A presentation on

Design & Development of Geneva Wheel Based

Auto Roll Punching Machine

Department of Mechanical Engineering

Gokhale Education Society’s
R. H. Sapat College of Engineering, Management
Studies & Research, Nashik
PROJECT TEAM

Project Members:
Aashish D. Thakare.
Vinayak S. Supekar.
Ganesh S. Supekar.
V. Ghegadmal.

Under the guidance of

Prof. V. T. Mandlik
 CONTENT

Introduction
Literature Survey
Project Execution
Project Action Plan
Major Components
Selection of Material
Design
Assembly Flowchart
Cost Estimation
Results & Discussions
 Introduction
Punching or pressing is the main or initial operation in
sheet metal process sequence
The proposed work describes the design & fabrication of
prototype of automatic punching machine
Geneva Drive is a mechanism which translates
continuous rotary motion into intermittent rotary motion
Geneva Mechanism: simple in construction, accurate,
self-locking function
 Literature Review
Sr. No. Title Researchers Key Points
01. Automatic Punching Arun S, Sree • The proposed work describes
Machine: A Low Cost Rajendra and the design and fabrication of
Approach Vijayavithal prototype of auto. Punching
Bongale machine
• By automating this process one
can have a greater control over
the process.
• This system can replace
existing manual feed and
operated punching machine.
02. Optimization of M. Heidari, M. • paper discusses the use of
Kinematic Characteristic Zahiri, and H. variable input speed for
of Geneva Mechanism Zohoor optimization of kinematic
by Genetic Algorithm characteristic of Geneva
mechanism.
• The objective is lowering
maximum acceleration and jerk
of driven wheel.
 Sr. No. Title Researchers Key Points
03. Dynamic Optimization Vivek A. Sujan, • It presents design of Geneva
of Geneva mechanism Marco A. wheel mechanism that
Meggiolaro performs better than
conventional approach.
• Design goal is to minimize the
maximum angular jerk of
wheel

04. Design of Varadarajan • The paper discusses design and

Micromachined Geneva Vidya, Palani fabrication of Geneva
wheel to obtain Kumaresan mechanism
intermittent motion • The system is simple to layout
& can be fabricated using the
standard process
 Project Execution
Problem Identification:

In conventional Punching Machine, The job is to

be marked
The sheet is to be aligned and fed manually for
every punched hole
Lead time of system is more due to manual feeding
The safety of worker is at stake
Requires higher material handling time
 Scope of Project

This is a low cost automation

It is economical as compared to hydraulics and
pneumatics
Operation is smooth and requires less efforts
Once the job is fed it is punched with the help of
intermittent motion of Geneva Mechanism
 Project Action Plan
Weeks
 Major Components

Geneva Mechanism Wiper Motor

Chain Drive Punching Machine

 Sheet Metal Pillow Block Bearing

Rubber Rollers Battery

 Design
 Procedure in Machine Design

 General Steps followed are as follows:

 Preparation of statement indicating the purpose of
machine
 Selection of Mechanism for desired motion
 Calculation of forces and dimensions involved
 Selection of material
 Preparation of component drawing & manufacturing
 Assembly of component
 Testing machine for functioning
I. Geneva Mechanism
1] Centre Distance = C = b/cos(180/n) = 120/cos(180/4)
c = 170mm
2] a = drive crank radius = c2 – b2 =170 2 - 1202
a = 120mm
3] s = slot centre length = (a+b) – c = (120 + 120) – 170
S = 70mm
4] W = slot width = P + t = 10+7
W = 17 mm
5] y = stop arc radius = a - (P*1.5)
y = 105 mm
6] Z = stop disc radius = y – t =105 – 7
Z = 100 mm
7] V = Clearance arc = bz/a = (120*98)/120
V = 98 mm
II. Punching Force
Punching Force = p x t x ῑ
P.F = [perimeter (mm) x thickness(mm) x shear strength (N/mm2) ]
9806.65 (N/tonne)
P.F = [π*4*1*0.65*65]/9806.5
 P.F = 0.0541 tonne

III. Connecting rod length:

obliquity ratio= Length of C.R./Radius of disc
2 = l/100
l = 200 mm
IV. Chain Calculations:

1] Motor power
P = (2πNT)/60 Watt
P = (2*3.14*65*12)/60
P = 81.68 W = 0.081 kW

2] kW Rating Of Chain :
= [(kW to be transmitted) * Ks]/(K1 * K2)
= (0.081 * 1.0) / 1.0 * 1.18 = 0.068 kW
Where,
Ks = Service Factor; K1 = Multiple Strand Factor
K2 = Tooth Correction Factor

3] Dimensions :
Pitch = p = 9.525 mm
Roller diameter = 6.35 mm
Width = w = 5.27 mm
Transverse pitch = 10.24 mm
4] Pitch Circle Diameter Of Driving and Driven Pulleys

