAD Ph d for providing us the necessary facilities to make this project

We also express our sincere and heartful thanks & acknowledge to our head
of the department in mechanical engineering Sri. K phani babu M.Tech for his
spontaneous expression of knowledge and highly valuable suggestions with help us
a lot in bringing up this project all through this academic year

We also express our sincere thanks to our project guide Mr. U.RAJESH
whose valuable suggestions and guidance helped us a lot in completing and
presenting our project work on FABRICATION OF PNEMATIC SHEET
CUTTING MACHINE

Lastly, we thank one and all who helped us directly & indirectly in
completing the project successfully.

Project associates……
ABSRACT

Use of galvanized iron (GI Sheet) is used now a days in many industries like
automobile, packing, medical etc.., The reason behind this is that the GI made
things are quiet easier to manufacture, handling the reliable to use. Hydraulically
operated machines are too costlier for small and medium scale industries

The sheet metal cutting process is a main part of the all industries. Normally
the sheet metal cutting machine is manually hand operated one for medium and
small scale industries. In our project is “AUTOMATIC SHEET METAL
CUTTING MACHINE”.

Automation in the modern world is inevitable. Any automatic machine


aimed at the economical use of man, machine, and material worth the most. In our
project is solenoid valve is used for automation.

The sheet metal cutting machine works with the help of pneumatic double
acting cylinder. The piston is connected to the moving cutting tool. It is used to cut
the small size of sheet metal. The machine is portable in size, so easy transportable

Contents
CHAPTER TITLE P.NO

1 Introduction
1.1. SHEET METAL 1
1.2. SHEET METAL CUTTING 2
2. COMPONENTS USED 3
3. SPECIFICATIONS 4
4. PNEUMATIC CYLINDERS 5
5. DIRECTION CONTROL VALVE 7
5.1 TYPES OF CONTROL VALVE
5.2 TWO WAY DIRECTION VALVE
5.3 THREE WAY DIRECTION VALVE
5.4 FOUR WAY DIRECTION VALVE
5.5 FIVE WAY DIRECTION VALVE
6 compressor
1. INTRODUCTION
1.1. SHEET METAL:

Sheet metal is simply a metal formed into thin and flat pieces. It is one of the fundamental
forms used in metal working and can be cut and bent into a variety of different shapes. Countless
everyday objects are constructed of the material. Thicknesses can vary significantly, although
extremely thin thicknesses are considered foil or leaf, and pieces thicker than 6 mm (0.25 in) are
considered plate.

Sheet metal is available in flat pieces or as a coiled strip. The coils are formed by running a
continuous sheet of metal through a roll slitter.

The thickness of the sheet metal is called its gauge. Commonly used steel sheet metal ranges
from 30 gauge to about 8 gauge. The larger the gauge number, the thinner the metal. Gauge is
measured in ferrous (iron based) metals while nonferrous metals such as aluminum or copper are
designated differently; i.e., Copper is measured in thickness by Ounce.

There are many different metals that can be made into sheet metal, such as galvanized iron
aluminum, brass, copper, steel, tin, nickel and titanium. For decorative uses, important sheet
metals include silver, gold and platinum (platinum sheet metal is also utilized as a catalyst.)

Sheet metal also has applications in car bodies, airplane wings, medical tables, roofs for buildings
(Architectural) and many other things. Sheet metal of iron and other materials with high magnetic
permeability, also known as laminated steel cores, has applications in transformers and electric machines.
Historically, an important use of sheet metal was in plate armor worn by cavalry, and sheet metal
continues to have many decorative uses, including in horse tack. Sheet metal workers are also known as
"Tin Bashers",("Tin Knockers") which is derived from the hammering of panel seams when installing tin
roofs.
There are three primary procedures in Layout
1 Parallel
2 Radial
3 Triangulation

1.2. SHEET METAL CUTTING:


Cutting processes are those in which a piece of sheet metal is separated by applying a
great enough force to cause the material to fail.

