A

PROJECT REPORT
ON

Submitted By

Under the Guidance of

DEPARTMENT OF MECHANICAL ENGINEERING

WALCHAND COLLEGE OF ENGINEERING, SANGLI
2014-2015
 CERTIFICATE
This is to certify that the project report entitled

Submitted by

Of T. Y. Mechanical Engineering Branch

Is the report of their own work carried out by them for the award of

DIPLOMA IN MECHANICAL ENGINEERING

OF
M. S. B. T. E. MUMBAI
Under my guidance during the academic year

2014 – 2015

Date: /0 /2015 Place: WCE, Sangli.

Prof. H. N. TIKEKAR Prof. S. B. JALIHAL

(Guide) (HOD)

DEPARTMENT OF MECHANICAL ENGINEERING

WALCHAND COLLEGE OF ENGINEERING, SANGLI
2014-2015
 ACKNOWLEDGEMENT
We are rather infused by the kind guidance of Prof. H. N.
Tikekar who put us in the cradle of our engineering studies and
evaluated us to this end and mean of our project without his
guidance, we are sure to be an orphan in the vast ocean of the
subject. Ultimately no tongue could describe the deep sense of co-
operation and ready nature to help us even in minute details of our
write up this project report.

Thanks and gratitude goes to Prof. S. B. Jalihal Head,

Department of Mechanical Engineering Polytechnic Wing, who made
very valuable guidance and co-operation during our project.

Further we are thankful to all the staff and non-teaching

members of Mechanical Engineering Department for the co-
operation during the project work. We are very grateful to those
who in the form of books had conveyed guidance in this project
work. Last but not the least we are thankful to our colleagues and
those helped us directly or indirectly throughout this project work.

Special thanks go to Mr. L. L. Kamble sir of machining

workshop.

Projects Associates:
Sr. Pg.
Topic
No. No.
1. Synopsis 1
2. Introduction 3
3. Literature Survey 4
4. Prior Concepts 6
5. Construction 7
6. Design 8
7. Specifications 10
8. Drawings 12
9. Figures 18
10. Working 21
11. Process Sheet 26
12. Cost Sheet 28
13. Merits & Demerits 30
14. Future Scope 31
15. Conclusion 32
16. References 33
17. Photographs 34
 Synopsis
The objective of the project is to prepare a machine which
cuts sheet metal without human efforts but operates
pneumatically. Compressed air is used as working media. The
compressed air moves the blades of machine to cut the sheet of
metal.

The idea of the project generated due to a manual sheet

metal sheering machine in workshop of our college. In that
machine sheet metal is placed in between the two sheering blades
of machine and the lever is pulled down to move the upper
movable blade and cut the work-piece.

But in that machine large force is required which can make

tire to a worker who continuously works on it for mass production
in large scale industry; so to reduce the human efforts pneumatic
machine should chose. Hence for some development of machine,
we have chosen this subject for our project. We hope that a good
idea will develop and we can use it in many industries in
surrounding and our practical knowledge, team-working skill,
leadership skills will be improved.
Figure: Concept Image for Project
 Introduction
The formation of any business begins with someone
producing the initial idea for the project. The continued success of
an established business depends upon the number and quality of
the ideas fed into it. Without a continual flow of new ideas, a
business cannot function profitably or expand successfully and
must, therefore eventually fade into total obscurity.
Ideas for a new business project, a new product, a means of
reducing manufacturing costs or for solving industrial labour
problems, begin in the human mind. Most people conceive their
ideas unconsciously, and because they are unaware of the mental
mechanics that caused the ‘idea’ to be produced, they cannot
repeat the ideation process to produce further profitable ideas at
will.
Fortunately, there are available established creative
techniques which, when used correctly, do enable a person to
produce a large number of first-class ideas at will. One such
creative technique, and probably the most widely used in American
industry, is ’brainstorming’.
 Literature survey
In shearing or cutting operation as or blade descends upon
the metal, the pressure exerted by the blade first cause the plastic
deformation of the metal. Since the clearance between the two
blades is very small, the plastic deformation takes place in a
localized area and the metal adjacent to the cutting edges of the
blade edges becomes highly stressed, which causes the fracture
to start on both sides of the sheet as the deformation progresses
and the sheet is sheared.

