DESIGN AND FABRICATION OF

PNEUMATICALLY OPERATED AND

GENEVA MECHANISM DRIVEN SHEET
PUNCHING MACHINE
MAJOR PROJECT REPORT
SUBMITTED IN PARTIAL FULFILMENT OF THE REQUIREMENTS FOR THE
AWARD OF THE DEGREE OF

BACHELOR OF TECHNOLOGY

(Mechanical)

SUBMITTED BY: UNDER GUIDANCE:

ABHINAV MISHRA (1706934) Er. GURPREET SINGH BATH

CHARANJOT SINGH GILL (1706977)

GAGANPREET SINGH (1706991)

HARMEET SINGH (1707013)

DEPARTMENT OF MECHANICAL ENGINEERING

GURU NANAK DEV ENGINEERINCOLLEGE, LUDHIANA

 GURU NANAK DEV ENGINEERING COLLEGE, LUDHIANA

CERTIFICATE
We hereby certify that the work which is being presented in the minor project report entitled
“DESIGN AND FABRICATION OF PNEUMATICALLY OPERATED AND GENEVA
MECHANISM DRIVEN SHEET PUNCHING MACHINE” by “Abhinav Mishra,
Charanjot Singh, Gaganpreet Singh, Harmeet Singh ” in partial fulfilment of requirements
for the award of degree of B.Tech. (Mechanical) submitted in the Department of Mechanical
Engineering at Guru Nanak Dev Engineering College, Ludhiana under Punjab Technical
University, Kapurthala is an authentic record of our own work carried out during a period
from JAN to JULY under the guidance of Er .Gurpreet Singh Bath. The matter presented
in this project report has not been submitted by us in any other University / Institute for the
award of any Degree or Diploma.

ABHINAV MISHRA (1706934)

CHARANJOT SINGH GILL (1706977)

GAGANPREET SINGH (1706991)

HARMEET SINGH (1707013)

This is to certify that the above statement made by the candidates are correct to the best of our
knowledge.

Signature of the Major Project Guide

Er. Gurpreet Singh

(Asstt. Professor, Department of Mechanical, GNDEC)

 ACKNOWLEDGEMENT

The authors are highly grateful to the Director, Guru Nanak Dev Engineering College (GNDEC),
Ludhiana, for providing this opportunity to carry out the present major project work . The constant
guidance and encouragement received from Dr.Paramjit Singh Bilga (Professor Head,
Department of Mechanical Engineering, GNDEC) has been of great help in carrying out the present
work and is acknowledged with reverential thanks.The authors would like to express a deep sense of
gratitude and thanks profusely to Er.Gurpreet Singh Bath (Asstt. Professor, Department of
Mechanical, GNDEC), who was our major project guide. Without the wise counsel and able
guidance, it would have been impossible to complete the in this manner. The author express gratitude
to other faculty members of Mechanical Engineering Department, GNDEC and Head and Staff of
Workshops, GNDEC for their intellectual support throughout the course of this work. Finally, the
authors are indebted to all whosoever have contributed in this major project work.

ABHINAV MISHRA (1706934)

CHARANJOT SINGH GILL (1706977)

GAGANPREET SINGH (1706991)

HARMEET SINGH (1707013)

 LIST OF FIGURES

1.Geneva drive Fig 1

2. Punching mechanism Fig 2

3.Model of Geneva mechanism Fig 3

4.Conventional punching machine Fig 4

5.Industrial processes Fig 5

6.Punched Sheet Fig 6

7.3-d model Fig 7

 CONTENTS

Page No.

Candidate's Declaration i

Acknowledgement ii

List of Figures iii

Chapter 1: INTRODUCTION AND BACKGROUND OF THE PROJECT 5

Chapter 2: LITERATURE SURVEY 10

Chapter 3: PRESENT WORK 13

3.1 Problem Formulation 13

3.2 Objectives 14

3.3. Methodology 14

Chapter 4: CONCLUSION 22

REFERENCES 23
1. INTRODUCTION
In today’s industrial league each and every field is making sure that there is a minimum cost

and highest production thus in order to achieve that every field try to make their purpose

machines in such a manner that it should be a less time consuming and a very significant

one .Also in our country’s scenario we can see that the high production giant industries are

making their production as maximum as they can but if we see the msme sector of India

which is the helping hand of these giant industries they are lagging behind due to less

expertise and less advancement .