The most common cutting processes are performed by applying a shear force, and are
therefore sometimes referred to as shearing processes.

When a great enough shearing force is applied, the shear stress in the material will
exceed the ultimate shear strength and the material will fail and separate at the cut location.

This shearing force is applied by two tools, one above and one below the sheet. Whether
these tools are a punch and die or upper and lower blades, the tool above the sheet delivers a
quick downward blow to the sheet metal that rests over the lower tool.

A small clearance is present between the edges of the upper and lower tools, which
facilitates the fracture of the material. The size of this clearance is typically 2-10% of the
material thickness and depends upon several factors, such as the specific shearing process,
material, and sheet thickness.

The effects of shearing on the material change as the cut progresses and are visible on
the edge of the sheared material. When the punch or blade impacts the sheet, the clearance
between the tools allows the sheet to plastically deform and “rollover” the edge. As the tool
penetrates the sheet further, the shearing results in a vertical burnished zone of material.

Finally, the shear stress is too great and the material fractures at an angle with a small burr
formed at the edge. The height of these portions of the cut depends on several factors, including
the sharpness of the tools and the clearance between the tools.

2. COMPONENTS USED
 Double acting cylinder

 Pneumatic hand operated valve

 High speed steel blade

 Compressor

 Lever shear
3. SPECIFICATIONS

1. Pneumatic Cylinder-
Quantity: 1
Total Length: 375mm
Bore: 40mm
Stroke: 200mm
Piston Rod Diameter: 20mm
Max Working Pressure: 8 bar
Weight: 3kg
2. DC Valve-

Quantity :1
Operation : Manual
Type : Hand Lever, Detent Type
Number of Ports: 5
Number of Positions: 3
Construction : Sliding spool type
3. Pneumatic Pipe-

Quantity : 5000mm
Diameter : 8mm
Thickness : 1mm
4. Fork End Nut-

Quantity :2
Length : 16mm
Size : M16

SHEET CUTTER

Length of cut : 7 inch


Thickness : 0.5-6 mm

Compressor
Engine : 1HP
Capacity : 1-10 kg
Power : 12 volts
4. 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.

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. Engineers
prefer to use pneumatics sometime because they are quieter, cleaner, and do not
require large amounts or space for fluid storage.

Figure (i)

5
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
DisneyTiki Room, pneumatics are used to prevent fluid from dripping onto people
below the puppet.

4.1They are two types of pneumatic sheet cutting machine

1) Single acting cylinder


2) Double acting cylinder
4.1 SINGLE- ACTING CYLINDER

Pneumatic cylinder(s) (sometimes known as air cylinders) are mechanical devices which


use the power of compressed gas to produce a force in a reciprocating linear motion

hydraulic cylinders something 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.
[1] :85
   Engineers sometimes prefer to use pneumatics 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 pneumatics are used to
prevent fluid from dripping onto people below the puppets
4.2 DOUBLE-ACTING CYLINDER

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 out-stroke and one
for in-stroke. 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 by using design data hand book using some relations between
cylinder and pressure we can accurately find out bending and buckling of tie rod.

4. 2D VIEW:

Figure (ii)

6
5 Directional Control Valves

Directional control valves perform only three functions:


1. stop fluid flow
2. allow fluid flow, and
3. change direction of fluid flow.

These three functions usually operate in combination.

The simplest directional control valve is the 2-way valve. A 2-way valve stops flow or allows
flow. A water faucet is a good example of a 2-way valve. A water faucet allows flow or stops
flow by manual control.

A single-acting cylinder needs supply to and exhaust from its port to operate. This requires a 3-
way valve. A 3-way valve allows fluid flow to an actuator in one position and exhausts the fluid
from it in the other position. Some 3-way valves have a third position that blocks flow at all
ports.