 Types of shearing Machine:

1) Pneumatically operated
2) Hydraulically operated
3) Rack and pinion operated
4) Spring operated
Brief description of all the types is as follows.

1) Pneumatically operated:-
Here the advancement of the header is carried out in the
upward and the downward direction using the pneumatic double
acting piston and cylinder unit arrangement along with the foot
operated direction control valve. In this type of machine high
pressure air is used as the working fluid for the transfer of power
and the motion.
 2) Hydraulically operated:-
Here the lowering and raising of the header is carried over
using the hydraulic piston and cylinder arrangement. To actuate
the piston and cylinder, the oil is allowed to enter the cylinder from
front or the back side of the piston. But the oil is comparatively
costlier and its leakage may cause so many problems.

3) Rack and pinion operated:-

Here the lowering and the raising of the header are carried
out manually using the rack and pinion arrangement. In this case
the required pressure is applied manually using direct hand
pressure on the rack using pinion and lever arrangement. Since
the machine is robust and requires large pressure, hence it is not
suitable.

4) Spring operated:-
The working of spring operated machine is similar to the rack
and pinion operated machine but differs from it in construction.
Here the lowering and the raising of the heating handle are carried
out manually and it requires too much pressure for its operation
and also there is possibility of having damage to the work piece if
not handled carefully.
 Prior concepts
Pneumatics, from the Greek (pneumatikos, coming from the
wind) is the use of pressurized gases to do work in science and
technology. Pneumatics was first documented by Hero of
Alexandria in 60 A.D., but the concept had existed before then.
Pneumatic products represent a multi-billion dollar industry today.
Pneumatic devices are used in many industrial applications.
Generally appropriate for applications involving less force than
hydraulic applications, and typically less expensive than electric
applications, most pneumatic devices are designed to use clean
dry air as an energy source. The actuator then converts that
compressed air into mechanical motion. The type of motion
produced depends on the design of the actuator. Pneumatics is
employed in a variety of settings.
In dentistry applications, pneumatic drills are lighter, faster
and simpler than an electric drill of the same power rating,
because the prime mover, the compressor, is separate from the
drill and pumped air is capable of rotating the drill bit at extremely
high rpm. Pneumatic transfer systems are employed in many
industries to move powders and pellets.
Pneumatic devices are also used where electric motors
cannot be used for safety reasons, such as mining applications
where rock drills are powered by air motors to preclude the need
for electric motors deep in the mine where explosive gases may be
present.
 Construction
 Raw Material Used-
1. Mild Steel bars for base frame.
2. 35C8 material for shearing blades.
3. Cylinder fittings like fork end, base plates, support links.
4. Angle section for blade fitting.
5. Connecting link.
6. Blade link.
 Ready Items Used-
1. Pneumatic double acting cylinder.
2. Direction & flow control valves.
3. Pneumatic pipe & pipe fittings.
4. Bolts & nuts.
5. Antirust coat & paint.
 Machines & Tools Used-
1. Cutting Machine.
2. Hacksaw Cutting Machine.
3. Sensitive Drilling Machine.
4. Horizontal Milling Machine.
5. Electric Arc Welding Machine.
6. Table Grinder.
7. Hand Grinder.
8. Surface Grinding Machine.
9. Tap & Tap Holder.
 Design
1. Base Frame-
Quantity: 1
Height: 300mm
Length: 900mm
Width: 300mm
Weight: 5kg
2. Shearing Blade-
Quantity: 2
Length: 300mm
Height: 60mm
Thickness: 15mm
Blade Angle: 15o
Weight: 3.5kg
3. Base Plate-
Quantity: 1
Height: 65mm
Width: 65mm
Thickness: 6mm
4. Fork End-
Quantity: 1
Length: 75mm
Width: 20mm
Thickness: 5mm
5. Angle Section-
Quantity: 1
Height: 45mm
Length: 300mm
Width: 45mm
Thickness: 7mm
Weight: 0.5kg
6. Connecting Link-
Quantity: 1
Length: 360mm
Thickness: 5mm
Height: 25mm
Weight: 0.3kg
7. Support Links-
Quantity: 2
Height: 90mm
Width: 25
Thickness: 5
8. Blade Link-
Quantity: 1
Height: 90mm
Width: 20mm
Thickness: 5mm
Welded Length: 30mm
 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: 3000mm
Diameter: 8mm
Thickness: 1mm
4. Fork End Nut-
Quantity: 2
Length: 16mm
Size: M16
5. Cylinder Base Plate Bolts-
Quantity: 4
Length: 32mm
Size: M6
6. Blade Fixing Bolts-
Quantity: 3
Length: 25mm
Size: M10
7. Connecting Link Bolts-
Quantity: 2
Length: 45mm
Size: M6
Drawings

