DESIGN AND FABRICATION OF

PNEUMATIC SHEET METAL CUTTING MACHINE

A PROJECT REPORT
Submitted by
MANOJ KUMAR V 911519114008
SARAVANAN S 911519114025
YUVARAJ S 911519114030

In partial fulfillment for the award Of the degree

of
BACHELOR OF ENGINEERING
in
MECHANICAL ENGINEERING

MOHAMED SATHAK ENGINEERING COLLEGE

KILAKARAI-623 806, RAMANATHAPURAM
ANNA UNIVERSITY::CHENNAI-600 025
APRIL 2022
 BONAFIDE CERTIFICATE

Certified that this project report “DESIGN AND FABRICATION

OF
PNEUMATIC SHEET METAL CUTTING MACHINE” is the
bonafide work of “MANOJ KUMAR V(911519114008),
SARAVANAN(911519114025),YUVARAJ(911519114030)” in
MOHAMED SATHAK ENGINEERING COLLEGE who carried
out the project work under my supervision.

SIGNATURE SIGNATURE
DR.C.JEYASEELAN,M.E.,(Ph.D). Mr.K.SAKTHIVEL RAJAN,M.E
HEAD OF THE DEPARTMENT, SUPERVISOR,
Professor Assistant Professor
DEPT OF MECH ENGG, DEPT OF MECH ENGG
Mohamed Sathak Mohamed Sathak
Engineering College Engineering College
Kilakarai - 623806 Kilakarai - 623806

Submitted for the Project Viva – Voice examination held on 22/06/2022.

Internal Examiner External Examiner

 ACKNOWLEDGEMENT

Our sincere thanks to our respected

Principal Dr. Mohamed Sheriff. N. B.E.,M.Tech.,Ph.D., for
providing ample facilitates to carry out the project.
We express our deep senses of gratitude to
Dr. C. Jayaseelan, M.E.Ph.D Head of the Department,
Department of Mechanical Engineering for his valuable
innovative ideas and pleasant relationship during the course
of our project work.
We portray our indebtedness to Mr. K.
Sakthivelrajan, M.E our project guide, for his valuable
guidance and offering his suggestions and constructive criticisms
in all stages of this project.
We also extend our gratitude the project
coordinator Mr. J. Mohamed Azharudeen M.E Department of
Mechanical Engineering for his critical advice and guidance
without which this project would not been possible.
We extend our thanks to all the staff members
and technical staffs for their assistance and co-operation
while undergoing this project.
We express our heartfelt gratitude to our
beloved parents and the almighty for being with us during this
project.
 Topic Pg.
S.No. No.
1. Abstract 1
2. Introduction 3
3. Literature Survey 5
4. Prior Concepts 7
5. Construction 7
6. Design 9
7. Required components 11
8. Controlling 13
9. Recommendation 19
10. Methodology 21
11. Working 25
12. Data Analysis 31
13. Process sheet 33
14. Cost sheet 35
15. Merits and Demerits 37
16. Conclusion 37
17. References 39
18. Photographs 40
 Abstract

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.

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 operate
Brief description of all the types is as follows.
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.

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.

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.

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.
4)Connecting link.
5)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: 3kg

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

Required Components:
The common components of this pneumatic sheet metal
cutting machine are double acting cylinder, pneumatic hand
operated valve and high speed steel blade, air pipe etc.

3.3.1 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 as shown in Fig
3. Stroke length for this design is not limited, however, the
piston rod is more vulnerable to buckling and bending. [3]
 Fig 3: Double acting cylinder
3.3.2 PNEUMATIC HAND OPERATED VALVE:
3.3.2.1 2/2 DIRECTIONAL CONTROL VALVE:
The structure of a 2/2 directional control valve is very simple. It
uses the thrust from the spring to open and close the valve,
stopping compressed air from flowing towards working tube
‘A’ from air inlet ‘P’. When a force is applied to the control
axis, the valve will be pushed open, connecting ‘P’ with ‘A’ as
shown in Fig.4. The force applied to the control axis has to
overcome both air pressure and the repulsive force of the
spring. The control valve can be driven manually or
mechanically, and restored to its original position by the spring.
[3]

Fig 4: 2/2 directional control valve

3/2 DIRECTIONAL CONTROL VALVE:
A 3/2 directional control valve can be used to control a single
acting cylinder (Fig. 5). The open valves in the middle will close
until ‘P’ and ‘A’ are connected together. Then another valve will
open the sealed base between ‘A’ and ‘R’ (exhaust) as shown in
Fig 5.The valves can be driven manually mechanically, electrically
or pneumatically. 3/2 directional control valves can further be
divided into two classes: Normally open type (N.O.) and normally
closed type
(N.C.). [3]