A double-acting actuator requires a 4-way valve. A 4-way valve pressurizes and exhausts two
ports interdependently. A 3-position, 4-way valve stops an actuator or allows it to float. The 4-
way function is a common type of directional control valve for both air and hydraulic circuits. A
3-position, 4-way valve is more common in hydraulic circuits.

The 5-way valve is found most frequently in air circuits. A 5-way valve performs the same
function as a 4-way valve. The only difference is an extra tank or exhaust port. (Some suppliers
call their 5-way valves, “5-ported 4-ways.") All spool valves are five ported, but hydraulic valves
have internally connected exhaust ports going to a common outlet. Because oil must return to
tank, it is convenient to connect the dual tank ports to a single return port. For air valves,
atmosphere is the tank, so exhaust piping is usually unimportant. Using two exhaust ports makes
the valve smaller and less expensive. As will be explained later, dual exhausts used for speed-
control mufflers or as dual-pressure inlets make this configuration versatile.
Following are schematic symbols for commonly used directional control valves

5.1 In direction control valves are so many types


1) 2-way directional control valves
2) 3-way directional control valves
3) 4-way directional control valves
4) 5-way directional control valves etc…,

In most of case we can be used the 2 way direction control valve


5.2 2 way direction control valve

A 2-way directional valve has two ports normally called inlet and outlet. When the inlet is blocked in
the at-rest condition, as shown in Figure 8-1, it is referred to as "normally closed" (NC). The at-rest
box or the normal condition is the one with the flow lines going to and from it.

The boxes or enclosures represent the valve’s positions. In Figure 8-1, the active box shows blocked
ports, or a closed condition, while the upper box shows a flow path. When an operator shifts the
valve, it is the same as sliding the upper box down to take the place of the lower box. In the shifted
condition there is flow from inlet to outlet. Releasing the palm button in it allows the valve spring to
return to the normal stop flow condition. A 2-way valve makes a blow-off device or runs a fluid
motor in one direction. By itself, a 2-way valve cannot cycle even a single acting cylinder.

Figure 8-2 shows a "normally open" (NO) 2-way directional valve. Energizing the solenoid on this
valve stops fluid flow. Valve operators come in different types. A solenoid pilot operator using
solenoid-controlled pressure from the inlet port to move the working directional spool cam -operated
valve. A moving machine member usually operates this type valve.

5.3 3-way directional control valves


A 3-way valve has three working ports. These ports are: inlet, outlet, and exhaust  A 3-way valve
not only supplies fluid to an actuator, but allows fluid to return from it as well. schematic symbols for 3-
way directional control valves.

In all-ports-blocked, 3-way, 3-position valve. A valve of this type connected to a single-acting,


weight- or spring-returned cylinder could extend, retract, or stop at any place in the stroke.
Some 3-way valves select fluid flow paths as in Figure 8-9. Use a spool-type valve for this
operation. Another flow condition is the diverter valve A diverter valve sends fluid to either of two
paths.

5.4 4-way directional control valves

It show different configurations available in 4-way directional control valves. They range from the
simple, two-position, single, direct solenoid, spring-return valve to the more complex three-position, double
solenoid, pilot-operated, spring-centered, external-pilot supply.

Lines to the boxes show flow to and from the valve, while lines with arrows in the boxes show direction of
flow. The number of boxes tells how many positions the valve has. shows a single solenoid, spring-
centered valve. This valve has a third position but there is no operator for it. Use this spring-centered,
single solenoid valve in control circuits for special functions. In the past, to get this configuration,
you only had to wire one solenoid of a double-solenoid, three-position valve.
5.5 5-way directional control valves

Most spool-type air valves come in a 5-way configuration. Because air usually exhausts to
atmosphere, the extra exhaust port is no problem. Many valves use the two exhaust ports for speed
control mufflers. Mufflers not only make the exhaust quieter, but throttle the exhaust, which in turn
controls cylinder speed in a meter-out circuit.
6 COMPRESSORS
An air compressor is a device that converts power (using an electric motor, diesel or gasoline
engine, etc.) into potential energy stored in pressurized. The energy can be used for the variety of
applications. Usually by utilizing the kinetic energy of the air it is depressurized