As far as our project is concerned it will prove to be very fruitful for these

medium scale and small scale industries or in any workshop of the giant industries .In this

project the sheet metal is punched with the help of the pneumatically operated cylinder and

such that the continuous feed is given by that of the GENEVA MECHANISM also the

following is the introduction and the advantages of these two mechanisms:

1.1GENEVA MECHANISM

Geneva mechanism is commonly used indexing mechanism where an intermittent motion is

required. The Inverse Geneva mechanism, which is a variation of the Geneva mechanism, is

used where the wheel has to rotate in the same Direction as crank. It requires less radial space

and the locking device can be a circular segment attached to the crank that locks by wiping

against a built up rim on the periphery of the wheel.

               The design and fabricating of a conventional Geneva mechanism is generally simple

and inexpensive because there is no specially curved profile on any of the components except

straight lines and circular arcs. However, due to the discontinuity of the acceleration at the
beginning and ending positions, the shortcoming of using conventional Geneva mechanism is

the large impact when the driving crank engages and disengages with the wheel slot.

Fig 1

CLASSIFICATION OF GENEVA MECHANISM

 EXTERNAL GENEVA MECHANISM:

 INTERNAL GENEVA MECHANISM:

 SPHERICAL GENEVA MECHANISM: 

ADVANTAGES OF GENEVA MECHANISM

i. Geneva mechanism may be the simplest and least Expensive of all intermittent motion

mechanisms.

ii. They come in a wide variety of sizes, ranging from those used in instruments, to those used

in machine tools to index spindle carriers weighing several tons.

iii. They have good motion curves characteristics compared to ratchets, but exhibit more

“jerk” or instantaneous change in acceleration, than better cam systems

iv. Geneva maintains good control of its load at all Times, since it is provided with locking

ring surfaces.

DISADVANTAGES OF GENEVA MECHANISM

i. The Geneva is not a versatile mechanism.

ii. The ratio of dwell period to motion is also established Once the no of dwells per revolution

has been selected.

iii. All Geneva acceleration curves start and end With finite ac-celeration & deceleration.

iv. This means they produce jerk.

APPLICATIONS & USES

 STEPPER

 MECHANICAL WATCHES

 PLOTTERS

 CNC MACHINE

 IRON RING CLOCK

 Modern film projectors may also use an electronically controlled indexing

mechanism or stepper motor, which allows for fast-forwarding the film.

 Geneva wheels having the form of the driven wheel were also used in

mechanical watches, but not in a drive, rather to limit the tension of the spring, such that it

would operate only in the range where its elastic force is nearly linear.

 Geneva drive include the pen change mechanism in plotters, automated sampling

devices

 Indexing tables in assembly lines, tool changers for CNC machines, and so on.

 The Iron Ring Clock uses a Geneva mechanism to provide intermittent motion to one

of its rings.
1.2 PNEUMATIC PUNCHING MACHINE

The pneumatic system has gained a large amount of importance in last few decades. This

importance is due to its accuracy and cost. This convenience in operating the pneumatic

system has made us to design and fabricate this unit as our project. This unit, as we hope that

it can be operated easily with semi skilled operators. The pneumatic press tool has an

advantage of working in low pressure, that is even a pressure of 6 bar is enough for operating

the unit. The pressurized air passing through the tubes to the cylinder, forces the piston out

whose power through the linkage is transmitted to the punch. The work piece thus got is for

required dimensions and the piece can be collected through the land clearance provided in the

die. The die used in this is fixed such that the die of required shape can be used according to

the requirement. This enables us to use different type punch dies resulting in a wide range of

products. Different types of punch as requirement can be thus got. According to the work

material the operating pressure can be varied.

1.3 PUNCHING

Punching is a cutting process in which material is removed from a piece of sheet metal by

applying a great enough shearing force. Punching is very similar to blanking except that the

removed material, called the slug, is scrap and leaves behind the desired internal feature in the

sheet, such as a hole or slot. Punching can be used to produce holes and cutouts of various

shapes and sizes. The most common punched holes are simple geometric shapes (circle,

square, rectangle, etc.) or combinations thereof. The edges of these punched features will have

some burrs from being sheared but are of fairly good quality.
The punching process requires a punch press, sheet metal and die. The sheet metal stock is

positioned between the punch and die inside the punch press. The die, located underneath the

sheet, has a cutout in the shape of the desired feature. Above the sheet, the press holds the

punch, which is a tool in the shape of the desired feature. Punches and dies of standard shapes

are typically used, but custom tooling can be made for punching complex shapes. This

tooling, whether standard or custom, is usually made from tool steel or carbide. The punch

press drives the punch downward at high speed through the sheet and into the die below.

