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SYNOPSIS
Compressed air from the compressor storage tank used as the working
fluid.
Depending upon the type of rivet head different types of Rams and
Anivls are used.
CONTENTS
1. Introduction
2.1) Cylinder
2.2) Piston
2.3) Piston Rod
2.4) Sealing
2.5) Valves
2.6) Cushioning
2.7) Silencers
2.8) Specifications
III. Rivets
V. Cost Estimation
VI. Fabrication
IX. Drawings
X. Photographs
XI. Bibliography
INTRODUCTION
CHARPER I
INTRODUCTION
1.1) INTRODUCTION
The use of rivets and machine riveting has been constantly expanding for
both job-shop and production-line operations. The automotive, electronic
appliances, electronic furniture, hardware, military, sheet metal are among
the many in which riveting is a popular fastening method. This growth in
riveting has occurred because of further refinement of high sped riveting
techniques and because over the years, it is inherent advantages have
become more and more valuable with changes in manufacturing.
1.2) THE RIVETS
The length of the shank of the rivet should accommodate the thickness
of the connecting plates and also provide sufficient material for forming the
head at the tail end.
Classification of Rivets
RIVET
SOLID TABULAR
In both solid and tubular rivets, two or more parts are fastened
together by the rivet head on one side and a formed shape at the end of the
rivet shank on the other side.
Solid Rivets
The Rivets are shown in Fig. 2. In solid rivets the formed shape is
produced by heading over, hammering.
Tubular Rivets
Rivets Heads
Materials
3) How many different rivet sizes, diameter and length are involved in
the assembly?
The orientation of the atoms in a given is uniform but differs from that
in adjacent grains.
Slip planes develop through the lattice structure at points where the
atomic bonds of attraction are the weakest and whole blocks of atoms are
displaced. In cases where atoms are reoriented twinning occurs. IN
twinning, the lattice on one side of a plane is oriented in different fashion
from the other but the atoms have a shape identical to the adjacent atoms.
Slip is the most common method of bringing about metal deformation.
1. Stresses are set up in the metal which remains unless they are
removed by subsequent heat treatments.
1. Higher pressure and heavier equipments are needed for cold working
process.
5) Any material than can be cold worked can be made into rivets.
7) Rivets can also serve as pivot shafts, spacers, electric, contacts, stop
and inserts.
1) Their tensile and fatigue strengths are lower than those of bolts.
2) High tensile loads can pull out the clinch and severe vibrations can
loosen the Riveted joints may not be either watertight or airtight.
Single acting air cylinder differs in that the air pushes the piston which
return by spring action or gravity. The force for the return stroke for double-
acting cylinders is slightly less as the effective area of the piston is reduced
by the sectional area of the piston rod.
Cylinder Material
Brass and copper are ideal materials for pneumatic cylinders because
they reduce frictional losses considerably. However their drawback lies on
the fact that they posses lesser strength compared to steel materials. M S
and graded C I are usually used as cylinder head materials.
2.2) THE PISTON
Aluminum, brass, copper, C I and steel are some of the material used
for pistons depending on whether the application involves light or heavy
duty. Further pistons many be one-pieces, two-pieces or three-pieces in
construction according to the type of packing used.
For example “U” rings require one piece construction where as cup
packing requires three-pieces construction. The various kinds of packing
generally used include the cup type “U” rings, ‘O’ rings and synthetic
packing depending on service conditions.
A pneumatic cylinder operating valve must have three ports viz., one
inlet, one outlet and one exhaust. A single acting cylinder can be operated
by three ports but a double acting cylinder required two or three port valves.
However, on practice, a paid of three valves are combined to function as one
unit.
TYPES OF VALVES
Poppet Valves
Poppet vales are used for controlling devices such as air drills due to
their simplicity and ease of operation.
Spool Valves
Solenoid Valves
2.8) SPECIFICATIONS
d) Materials – Brass
A cylinder of before 25mm and stroke 25mm was selected which can
develop 30 kg at a maximum operating pressure of 2 gk/mm
A square rod column section is used support the cylinder. The whole
cylinder is bolted to the column.
3.2) WORKING PRINCIPLE
The riveting machine makes use of a pneumatic cylinder for its drive.
The cylinder get compressed air from the compressor unit through a pressure
regulator. The movement of cylinder is controlled by a hand operated valve.
By altering the flow of compressed air on both the sides of piston (double
acting) it is possible to achieve.
