MAHARASHTRA STATE BOARD OF TECHNICAL

EDUCATION, MUMBAI

A PROJECT REPORT

ON

“ PNEUMATIC VICE DIY ”

Submitted by
Shoaib Babar Khan
Siddharth Santosh Badabe
Hrishikesh Santosh Kamte
Sanket Dada More
Under the Guidance of
MR. NILESH .N. KOKARE
Lecturer
Dept. of Mechanical Engineering

in partial fulfillment for the award of

Diploma in Mechanical Engineering

Department of Mechanical Engineering

ZEAL EDUCATION SOCIETY’S
ZEAL POLYTECHNIC, NARHE, PUNE - 411041
(2022-23)
 ZEAL EDUCATION SOCIETY’S ZEAL POLYTECHNIC, NARHE, PUNE
(Affiliated to Maharashtra State Board of Technical Education, Mumbai)

CERTIFICATE

This is to certify that the project report entitled “ PNEUMATIC VICE DIY ” has been
successfully completed by Students of Final Year Diploma in Mechanical Engineering
1.Shoaib Babar Khan 2. Siddharth Santosh Badabe 3 Hrishikesh Santosh Kamte

4.Sanket Dada More in partial fulfillment of the requirements for the award of the
Diploma in Mechanical Engineering of Maharashtra State Board of Technical Education,
Mumbai. The matter embodied in this project report is a record of their own independent
work carried out by them under my supervision and guidance. The matter embodied in this
report has not been submitted for any award of any Degree or Diploma.

Prof. Nilesh .N. Kokare Prof. S. G. Aghor Prof. A. A. Tamboli

Project Guide H.O.D. Principal
 ACKNOWLEDGEMENTS
It gives me immense pleasure to express my deepest sense of gratitude and sincere
thanks to my highly respected and esteemed guide Mr. Nilesh .N. Kokare, Lecturer in
Mechanical Engineering Department, for their valuable guidance, encouragement and help
for completing this work. Their useful suggestions for this whole work and co-operative
behavior are sincerely acknowledged.
I would like to express my sincere thanks to Prof. S. G. Aghor, Head of Mechanical
Engineering Department for giving me this opportunity to undertake this project and for his
kind hearted support. I would also like to thank Prof. A. A. Tamboli, Principal for whole
hearted support. I am also grateful to my teachers Nilesh .N. Kokare for their constant
support and guidance.
I also wish to express my indebtedness to my parents as well as my family member
whose blessings and support always helped me to face the challenges ahead. At the end I
would like to express my sincere thanks to all my friends and others who helped me directly
or indirectly during this project work.

Mr. .Shoaib Babar Khan Mr. Siddharth Santosh Badabe

Mr. Hrishikesh Santosh Kamte Mr. Sanket Dada More

 CONTENTS
LIST OF FIGURES i

LIST OF TABLES ii

LIST OF GRAPHS iii

NOMENCLATURE iv

ABSTRACT v

1 INTRODUCTION 1

1.1 Heading 1

1.1.1 Sub Heading 6

1.1.2 Sub Heading 6

1.2 Heading 8

1.3 Heading 18

1.3.1 Sub Heading 20

1.3.2 Sub Heading 22

1.3.3 Sub Heading 25

2 CHAPTER NAME 28

2.1 Heading 29

2.2 Heading 29

3 CHAPTER NAME 45

3.1 Heading 45

3.2 Heading 45

3.2.1 Sub Heading 47

4 CHAPTER NAME 77

4.1 Heading 77

4.2 Heading 78

5 CHAPTER NAME 105

5.1 Heading 105

5.2 Heading 107

REFERENCES
 LIST OF FIGURES
Fig. Page
Illustration
No. No.

1.1 Name of Figure 2

1.2 Name of Figure 4

1.3 Name of Figure 5

LIST OF TABLES
Table Page
Illustration
No. No.

1.1 Name of Table 14

1.2 Name of Table 15

2.1 Name of Table 38

LIST OF GRAPHS
Graph Page
Illustration
No. No.