There is a small clearance between the edge of the punch and the die, causing the material to

quickly bend and fracture. The slug that is punched out of the sheet falls freely through the

tapered opening in the die. This process can be performed on a manual punch press, but today

computer numerical controlled (CNC) punch presses are most common. A CNC punch press

can be hydraulically, pneumatically, or electrically powered and deliver around 600 punches

per minute. Also, many CNC punch presses utilize a turret that can hold up to 100 different

punches which are rotated into position when needed.

 Fig 2

2. LITERATURE SURVEY

2.1 INTERNATIONAL JOURNAL OF ENGINEERING RESEARCH &

TECHNOLOGY (IJERT) VOL1.

2.1.1PRODUCTION OF COMPRESSED AIR

Pneumatic systems operate on a supply of compressed air, which must be made available in

sufficient quantity end at a pressure to suit the capacity of the system. When a pneumatic

system is being adopted for the 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

the compressor. A compressor is a machine that takes in air, gas or vapours at any certain

pressure and delivers the air at a high pressure. Compressor capacity is the actual quantity of

air compressed and delivered and the volume expressed is that of the air at intake conditions,

namely at atmosphere pressure and normal ambient temperature. Clean condition of the

suction air is one of the factors, which decides the life of the compressors.

Compressors may be classified into two types, namely

1. Positive displacement compressors .

2. Turbo compressors

Positive displacement compressors are most frequently employed for compressed air plants

and have proved highly successful to supply air for pneumatic control application. The types

of positive Compressors are, a. Reciprocating type compressors b. Rotary type compressors.

Turbo compressors are employed where large capacity of air is required at low discharge
pressures.They cannot attain pressure necessary for pneumatic control applications unless

built in multi stage designs are seldom counted in pneumatic service.

Fig 3

2.1.2 PRINCIPLE OF OPERATION OF A PRESS :

Every press has got certain basic units. They are bed frame, sliding ram, drive for the ram and

power source. Base or bed is the lower part of the press frame. A thick plate called bolster

plate is placed on the top of the bed. A die is fitted on the top of the bolster plate. The driving

mechanism is mounted on the frame. The frame has got guide ways for the sliding movement

of the ram. The driving mechanism is connected to the ram. The punch is fitted at the bottom

of the ram. The die and punch are correctly aligned. The work piece is in the form of sheet

metal. It is fed over the die. When the ram comes down, the punch presses the sheet metal.

The required operation is carried out. As said earlier the force from the press is used to do a

particular operation. This is done by two main parts die and punch.

2.1.3 WORKING PRINCIPLE (Press Working – Shecklos, S.Elanger vol.2)

Compressed air from a compressor is used to press the work by means of the piston and piston

rod, cylinder through a lever. The high pressurized air striking against the piston tends to push
it upwards. This force is transmitted to a punch by means of a lever by its mechanical

advantage. The punch forced downward pierces the work material. This is the main principle

of the unit and the predefined feed is given to that of the sheet metal and so thus the equally

spaced automatic punching s done.

2.1.4 GENEVA MECHANISM:

Geneva mechanism is a simple and widely used timing mechanism that provides intermittent

motion from a continuously rotating input. It consists of a rotating drive wheel (Driver) with a

pin that reaches into a slot of the driven wheel (Geneva wheel) advancing it by one step. They

are cheaper than cams, have good motion curve characteristics compared to ratchets and

maintain good control of its load at all times. In addition, if properly sized to the load, the

mechanism generally exhibits very long life. It is used in machine tools to index spindle

carriers weighing several tonnes, in transfer machines for indexing work piece from one work

station to another, as a turret indexing mechanism in automatic lathe, in counting instruments,

peristaltic pump drives in integrated circuit manufacturing, intermittent advance of films in

motion-picture projectors and discrete motion drives with high load capacity in robotic

manipulators. One of the most important processes in beverage production is bottle washing.

The high quality of the product depends largely on how thoroughly the bottles are cleaned

immediately before filling. Manual washing of bottles does not give the desired productivity

requirement of industrial setting. On this note, a mechanized system of washing and

detoxification is very imperative in order to achieve the desired productivity for industries.