6.1 TYPES OF AIR COMPRESSOR

1) Reciprocating
2) Rotary screw
3) Centrifugal

6.1.1 These types are future specified by:

 The number of compression stages


 Cooling method (air, water, oil)
 Drive method (motor, engine, steam, other)
 Lubricating (oil, oil-free where oil free means no lubricating oil contact the compressed
air)
 Packed or custom -built

6.2 RECIPROCATING AIR COMPRESSOR

A reciprocating compressor or piston compressor is a positive displacement


compressor that uses pistons driven by a crankshaft to deliver gases at high pressure. The intake
gas enters the suction manifold, then flows into the compression cylinder where it gets
compressed by a piston driven in a reciprocating motion via a crankshaft, and is then discharged.
Applications include oil refineries.  gas pipelines., chemical plants. Naturally processing plants
and refrigeration plants. One specialty application is the blowing of plastic bottles made
of polyethylene terephthalate (PET).
In the ionic liquid piston compressor many seals and bearings were removed in the design as the
ionic liquid does not mix with the gas. Service life is about 10 times longer than a
regular diaphragm compressor with reduced maintenance during use, energy costs are reduced
by as much as 20%. The heat exchangers that are used in a normal piston compressor are
removed as the heat is removed in the cylinder itself where it is generated. Almost 100% of the
energy going into the process is being used with little energy wasted as reject heat
The compressor in single and double stage reciprocating compressor are commercially available

 Single stage compressor are generally used for the pressure in the range of 70 N/mm 2 to
100 N/mm2
 Double stage compressor are generally used for higher pressure in the range of 100
N/mm2 to 250N/mm2

The reciprocating air compressor is single acting when the compressing is accomplished
using only one side of the piston. A compressor using both sides of the piston is considered
double acting.

Load reduction is achieved by unloading individual cylinder typically this is accomplished by


throttling the suction pressure to the cylinder or by passing air either within or outside the
compressor. Capacity control is achieved by varying the speed in engine-driven unit throught
fuel flow control.

Reciprocating air compressor are available either as air cooled or water cooled in lubricated
and non-lubrication configuration and provide a wide range of pressure capacity selection
6.2 ROTARY SCREW COMPRESSOR
A rotary-screw compressor is a type of gas compressor that uses a rotary-type positive-
displacement mechanism. They are commonly used to replace piston compressors where large
volumes of high-pressure air are needed, either for large industrial applications or to operate
high-power air tools such as jackhammers
The gas compression process of a rotary screw is a continuous sweeping motion, so there is very
little pulsation or surging of flow, as occurs with piston compressors.

Since the cooling take place right inside compressor the working part never experience
extreme operation temperature. The rotary compressor, therefore is a continuous duty part air
is cooled or water cooled compressor package

Rotary screw compressor are easy to maintain and operation. Capacity control for these
compressors is accomplished by varies speed and variable compressor displacement. For the
latter control technique, a slide valve opens bypassing a portion of the compressed air back to
the suction. Advantage of the rotary screw compressor include smooth pulse-free air output in
a compact size with high output volume over a long life

Oil free rotary screw compressor utilizes special design air ends to compress air without
oil in the compression chamber yielding true oil free air. Oil free rotating screw air compressor
are available air cooled and water cooled and provide the flexibility as oil flooded rotaries when
oil free air is required
Operation
Rotary-screw compressors use two meshing helical screws, known as rotors, to compress the gas. In a
dry-running rotary-screw compressor, timing gears ensure that the male and female rotors maintain precise
alignment. In an oil-flooded rotary-screw compressor, lubricating oil bridges the space between the rotors, both
providing a hydraulic seal and transferring mechanical energy between the driving and driven rotor. Gas enters
at the suction side and moves through the threads as the screws rotate. The meshing rotors force the gas
through the compressor, and the gas exits at the end of the screws.
The effectiveness of this mechanism is dependent on precisely fitting clearances between the helical rotors and
between the rotors and the chamber for sealing of the compression cavities. However, some leakage is
inevitable, and high rotational speeds must be used to minimize the ratio of leakage flow rate over effective
flow rate.