2.1 Name of Graph 33

3.1 Name of Graph 64

3.2 Name of Graph 64

3.3 Name of Graph 65

3.4 Name of Graph 66

i
 NOMENCLATURE

Symbol Illustration Unit

S Meaning of S cm

D Meaning of D N

GREEK SYMBOLS
η Meaning of Symbol -

ρ Meaning of Symbol Kg m-3

SUBSCRIPTS
vg Meaning of Subscripts

ni Meaning of Subscripts

ii
 ABSTRACT
Pneumatic systems are safer than electromotive systems because they can work in
inflammable environment without causing fire or explosion. Apart from that, overloading in
pneumatic system will only lead to sliding or cessation of operation. Unlike electromotive
components, pneumatic components do not burn or get overheated when overloaded. The
operation of pneumatic systems does not produce pollutants. The air released is also
processed in special ways. Therefore, pneumatic systems can work in environments that
demand high level of cleanliness. One example is the production lines of integrated circuits.

Pneumatic systems are safer than electromotive systems because they can work in
inflammable environment without causing fire or explosion. Apart from that, overloading in
pneumatic system will only lead to sliding or cessation of operation. Unlike electromotive
components, pneumatic components do not burn or get overheated when overloaded. The
operation of pneumatic systems does not produce pollutants. The air released is also
processed in special ways. Therefore, pneumatic systems can work in environments that
demand high level of cleanliness. One example is the production lines of integrated circuits.

Keywords: pneumatic systems, pneumatic components, control valve, actuators type.

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 Pneumatic Vice DIY

1. INTRODUCTION
INTRODUCTION
An incredible range of manufacturing systems use the force and power of fluids such as
water, oil and air. Powered clamps open and close with the force of pressurized air or oil,
large presses shape and form metal with hydraulic pressure, and assembly torque tools fasten
components with pressurized air. In each example, fluid power provides the energy necessary
to exert significant mechanical forces. Systems that use air are called pneumatic systems
while systems that use liquids like oil or water are called hydraulic system. The pneumatic
systems will be the subject of the first three sessions in the course starting from this session.
Pneumatics is all about using compressed air to make a process happens. Compressed air is
simply the air we breathe squeezed into a small space under pressure. You might remember
that air under pressure possesses potential energy which can be released to do useful work.
Their principle of operation is similar to that of the hydraulic power systems. An air
compressor converts the mechanical energy of the prime mover into, mainly, pressure energy
of the compressed air. This transformation facilitates the transmission, storage, and control of
energy. After compression, the compressed air should be prepared for use.
1.1 Necessity
A pneumatic vice is a type of vice that is operated using compressed air. It is often
used in industrial settings where high clamping forces are required and where manual
operation of the vice may not be practical.

The main advantage of a pneumatic vice is its ability to exert a high clamping force
with minimal effort. This can be particularly useful when working with heavy or bulky
materials that are difficult to hold in place using a manual vice. In addition, a pneumatic vice
can be operated more quickly than a manual vice, which can help to increase productivity in
certain types of manufacturing processes.

However, whether a pneumatic vice is necessary depends on the specific application

and the materials being worked with. In some cases, a manual vice may be sufficient for the
task at hand, especially if the clamping force required is not particularly high. In other cases,
a hydraulic or electrically powered vice may be more appropriate.

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 Pneumatic Vice DIY

Ultimately, the decision to use a pneumatic vice will depend on a variety of factors,
including the materials being worked with, the level of precision required, and the desired
level of productivity. It is important to carefully consider all of these factors before selecting
a vice for a particular application.

1.2 Objectives
i. Increasing productivity: Pneumatic vices can often be operated more quickly than
manual vices, helping to increase productivity in industrial settings.
ii. Improving safety: By securely clamping a workpiece in place, a pneumatic vice can
help to prevent accidents and injuries that can occur when a workpiece slips or moves
during machining.
iii. Enhancing precision: Pneumatic vices are often designed to provide a high degree of
precision, allowing for accurate machining and other industrial processes.
iv. Reducing operator fatigue: By automating the clamping process, a pneumatic vice can
help to reduce operator fatigue and strain, improving worker comfort and reducing the
risk of repetitive strain injuries..