BASE FRAME
Shearing Blades & Blade Link
 Angle Section

Connecting Link
Base Plate
Support Links
Fork End
 Figures

Pneumatic Cylinder
Direction Control Valve
Flow Control Valve
 Working
The following figure shows general layout for the machine.

Figure: General Layout

Initially the air-compressor is started and allowed the receiver

tank air pressure to reach up to 8 bar. The supply air is then
passed to the manifold through FRL unit to condition the air and
eligible to industrial use.

From the manifold a separate supply for the machine is

taken out and given to ON-OFF switch, so as to operate the
machine at will without interrupting the running of compressor.

Then the pipe carries compressed air first to machine’s

Direction Control Valve. At position ‘A’ shows the non-actuated
circuit diagram. At this position the piston is steady and locked. All
ports are in closed condition.
Position ‘A’
 At position ‘B’, the DC valve is at left hand position as shown
in figure. The cap end port & pressure port get connected to each
other and the rod end port gets connected to the exhaust port. The
compressed air comes in the cap end of the cylinder and pushes
the pistons outwards. The air already present in the rod end side is
pushed out of the cylinder.

When the piston moves outwards, the force is transmitted

through the connecting link and the upper blade moves
downwards. Before the actuating DC valve the sheet is inserted in
between the upper & lower blades. As upper blade moves
downwards, the stress is generated in the sheet metal and goes
beyond ultimate shear stress of sheet metal. And thus the
shearing action takes place.

Now the DC valve is operated to come at position ‘C’, as

shown in figure. The rod end port & pressure port get connected to
each other and the cap end port gets connected to the exhaust
port. The compressed air comes in the rod end of the cylinder and
pushes the pistons inwards. The air already present in the cap end
side is pushed out of the cylinder.

The sheet metal is either again inserted for further cutting in

case of large pieces; the small cut pieces are removed and the
next sheet is inserted to cut.
Position ‘B’
Position ‘C’
 Process sheet
Part Part
Material Quantity Process Equipment Time
No. Name
Cutting Cutting Machine 80
Grinding Table Grinder 40
Electric Arc
Welding 100
Welding Machine
Mild
1) Frame 1 Grinding Hand Grinder 10
Steel
Anti-rust
Hand Brush 20
Coating
Colour
Hand Brush 35
Painting
Hacksaw Cutting
Cutting 15
Machine
Sensitive Drilling
Drilling 15
Machine
3/8" BSW Tap &
Tapping 15
Holder
2) Blades 35C8 2
Surface Surface Grinding
80
Grinding Machine
Angular Horizontal Milling
90
Milling Machine
Filing File 20
Greasing Grease 5
Cutting Cutting Machine 10
Grinding Table Grinder 5
Angle Mild Sensitive Drilling
3) 1 Drilling 15
Section Steel Machine
Electric Arc
Welding 10
Welding Machine
 Cutting Cutting Machine 10
Connecting Mild Grinding Table Grinder 5
4) 1
Link Steel Sensitive Drilling
Drilling 5
Machine
Cutting Cutting Machine 5
Grinding Table Grinder 5
Mild Sensitive Drilling
5) Fork End 1 Drilling 10
Steel Machine
Electric Arc
Welding 15
Welding Machine
Cutting Cutting Machine 5
Grinding Table Grinder 5
Cylinder Mild Sensitive Drilling
6) 1 Drilling 10
Base Plate Steel Machine
Electric Arc
Welding 5
Welding Machine
Cutting Cutting Machine 8
Grinding Table Grinder 5
Sensitive Drilling
Cylinder Drilling 7
Mild Machine
7) Support 2
Steel 3/8" BSW Tap &
Links Tapping 10
Holder
Electric Arc
Welding 15
Welding Machine
Cutting Cutting Machine 5
Grinding Table Grinder 5
Mild Sensitive Drilling
8) Blade Link 1 Drilling 5
Steel Machine
Electric Arc
Welding 10
Welding Machine