It can seen from the Fix. 5 that as soon as one side of piston gets
compressed air, the other side gets simultaneously emptied through exhaust.
This is effected by the valve.
Compressed air is passed through the line via the valve. The air then
enters the cylinder from top and forces the piston down. When the valve
position is changed compressed air fill the bottom of the cylinder, while the
air in top portion of the cylinder is exhausted thought the valve, thereby
completing one cycle.
Assumptions
4. The force acts at the intersection of the diagonais from E.q.n. 8.8 Pg.
104 of machines design.
We have for,
a = 320 mm
b = 260 mm
od = 3 kg/mm2
F = 30 kg
Abf
h = ---------------------
Od (a2+a2)
= 2.158 mm
4.2) COLUMN
a) w.r.t. bending
Assumptions
MB = F X 180
= 30X 180
= 5400 kgf-mm
h = 30 x 25.4 0.0777
------------ = ----------
gxm m
where g = 9810mm/sec2
Using these date in eqn. 3-12. page of 49 machine design data handbook
(Dr. Lingaiah)
O1 = w 1 + 2hEA
---------- 1+ ------------
A MxL
Where, W = 30 kgf
A = 12 x 12 = 14 mm2
h = 0.0777/m
mL = 21858.50
but m = A x L x p,
where p = density = 7.85 gram/m3
A = area of cross section = 14 mm2
14 x 12 x 7.35 = 169840.43
L = 12.66 mm
(both tensile and compression are equal)
= F 30
------------------- = --------------------- kgf/mm2
A t2
= 30 + 32400
-------------------- ------------------------
t2 t3
3 = 30 + 32400
-------------------- ------------------------
t2 t3
3t3 – 30 t – 3240 = O.
Column thickness t = 25 mm
Fcr = n E1
------------------------
12
where n = 0.25 for one end fixed and other end free (table 2.4 pg 41)
bd3 t4
1 = -------------------- = -------------------- where, t = 2.5cm
12 12
nEl
1 = ------------------------
Fcr
= 423 mm
t = 25 mm
= d2
------------------- x pa
4
d2
30 = ------------------------ x 0.06
4
d = 25.23 mm
Is = Stroke required 25 mm
F = 30
2x 30 x 25.4
Final velocity v = 2 as = -------------------- mm/sec
M
Assumptions
1. a = 60 mm
2. b = 40 mm
3. od = 3 kg/m2
we have k4 = 1.28
abF
t1 = k4 -----------------------
Od (a2+a2)
(a) Column
to find hw
from table 12.1 pg. 160 of machine design handbook (Dr. Lingaiah)
for the similar case with Od for weld = 2 kg/mm2 (for appropriate welding
rod)
540 x 4.24
Ob = ------------------------------------------
hw (25.2 + 3 X 25 (25 + hw)
The same is adopted for al other welds since this is the critical section.
4.7) DESIGEN OF BOLTS ( Refer to Fig. 11)
No. of bolts = 2
30 x 180
1 64.2
2700d
= --------------------- x ------------------
2
d4
-----------------------
64
27502
= ------------------------
d3
direct (tensile)stress
F 30 38.2
A d2
d2
----------------------
4
27502 38.2
= ------------------ + --------------------
d3 d2
which gives d = 8 m
adopt M8 bolts
CHAPTER V
COST ESTIMATION
------------------
Total Rs. 2,625.00
-------------------
FABRICATION
CHAPTER VI
FABRICATION
a) First the base plate is cur to the required dimension, after this the
bottom supporters (Legs) are welded at four corners.
b) A hole drilled on the base plate and the anvil (platform welded to
anvil) is bolted on the base plate.
c) Then the column (square rod) is welded and the cylinder is fixed to it
with the help of clamp, bolts and nuts.
e) The valve is supported on the base plate and is secured to it with the
help of bolts and nuts.
f) The nozzles are fixed on to the valve and the hose pipes are secured
on the nozzles using worm clips.
CHAPTER VII
TEST AND RESULTS
1. Visual inspection of
Nil ------------------
joints for faults
Deflection can be
2. Deflection of avoided by giving
Moderate
structural component extra support to the
column
3. Dynamic stability
under maximum Stable ------------------
working pressure
CHPARTER V I I I
SUGGESTED MODIFICATIONS
BIBLIOGRAPHY
7. Westermann’s Tables
PNUEMATIC
MACHINE/
VALVE
…………. BASE
CYCLIN
DER
STAND