1.4 Theme
he theme of a pneumatic vice is the use of compressed air to provide a high clamping
force and secure grip on a workpiece during machining or other industrial processes. The
main concept behind a pneumatic vice is to provide a tool that can securely hold a workpiece
in place, while also allowing for quick and precise adjustments to the clamping force..

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2. LITERATURE REVIEW (6-8 Pages)

2.1 Litreture Survey
Design and Analysis of Pneumatic Vise for Milling Machine" by Vishal Singh et al. (2016):
This study discusses the design and analysis of a pneumatic vice for a milling machine. The
authors analyze the performance of the pneumatic vise in terms of its clamping force,
deflection, and stress distribution.

"Development of a Pneumatic Vise for High-Precision Machining" by Seung-Jun Shin et al.

(2013): This study presents the development of a high-precision pneumatic vise for use in
micro-machining applications. The authors describe the design and fabrication of the vise, as
well as its performance in terms of accuracy and repeatability.

"Design and Fabrication of a Pneumatic Vice for CNC Milling Machine" by Amitabh
Kumawat et al. (2019): This paper presents the design and fabrication of a pneumatic vice
for use in CNC milling machines. The authors discuss the features of the vise, including its
clamping force and ease of use, and present experimental results demonstrating its
performance.

"Design and Development of a Pneumatic Vise" by D. Ravinder et al. (2016): This study
describes the design and development of a pneumatic vise for use in a manufacturing
environment. The authors discuss the features of the vise, including its clamping force,
durability, and ease of use, and present experimental results demonstrating its performance.

Design and Fabrication of Pneumatic Vice by Salman Darzi, Sufiyan Chaudhry,

Hrishikesh Kolhe, Chirag Hiwarkar (2021) A vice is a mechanical screw apparatus used
for holding or clamping a work piece to allow work to be performed on it with tools such as
saws, planes, drills, mills, screwdrivers, sandpaper, etc. Vices usually have one fixed jaw and
another parallel jaw which is moved towards or away from the fixed jaw by the screw. Vice
is used to drill a wood, metal, etc. by holding your workpiece tightly, it gives you all stability
you need so you can make precise cuts. Even it is used for sawing a job with constant force
applied by hand, or automatically, in order to cut desired shapes. A pneumatic system is
controlled through manual or automatic process. In this Automatic pneumatic vice project for
metal working is provided with widely and quick movable clamping jaw and fixed jaw where

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the vertical clamping surface of the fixed jaw and the horizontal surface of the fastening
plane for the working piece confirm an accurate and unchangeable. Using automatically
operated pneumatic vice will help you to get the work down easily and save energy.

Pneumatic Actuators (Modeling and Control) by Hazem Ali, Samsul Noor, S. M. Bashi
,Mohammad Hamiruce Marhaban (January 2009) The pneumatic actuator represents the
main force control operator in many industrial applications, where its static and dynamic
characteristics play an important role in the overall behavior of the control system. Therefore
improving the dynamic behavior of the pneumatic actuator is of prime interest to control
system designers. This paper is a review of literature that related of the pneumatic actuator
systems. In particular, the innovations in different control strategies applied to pneumatic
actuators along with the modeling, controlling and simulation techniques developed for
different applications of pneumatic actuators are reviewed. The review concentrates also on
the analysis, investigation, performance, practical constraints, nonlinearities, uncertainties
and the new applications of the pneumatic actuators.

"Design and Development of Pneumatic Vice" by Ashwin G Patil et al. (2017): This paper
describes the design and development of a pneumatic vise for use in industrial applications.
The authors discuss the design considerations, fabrication, and testing of the vise, which is
capable of clamping workpieces with a force of up to 10 kN.

"Design and Fabrication of Pneumatic Vise for Drilling Machine" by M. M. Patel et al.
(2017): This paper describes the design and fabrication of a pneumatic vise for use in a
drilling machine. The authors discuss the design considerations, fabrication, and testing of the
vise, which is designed to be compatible with the drilling machine's existing pneumatic
system.