Size
Rotary-screw compressors tend to be compact and smoothly running with limited vibration, thus not
requiring spring suspension. Many rotary-screw compressors are, however, mounted using rubber vibration-
isolating mounts to absorb high-frequency vibrations, especially in rotary-screw compressors that operate at
high rotational speeds. Rotary-screw compressors are produced in sizes that range in pumping speeds from
10 cubic feet per minute to several thousand CFM. Rotary-screw compressors are typically used in
applications requiring more airflow than is produced by small reciprocating compressors but less than is
produced by centrifugal compressor
6.3 CENTRIFUGAL COMPRESSOR
In a centrifugal compressor, energy is transferred from a set of rotating impeller blades
to the gas. The designation “centrifugal” implies that the gas flow is radial, and the energy
transfer is caused from a change in the centrifugal forces acting on the gas. Centrifugal
compressors deliver high flow capacity per unit of installed space and weight, have good
reliability, and require significantly less maintenance than reciprocating compressors. However,
the performance characteristic of centrifugal compressors is more easily affected by changes in
gas conditions than is the performance of reciprocating compressors. On this page, the
performance characteristic curve is presented with emphasis on process control of capacity by
speed variation, suction throttling, or variable inlet guide vanes. Process control to avoid
operation in a damaging surge condition is also addressed.

The physical size (diameter) of a centrifugal compressor is determined by the volumetric


flow rate at the inlet. The compression ratio (or head) determines the number of stages
(length). The rotating speed of a centrifugal compressor is an inverse function of diameter to
maintain a desired peripheral speed at the outer diameters of the impellers regardless of the
physical size of the compressor. Very large (i.e., high-volume) flow compressors may operate at
speeds as low as 3,000 rpm. Conversely, low-volume flow compressors may operate at speeds
up to 30,000 rpm. Power requirement is related to mass flow, head, and efficiency. Depending
on the particular application, centrifugal compressor powers can range from as low as 500 hp
(400 kW) to more than 50,000 hp (40 MW).
At low volume flow rates, the width of the gas passages in a centrifugal compressor
becomes narrow, and the effects of friction become significant, resulting in reduced efficiency.
For this reason reciprocating compressors often are more appropriate for low-volume flow
applications. For further discussion of this subject, see the section below on compressor
selection
The API has produced an industry standard, API Standard 617, which is frequently used
to govern the design and manufacture of centrifugal compressors. A typical centrifugal
compressor package is shown in Fig. 1. The compressor shown is mounted on a single base
plate and is driven by an electric motor.
LEVER SHEAR

A bench shear, also known as a lever shear, is a bench mounted shear with a compound
mechanism to increase the mechanical advantage. It is usually used for cutting rough shapes out of
medium sized pieces of sheet metal, but cannot do delicate work. [1][2] For the small shear, it mostly
designed for a wide field of applications. Light weight and easy efficient operation, yet very sturdy in
construction. The cutting blades fitted are carefully and accurately ground to give easy, clean quick
cuts, and free of burrs. These special features help the operators save a great deal of their energy.
But some shearing machines can cut sheet bar and flat bar up to 10mm. It is electrically welded
together to make it a sturdy stable unit capable to withstand highest stresses due to heavy duty
usage. The footplates are reinforced with bracing angles so that they give firm stability to the shear.
The machine is provided with section knives with sliding blades which can be adjusted by hand to
make 90 cuts on angles and T-sections of different sizes as well as with openings for cutting round
and square bars.

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