Fig 5: 3/2 Directional control valve

3.3.2.3 5/2 DIRECTIONAL CONTROL VALVE:
When a pressure pulse is input into the pressure control port
‘P’, the spool will move to the left, connecting inlet ‘P’ and
work passage ‘B’. Work passage ‘A’ will then make release of
air through ‘R1’ and ‘R2’as shown in Fig 6. The directional
valves will remain in this operational position until signals of
the contrary are received. Therefore, this type of directional
control valves is said to have the function of ‘memory’ [3]
Fig 6: 5/2 Directional control valve
On the other hand there exists many important On the other
hand there exists many important components like: High speed
steel blade, Special Air pipe, Stainless Steel and most
important Air compressor.
Pneumatic Transmission of Energy:
The reason for using pneumatics, or any other type of energy
transmission on a machine, is to perform work. The accomplishment
of work requires the application of kinetic energy to a resisting
object resulting in the object moving through a distance. In a
pneumatic system, energy is stored in a potential state under the
form of compressed air. Working energy (kinetic energy and
pressure) results in a pneumatic system when the compressed air is
allowed to expand. For example, a tank is charged to 100 psi with
compressed air. When the valve at the tank outlet is opened, the air
inside the tank expands until the pressure inside the tank equals the
atmospheric pressure. Air expansion takes the form of airflow. A
positive displacement compressor basically consists of a movable
member inside a housing. The compressor has a piston for a
movable member. The piston is connected to a crankshaft, which is
in turn connected to a prime mover (electric motor, internal
combustion engine). At inlet and outlet ports, valves allow air to
enter and exit the chamber. [4]
Controlling:
CONTROL OF PNEUMATIC ENERGY:
Working energy transmitted pneumatically must be directed and
under complete control at all times. If not under control, useful work
will not be done and machinery or machine operators might be
harmed. One of the advantages of transmitting energy pneumatically
is that energy can be controlled relatively easily by using valves.

CONTROL OF PRESSURE:
Pressure in a pneumatic system must be controlled at two
points - after the compressor and after the air receiver tank.
Control of pressure is required after the compressor as a safety
for the system. Control of pressure after an air receiver tank is
necessary so that an actuator receives a steady pressure source
without wasting energy.

CONTROL OF PRESSURE AFTER A COMPRESSOR:

In a pneumatic system, energy delivered by a

compressor is not generally used
immediately, but is stored as potential energy
in air receiver tank in the form of compressed
air. In most instances, a compressor is
designed into a system so that it operates
intermittently. A compressor is a device that
usually delivers compressed air to a receiver
tank until high pressure is reached, then it is
shut down. When air pressure in the tank
decreases, the compressor cuts in and
recharges the tank. Intermittent compressor
operation in this manner is a power saving
benefit for the system. A common way of
sensing tank pressure and controlling
actuation and de-actuation of relatively small
(2-15 HP) compressors, is with a pressure
switch.
RECOMMENDATION
Pneumatic Sheet metal cutting machine is
very cheap as compared to hydraulic cutting
machine or laser cutting 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 machine. Pneumatic sheet metal
cutting machine can be used in various
industries or workshops

METHODOLOGY
The main goal of project studies is to study about pneumatic
control system. Then, to study about double acting cylinder. Then,
to study about the advantage of pneumatic hand operated valve.
Then, to study about high speed blade. Then, to design &
fabrication pneumatic sheet metal cutting machine. Then,
collecting the proper components. Then, machining them. Then,
assembling the all components to a proper shape. Finally,
Completion the process to make a proper pneumatic sheet metal
cutting machine.
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 it.
Position ‘B’

Position ‘C’