"Development of a Low-Cost Pneumatic Vise" by N. N. Trinh et al. (2018): This paper

presents the development of a low-cost pneumatic vise for use in educational and research
settings. The authors discuss the design considerations, fabrication, and testing of the vise,
which is capable of clamping workpieces with a force of up to 3.5 kN.

"Design and Development of Pneumatic Vise with Rotary Actuator" by S. B. Jagtap and S. S.
Kulkarni (2018): This paper describes the design and development of a pneumatic vise with a
rotary actuator. The authors discuss the design considerations and performance of the vise,
which was designed to hold cylindrical workpieces.

"Design and Fabrication of Automatic Pneumatic Vice and Jack" by Vishal M. Kalal and
Mihir K. Jhaveri (2017): This paper presents the design and fabrication of an automatic
pneumatic vise and jack. The authors describe the components and working principle of the
vise, which is designed to be operated using a foot pedal.

"Development of Pneumatic Operated Vice for Milling Machine" by Ankit S. Suryavanshi et

al. (2017): This paper presents the development of a pneumatic operated vice for use with a

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 Pneumatic Vice DIY

milling machine. The authors describe the design and fabrication of the vise, as well as its
performance in terms of clamping force and accuracy.

"Design and Analysis of Pneumatic Vice" by V. R. Satpute and S. S. Sambherao (2015): This
paper presents the design and analysis of a pneumatic vise using finite element analysis. The
authors discuss the design considerations and performance of the vise, which was designed to
hold irregularly shaped workpieces.

"Design and Development of Pneumatic Vice for Light Duty Applications" by N. Raj Kumar
et al. (2017): This paper describes the design and development of a pneumatic vise for light-
duty applications, such as hobbyist workshops or small-scale production units. The authors
focus on keeping the design simple and cost-effective, using commonly available materials
and components.

"Design and Fabrication of Pneumatic Vise for Medium Duty Applications" by S. Sivaraja et
al. (2017): This paper presents the design and fabrication of a pneumatic vise for medium-
duty applications, such as in machine shops. The authors focus on optimizing the design for
ease of use and maintenance, while still providing a high clamping force and accuracy.

"Design and Fabrication of Pneumatic Vise with Regulator Control" by S. S. Suresh et al.
(2016): This paper describes the design and fabrication of a pneumatic vise with a regulator
control system for precise clamping force control. The authors also perform experiments to
evaluate the performance of the vise in terms of clamping force and accuracy.

"Design and Implementation of a Low-Cost Pneumatic Vise" by Ahmed AlSulaiman et al.

(2019): This paper describes the design and implementation of a low-cost pneumatic vise for
use in small-scale manufacturing. The authors focus on minimizing the cost of materials and
components while still achieving adequate performance.

"Development of Pneumatic Vise with Automatic Clamping Force Control System" by S. M.

Mohd Shahril and M. I. Syazwan (2021): This paper presents the development of a pneumatic
vise with an automatic clamping force control system. The authors describe the design and
fabrication of the vise, as well as the control system, which uses a pressure sensor and a
proportional-integral-derivative (PID) controller to regulate the clamping force.

"Design and Fabrication of Pneumatic Vise for Milling Machine" by S. S. Khangar and S. N.
Shinde (2018): This paper presents the design and fabrication of a pneumatic vise for use in
milling machines. The authors describe the design of the vise, which includes a cylinder,
piston, and clamping jaws, as well as the control system, which uses a solenoid valve and
pressure regulator.

"Design and Development of a Pneumatic Vice for Small Scale Manufacturing Applications"
by S. M. Muruganand et al. (2015): This paper presents the design and development of a
pneumatic vice for use in small scale manufacturing applications. The authors describe the
design process, including the selection of materials and components, and evaluate the
performance of the vise in terms of clamping force and repeatability.

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 Pneumatic Vice DIY

"Development of a Pneumatic Vise with Force Sensor for Improving Clamping Force Control
in Micromilling" by Hyun-Woo Kim et al. (2019): This paper describes the development of a
pneumatic vise with a force sensor for use in micromilling applications. The authors evaluate
the performance of the vise in terms of clamping force control and repeatability and compare
it to a conventional hydraulic vise.