Total Process Time (in Minutes) 715

 Cost sheet
Sr. Material Machining Total
Part Name Material Quantity
No. Cost Cost Cost

A) Base Frame
Mild
1] Main Frame 20 Feet 600 500 1100
Steel
Angle Mild
2] 1 50 50 100
Section Steel
Cylinder Mild
3] 1 30 30 60
Base Plate Steel
Support Mild
4] 2 30 30 60
Links Steel
B) Pneumatic Circuit Components

Double Plain
5] Acting Carbon 1 4000 - 4000
Cylinder Steel
Flow Control Cast
6] 2 850 - 850
Valve Steel
7] Pipe PVC 3m 120 - 120
Direction Alloy
8] 1 700 - 700
Control Valve Steel
Pipe Fitting Cast
9] 3 150 - 150
Connections Steel

C) Blades & Accessories

Shearing
10] 35C8 2 300 400 700
Blades
Mild
11] Blade Link 1 20 30 50
Steel
Connecting Mild
12] 1 30 30 60
Link Steel
Mild
13] Fork End 1 50 50 100
Steel
 D) Others
Alloy
14] Bolts 11 80 - 80
Steel
Alloy
15] Nuts 3 10 - 10
Steel
16] Antirust Coat - 100 mL 20 - 20
17] Paint - 100 mL 40 - 40

Grand Total Cost (in Rupees) 7080 1120 8200

 Merits & Demerits
 Merits-
1. Hydraulics present certain advantages over pneumatics, but
in a given application, pneumatic powered equipment is more
suitable, particularly in industries where the factory units are
plumbed for compressed air.
2. Moreover, to avoid corrosive actions, oil or lubricants are
added so that friction effects can be reduced.
3. Compressed air is used in most of the machines and in some
cases compressed carbon dioxide, whereas cutting process is
become easy.
4. Fast cutting action is carried out.
5. Cutting without bending is achieved.

 Demerits-
1. Sheet more than 2 mm thickness cannot cut easily.
2. Compressed air is must.
3. Foundation is required also safety major must be taken.
 Future Scope
Since old age man is always trying to gain more and more
luxurious. Man is always trying to develop more and more modified
technique with increasing the aesthetic look and economic
consideration. Hence there is always more and more scope. But
being the Diploma Engineers and having the ability to think and
plan. But due to some time constraints, and also due to lack of
funds, we only have thought and put in the report the following
future modifications-
1. It can be made hydraulically power operated by installing the
gear oil pump at the place of air compressor and pneumatic
cylinder arrangement.
2. It can be made rack and pinion operated or spring and lever
operated, by replacing the pneumatic circuit by rack and the
pinion arrangement by the square threaded screw and nut
arrangement.
3. The place where there is scarcity of the electricity the electric
motor operate compressor is replaced by an I.C. Engine
installed compressor.
Thus in future there are so many modifications, which we can
make to survive the huge global world of competition.
 Conclusion
Now we know that Pneumatic Shearing machine is very
cheap as compared to hydraulic shearing machine.
The range of the cutting thickness can be increased by
arranging a high pressure compressor and installing more
hardened blades. This machine is advantageous to small sheet
metal cutting industries as they cannot afford the expensive
hydraulic shearing machine.
 References
1. Machine Design by R.S. Khurmi.
2. Manufacturing Process by O. P. Khanna and Lal.
3. Workshop Technology by R.K. Jain.
4. Pneumatic System: Principle & Maintenance by S.R.
Mujumdar.
5. Machine Tool Design Handbook.
6. P.S.G. Design Data Book.
7. Internet sites-
a) http://www.google.com/
b) http://www.engineersedge.com/
c) http://www.efunda.com/
d) http://www.mechanicalengineeringblog.com/
Photographs