The need to address this problem has led to the design of a mechanized bottle washing and

detoxification system using a rotary table propelled by a Geneva mechanism, designed and

developed a Geneva mechanism for Film Frame. In their design, a 4-slot mechanism was used

in which a driver, (A), rotates at uniform angular velocity and for every revolution of the
driver, the Geneva wheel makes a fraction part of the revolution which is a function of the

number of slots

Fig 4

2.2 VALUE ANALYSIS

A Systematic Analysis that identifies and select the best value alternative for designs ,
materials , processes and system.

Value Analysis is a concern to identify and eliminate product and service feature
that add no true value to the customer or the product by reducing cost to the process of
manufacturing or provision of the service.

2.2.1 VALUE ANALYSIS OF DESIGN

The aim of the machine is to reduce the timing for sheet punching without affecting
efficiency. Further sizes of the punching holes can be changed as per need of the user just by
changing the setting of the machine.

1. CHANGING THE NO. OF SLOTS ON GENEVA WHEEL

By changing the no. of slots on Geneva mechanism the time can be reduced. With
more slots , punching would be frequent i.e. will require less time to punch.

2. CHANGING THE DEPTH OF SLOTS ON GENEVA WHEEL

 By changing the depth of slots on Geneva wheel , time can be reduced (punching
time ) ,by reducing the depth. Hence, increasing the efficiency of punching.

3. INCREASING OR DECREASING THE RADIUS OF DRIVER PIN

By decreasing the radius of driver pin, the speed of the can be increased , hence ,
punching speed can be increased.

4. BY CHANGING THE ANGLE OF ROTATION

Machine uses 90° of rotation of Geneva wheel for feed and rest 270°(dwell) for
punching operation whereas our machine uses 180° for feeding and rest 180°(dwell)
for punching.
So it can be seen that dwell angle for Geneva wheel is reduced by
90° and the feed angle for Geneva wheel is increased by 90° which assure reduction in
time for punching and increasing the length of feed of the sheet.

5. ROLLER RADIUS OF SHEET METAL

By changing the radius of the sheet metal roller the speed of punching , time interval
and hole-to-hole distance will also change.

2.2.2VALUE ANALYSIS OF MATERIAL USED

1) USE OF ALUMINUM ALLOY INSTEAD OF IRON

Use of aluminum instead of iron because they are lighter in weight, non-ferrous metals
with good corrosive resistance, ductility and strength.

2) USE OF TUNGSTEN CARBIDE INSTEAD OF STEEL AS PUNCHING TOOL

AND DIE
Tungsten carbide punching tool is more strong, cheap and effective than hardened
steel.

3) USING ALUMINUM CYLINDER OF 0.1-1.5MPa WORKING PRESSURE

To reduce the cost without affecting the punching operation, an aluminum pneumatic
cylinder (0.1-1.5MPa ) with a bore sizing varying from (32-125) mm.
 4) USE OF ALUMINUM ROLLERS INSTEAD OF IRON/STEEL
Aluminum rollers are lighter, easier, faster installation and more effecting in punching
operation as compared to steel rollers.

5) USE BRASS/PVC VALVES

Use of Brass/PVC valvesfor pneumatic system because they are very cheap as well as
reliable and effective for working.

6) USE OF POLYURATHENE PNEUMATIC TUBES

Polyurathene pneumatic tubes are used because they are very reliable , flexible,
leakproof, long lasting and much cheaper than metallic pipes. So, these Polyurathene
pipes are used to reduce cost with increasing efficiency.

3.PRESENT WORK

3.1 PROBLEM FORMULATION

Conventional machines used in industries used to have levers that were needed to be pulled

manually to complete operations such as punching, embossing etc. The job is to be marked

, workpiece is to be aligned and fed manually. This requires manpower and time. Further
leads to less productivity, less efficiency & more chances of errors in the final product thus

decreasing quality standards.

Fig 5

Safety of workers is also a major concern as during handling of heavy material or thin sharp
sheets of metal and operating machines chances of injuries are more. This ultimately affects

the industry owner as production is stopped whole process of manufacturing a product is

affected.

Our project mainly aims SME’s as they are tight on budget and require LOW COST

AUTOMATION that can boost their production and decrease dependency on workers

and thus, increase profit. Geneva mechanism will feed material continuously and pneumatic

cylinder will quickly punch the sheet metal to cut out required shape or company logo.

3.2 OBJECTIVES

1. To design and develop such a pneumatic punching machine which uses compressed air to

generate high pressure to be applied on piston and this high-pressure air fed to punch, forces it

on the material. And thus, punching operation is performed.