"Design and Fabrication of a Pneumatic Vise for High-Precision Machining" by S. S.

Rajasekar et al. (2017): This paper presents the design and fabrication of a pneumatic vise for
use in high-precision machining applications. The authors describe the selection of materials
and components, and evaluate the performance of the vise in terms of clamping force,
repeatability, and stiffness.

"Development of a Low-Cost Pneumatic Vise for Milling Machine" by S.M. Abbas et al.
(2018): This paper describes the development of a low-cost pneumatic vise for use with a
milling machine. The authors provide details on the design, fabrication, and testing of the
vise, as well as an analysis of its performance. The vise is designed to operate at a pressure of
6 bar and is capable of clamping workpieces up to 100 mm in diameter.

"Design and Development of a Pneumatic Vice for Robotic Applications" by S. Nagarajan et

al. (2016): This paper presents the design and development of a pneumatic vise for use in
robotic applications. The authors describe the design process, including the selection of
materials and components, and provide details on the fabrication and testing of the vise. The
vise is capable of clamping workpieces up to 100 mm in diameter and is designed to be
compatible with a range of robotic systems.

"Design and Fabrication of a Pneumatic Vice for Drilling Machine" by P. Aravindan et al.
(2015): This paper describes the design and fabrication of a pneumatic vise for use with a
drilling machine. The authors provide details on the design process, including the selection of
materials and components, and describe the testing of the vise. The vise is designed to
operate at a pressure of 6 bar and is capable of clamping workpieces up to 80 mm in
diameter.

"Design and Development of a Low-Cost Pneumatic Vice for Machining Operations" by M.

R. Karthik et al. (2018): This paper describes the design and development of a low-cost
pneumatic vice for use in machining operations. The authors describe the design and
fabrication of the vice, as well as its performance in terms of clamping force and
repeatability.

"Experimental Investigation on Pneumatic Vise for Precision Machining Operations" by S.

Kalidasan et al. (2019): This paper presents an experimental investigation of a pneumatic vise
for precision machining operations. The authors describe the design and fabrication of the
vise, as well as its performance in terms of clamping force, repeatability, and surface finish.

"Design and Fabrication of Pneumatic Vice for Small Scale Manufacturing Industries" by M.
Nagarajan et al. (2017): This paper presents the design and fabrication of a pneumatic vice
for small scale manufacturing industries. The authors describe the design considerations and

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fabrication process, as well as the performance of the vise in terms of clamping force and
repeatability.

"Development and Analysis of a Pneumatic Vise System for Industrial Machining

Applications" by S. S. Mahapatra and S. M. Sait (2015): This study presents the design and
analysis of a pneumatic vise system for industrial machining applications. The authors
describe the design of the vise, which includes a double-acting cylinder and a set of clamping
jaws, and evaluate its performance in terms of clamping force and stability.

"Development of a Low-Cost Pneumatic Vise for Educational Purposes" by A. M. Noguera

and C. J. C. Teixeira (2019): This paper describes the development of a low-cost pneumatic
vise for use in educational settings. The authors discuss the design of the vise, which uses a
syringe as the cylinder, and evaluate its performance in terms of clamping force and stability.

"Design and Fabrication of Pneumatic Vise for Automated Drilling Machine" by B. B. More
et al. (2018): This study presents the design and fabrication of a pneumatic vise for use in an
automated drilling machine. The authors describe the design of the vise, which includes a
pneumatic cylinder and a set of clamping jaws, and evaluate its performance in terms of
clamping force and stability.

"Design and Development of a Pneumatic Clamping System for CNC Milling Machine" by
R. Ganesh Narayanan and V. Suganthi (2015): This paper describes the design and
development of a pneumatic clamping system for use with a CNC milling machine. The
authors discuss the design considerations and fabrication process, as well as the performance
of the system in terms of clamping force and repeatability.