DATA ANALYSIS & RESULTS

CYLINDER THRUST:
Cylinder thrust for double acting in forward stroke.
Then,
Cylinder thrust for double acting in return stroke -
𝐹 = (𝜋 /4) × (𝐷 – 𝑑) 2 × 𝑃
where D = Diameter of bore in mm. P = Pressure in bar.
(1 bar = 0.1N/mm2) d = Piston rod diameter in mm.
After putting corresponding values according to the equation
we can get that as per our consideration the maximum force
exerted by our cylinder is
10381.625N
THEORITICAL AIR CONSUMPTION:
𝐶 = {(π /4) × 𝐷2 × (P + 1) × L}/1000 where, P=
pressure in bar D= Diameter of bore in cm. L= Length
of stroke in cm. Theoretical Air Consumption of our
pneumatic machine was, C= C = 22.85litres.
SHEET METAL CUTTING FORCE
Cutting force = 𝐿 × 𝑆 × 𝑇𝑚𝑎𝑥
Stripping force =10% -20% of cutting force
𝐿 = Length of periphery to be cut in mm
𝑆 = Sheet thickness in mm 𝑇𝑚𝑎𝑥 = Shear strength in
N/mm2
𝑇𝑚𝑎𝑥 = 80% of tensile strength
After putting corresponding values according to the equation we can
get that aggregated cutting force of our Pneumatic Sheet Metal
Cutting Machine was F= 10080 N
Process sheet
Part Part
Material Quantity Process Equipment Time
No. Name
1) Frame Mild 1 Cutting Cutting 80
Steel Machine
 Grinding Table 40
Grinder
Electric
Arc
Welding 100
Welding
Machine
Grinding Hand 10
Grinder
Anti-rust Hand
20
Coating Brush
Colour Hand
35
Painting Brush
Hacksaw
Cutting Cutting 15
Machine
Sensitive
Drilling Drilling 15
Machine
3/8" BSW
Tapping Tap & 15
2) Blades 35C8 2 Holder
Surface
Surface
Grinding 80
Grinding
Machine
Horizontal
Angular
Milling 90
Milling
Machine
Filing File 20
Greasing Grease 5
Cutting Cutting 10
Machine
Angle Mild Grinding Table 5
3) 1
Section Steel Grinder
Drilling Sensitive 15
 Drilling
Machine
Electric
Arc
Welding 10
Welding
Machine

Cutting Cutting 10
Machine
Grinding Table 5
Connecting Mild
4) 1 Grinder
Link Steel
Sensitive
Drilling Drilling 5
Machine
Cutting Cutting 5
Machine
Grinding Table 5
Grinder
Mild Sensitive
5) Fork End 1
Steel Drilling Drilling 10
Machine
Electric Arc
Welding Welding 15
Machine
6) Cylinder Mild 1 Cutting Cutting 5
Base Plate Steel Machine
Grinding Table 5
Grinder
Sensitive
Drilling Drilling 10
Machine
Welding Electric Arc 5
Welding
 Machine
Cutting Cutting 8
Machine
Grinding Table 5
Grinder
Sensitive
Cylinder Drilling Drilling 7
Mild
7) Support 2 Machine
Steel
Links 3/8" BSW
Tapping Tap & 10
Holder
Electric Arc
Welding Welding 15
Machine
Cutting Cutting 5
Machine
Grinding Table 5
Grinder
Mild Sensitive
8) Blade Link 1
Steel Drilling Drilling 5
Machine
Electric Arc
Welding Welding 10
Machine

Total Process Time (in Minutes) 715

Cost sheet
Sr. Quantit Material Machining Total
Part Name Material
No. y Cost Cost Cost
A) Base Frame
Mild
1] Main Frame 20 Feet 600 500 1100
Steel
2] Angle Mild 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
Cast
6] Control 2 850 - 850
Steel
Valve
7] Pipe PVC 3m 120 - 120
Direction
Alloy
8] Control 1 700 - 700
Steel
Valve
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 - 100 20 - 20
Coat mL
17] Paint - 100 40 - 40
mL

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 lubricantsare added
so that friction effects can be reduced.
4)Compressed air is used in most of the machines and in some
cases compressed carbon dioxide, whereas cutting process is
become easy.
5)Fast cutting action is carried out.
6)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
It can be made hydraulically power operated by installing the gear
oil pump at the place of air compressor and pneumatic cylinder
arrangement.

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.

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/

k.krantikumar, k.v.ss.saikiran, jakkoju satish, M.tech

“pneumatic sheet metal cutting machine” International journal
& magazine of engineering technology, management and
research.ISSN:23484845.
P.M.Pradhan, “Experimental Investigation and Fabrication of
Pneumatic Cutting tool”, International Journal of Innovative
Research in Science, Engineering and Technology, Vol. 2,
Issue 6, June 2013.
http://engelectric.blogspot.com/2013/pneumaticsystem-2.html
[1] https://en.wikipedia.org/wiki/Air_compressor
PHOTOGRAPHS:
1