D1 = P/sin (180/Z1)
= 9.525/ sin (180/20)
D1 = 60.88mm

For Driven Sprocket,

Z1 = Z2 = 20
D2 = P /sin (180/Z2) = 9.525/sin (180/20)
D2 = 60.88 mm
Where,
D1 = Diameter of Driving Sprocket; D2 = Diameter of Driven Sprocket
Z1 = No. of Teeth on Driving Sprocket; Z2= No. of Teeth on Driven Sprocket

5] Number Of Chain Links :

Range (30 p to 50 p)
 a = 45 p
 = 45 * 9.525 = 428.62 mm
6] Ln = no of links
= 2 (a/p) + ((Z1 + Z2)/2) + [((Z1 – Z2)/2)] * (p/a)
= 2 (450/9.525) + (20 + 20/2) + 0
Ln = 115

7] Correct Centre Distance

= [Ln – ((Z1 + Z2)/2)]
= [115 – ((20+20)/2)] = 95 mm
a = P/4{[Ln – ((Z1 + Z2)/2)] + [(Ln – (Z1+Z2)/2)2 – 8((Z1-Z2)/2π)2]}
a = 9.525/4 [95+(952 – 8*0)0.5]
a = 452.43 mm

8] To provide small sag, centre distance is given by

a = 0.998 * actual centre Distance
= 0.998 * 452.43
a = 451.52 mm
 Assembly Flowchart

Mounting of Geneva Mounting Wiper

Fabrication of stand
mechanism Motor

Engagement of
Attachment of Rubber Roller
Geneva Drive with
Connecting Rod Attachment
Roller by Chain Drive
3D Concept Drawing in Unigraphics
Actual Prototype
 Cost Estimation
Cost of Material

Total Cost of Material = Rs.750/-

Cost of machining :

 Total cost of machining = Rs.1140/-

Cost of Standard Part :

Total Cost of Standard Part = Rs.7450/-

 Cost of Transportation + Other Charges = Rs.1500/-

Total Cost = [Cost of (Material + Machining + Standard Parts) +VAT]
 = Rs.10840 + VAT (12.5%)
 = 10840 + 1335
 = Rs.12,195 /-
 Result and Discussion
Testing Results:

Sr. No. Job No. Time (Sec) Number of Punches

Manual Actual
Punching Prototype
Machine

1. 01 60 20 54

2. 02 60 21 53
Operation Time:
Average time for 10 punches is 30 sec.
For Auto roll punching machine,
Average time for 10 punches is 17 sec.
Operation time reduction in % = [(30-17)/30]*100
= 0.43 * 100
= 43%
Therefore, reduction in operation time = 43%
Advantages:
 Compared to pneumatics, it is economical.
 No need of expertise to operate the machine.
 Operation is done in a flow, so we can obtain
more output with less effort.
 This machine is simple in construction and
compact in size.
 Easy to assemble and disassemble.
 Low initial cost and maintenance cost.
Applications:

 Machine is very useful in making series of identical

holes with same diameter and same pitch.
 The machine can be used in applications where
equidistant punched holes are required.
 If the shape of punch is changed it can give variety in
punched shape as per requirement.
Conclusion:

 Operation time reduced from 30 seconds to 17

second for every 10 punches.
 43% reduction in Operation time.
 Machine ensures operator’s safety.
 The energy required for the machine is also less.
 The machine gives equidistant punched holes with
alignment.
Future Scope:

 If the electronic sensors are used to turn off the machine

as soon as the operation is over, we can reduced manual
operation as well as energy.
 If the slots in the Geneva wheel are increased, the number
of punched holes can also be increased without any
additional efforts.
 Reference

[1] Design of a Micromachined Geneva Wheel as a mechanism to

obtain intermittent motion from a constantly rotating source
Varadarajan Vidya Palani Kumaresan University of California,
Berkeley
[2] Wilson tool international journal 12912 farnaham avenue,
February 2013, MN 5511 –800-328-9646
[3] Design data book ISBN 978-81-927355-0-4, kalaikathir
achchgam, coimbatore. Page No.1.30
[4] Design of machine elements ISBN 978-00-706114-12, v. b.
bhandari, Page no. 545-560
[5] Materials Handbook, Fifteenth Edition, 2008, Mc-Graw-Hill
Handbooks, George S. Brady, Henry R. Clauser
Bibliography:
[6] https://newgottaland.com/2012/08/01/08/make-geneva-
wheels-of-any-sizes/
[7]www.directindustry.com/industrial-manufacturer/manual-
punching-machine-146110.html/
[8] www.penandpaper.co.in/p/2827/kangaro-metal-punching-
machine-dp-520/
[9] www.autozone.com/electrical-and-lighting/wiper-motor/
[10]www.bikesindia.org/reviews/drive-chains-o-ring-x-ring-vs-
non-standard-chains.html/
[11]www.thelibraryofmanufacturing.com/sheetmetal_basics.
html/
[12] www.bearingtips.com/pillow-block-bearing/
[13]www.batteryuniversity.com/learn/article/lead_acid_batte
ry_in_moderntimes
[14] www.kdjoshi.com/rubber-roller.html/