2. To make a fully automatic sheet metal feed such that the punching is done in such a way

that there is no need of marking and manual feed in such a way we can get a very low idle

time of the machine and thus we get the maximum production and high precision.
 Fig 6

3.3 METHODOLOGY
For this purpose, we first construct a frame to withstand and support the punching system. We

then assemble the pneumatic piston and hole support mount into the frame so as to achieve

the best punching results. Now we connect the pipes to the cylinder with necessary valves and

use an electronic control mechanism to control punching using the pneumatic piston. The

electronic system is used to trigger the valves into releasing necessary amount of air into the

piston pushing it in needed direction with force needed to punch through the material placed

on the bed mount.

System uses a 12V motor in order to drive the entire system. We use a shaft which is directly

connected to the motor. This motor shaft is connected to a Geneva shaft which is in

connection with Geneva mechanism. This mechanism ensures sheet metal feed of equal

length inserted at proper time intervals. System uses a supporting frame that maintains proper

coordination between feed and punching mechanism.

Further procedure wise methodology is described below:

 ANALYSING CONENTIONAL TECHNIQUE

FINALIZING COMPONENTS

DESIGN AND CALUCATIONS

FABRICATION AND WORKING

1.ANALYSING CONVENTIONAL TECHNIQUE

First step was to analyze how conventional machines work and what are the limitations of

them. Then solution was found to make Automatic Geneva based punching machine

and thus, doing a LOW-COST AUTOMATION without much affecting pocket of industry.

2.COMPONENTS FINALIZED
Components were decided on the basis of expectations from the machine: -

1. Frame

2. Rollers

3. Punching Tool

4. Die and Punch

5. Sheet Metal (Raw )

6. Pin

7. Geneva Mechanism

8. Indexing Wheel
9. Motor

10. Indexing Chain (Sprocket Mechanism )

12. Solenoid Valve

13. Controller

14. Pump

15. Pneumatic Cylinder

Cost Estimation
Cost of material

Sr . Part Name Material Total cost

1. Metal sheet Steel 635
2. Frame Iron 1000
3. Base Plywood 365

Total Rs.2000
Total Cost of Material = ₹2000

Cost of Machining

Machine Name Time(min) Rate/hour(Rs) Total cost (Rs)

Lathe Machine 40 500 335

Power Hacksaw 30 200 100

Welding 30 400 535

Grinding 20 200 70
Drilling 30 200 100

Total Rs.1140

Total Cost of Machining =₹1140

Cost of standard Parts

Sr.No Name Quantity Total Rate(Rs)

1. Die & Punch 1 1000
2. Pneumatic cylinder 1 700
3. Valve 1 500
4. Sprocket Mechanism 1 850
5. Geneva Mechanism 1 1000
6. Indexing Wheel 1 400
7. Circuit 1 600
 Total 5050

Total Cost of Material , Machining and Standard Parts = ₹8190

Cost of Transport and other charges = ₹600

Total Project Cost =₹9000

3. DESIGNING AND CALCULATIONS

A rough design was made to see how our machine will finally look and how it fulfills our

requirements being budget friendly too.

Fig 7

The placements of components were finalized. Calculations are made .

 CALCULATION OF FORCE
Cylinder diameter = 25mm =.025 m

Pressure = 5 bar =500000 Pa=500000 N/m2

Area (Piston of pneumatic cylinder) = ∏d2/4

 = 3.14 x (.025x.025)
4
=0.000490 m2

Force = 500000 x 0.000490

= 245 N/m2

In Kg = 245
9.8
= 25 Kg

4. FABRICATION AND CHECKING

After all preparations made earlier 3-d model was prepared and the calculations of the forces
were done by keeping in mind the various factors and functions that are needed to be
performed.

4.CONCLUSION
With help of automation process time is decreased about 40%(estimated) productivity is

increased, manpower is decreased and more over it ensures safety for workers.

As its simple in design and components its installation and maintenance cost are very

reasonable thus increase profit to the industry from all points.With same amount of force

every stroke the quality for punch remains consistence for thousands of workpieces unlike

lever operated machine. Also, same machine can be used for infinite no. of shapes by

changing the die.

5.REFERENCES

1.International Journal of Engineering Research & Technology (IJERT) VoL1.

2.Press Working – Shecklos, S. Erlanger vol.2

3.https://issuu.com/ajer.research/docs/i0411063073

4. https://www.irjet.net/archives/V6/i5/IRJET-V6I5228.pdf