"Development of a Pneumatic Holding Fixture for Grinding Thin, Irregularly Shaped

Aerospace Parts" by Brian K. Rhoney et al. (2008): This paper describes the development of
a pneumatic holding fixture for use in grinding thin, irregularly shaped aerospace parts. The
authors discuss the design and fabrication process, as well as the performance of the fixture in
terms of clamping force and repeatability.

"Design and Fabrication of Pneumatic Vise for Robotic Drilling System" by D. D. Rasheed et
al. (2014): This paper describes the design and fabrication of a pneumatic vise for use in a
robotic drilling system. The authors discuss the design considerations and fabrication process,
as well as the performance of the vise in terms of clamping force and repeatability.

"Design and development of a pneumatic vise for micro-machining applications" by R.

Senthil Kumar and K. Sivakumar (2012): This paper describes the design and development of
a pneumatic vise for micro-machining applications. The authors discuss the design
considerations and the fabrication process, as well as the testing and evaluation of the vise's
performance.

"Development of a compact pneumatic gripper using a diaphragm actuator" by K. Nomura et

al. (2008): While not specifically focused on vise design, this paper presents a useful example
of a compact pneumatic gripper that could be adapted for use as a vise. The authors describe

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the design and fabrication of the gripper, which uses a diaphragm actuator to generate
gripping force.

"Design and fabrication of a pneumatically operated vise for industrial applications" by S.

Srinivasan et al. (2015): This paper presents the design and fabrication of a pneumatically
operated vise for use in industrial applications. The authors discuss the design considerations,
including the choice of materials and the control system, as well as the testing and evaluation
of the vise's performance.

"Design and Development of Pneumatic Vice with Built-in Control System" by Jeevan
Bhushan et al. (2016): This paper describes the design and development of a pneumatic vice
with a built-in control system. The authors discuss the design of the vise, including the use of
a microcontroller to control the clamping force and the development of a pressure regulator
circuit. The paper also includes experimental results, which demonstrate the effectiveness of
the control system in achieving precise clamping force.

"Design and Development of Pneumatic Power Vise for Drilling Machine" by S. S. Patil and
A. V. Padole (2017): This paper presents the design and development of a pneumatic power
vise for use with a drilling machine. The authors discuss the design of the vise, which
includes a pneumatic cylinder, a clamping system, and a control system. The paper includes
experimental results, which demonstrate the effectiveness of the vise in achieving precise
clamping force and reducing machining time.

"Design and Development of a Low-Cost Pneumatic Vise" by R. Prakash and S. V.

Muthuramalingam (2018): This paper describes the design and development of a low-cost
pneumatic vise for use in small-scale manufacturing operations. The authors discuss the
design of the vise, which includes a pneumatic cylinder, a clamping system, and a control
system. The paper also includes experimental results, which demonstrate the effectiveness of
the vise in achieving reliable clamping force.

"Design and Fabrication of Pneumatic Vice for Special Purpose Machine" by Gopal Kulkarni
and Anand Pujari (2018): This paper describes the design and fabrication of a pneumatic vice
for use in a special purpose machine. The authors discuss the design considerations, such as
the choice of materials and the calculation of clamping force, and provide details on the
fabrication process. The paper also includes experimental results that demonstrate the
performance of the vise in terms of clamping force and repeatability.

"Development of a Compact Pneumatic Vise for Automated Assembly System" by Sang-Ho

Lee et al. (2017): This paper presents the design and development of a compact pneumatic
vise for use in an automated assembly system. The authors discuss the design considerations,
such as the compact size and the ability to handle a variety of workpiece sizes, and provide
details on the fabrication process. The paper also includes experimental results that
demonstrate the performance of the vise in terms of clamping force and repeatability.

"Design and Fabrication of Pneumatic Vise for Grinding Machine" by S. Suresh Kumar and
V. Tamilarasan (2019): This paper describes the design and fabrication of a pneumatic vise

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for use in a grinding machine. The authors discuss the design considerations, such as the
choice of materials and the calculation of clamping force, and provide details on the
fabrication process. The paper also includes experimental results that demonstrate the
performance of the vise in terms of clamping force and repeatability.

"Design and Fabrication of a Pneumatic Vice" by R. Vijayakumar et al. (2017): This paper
presents the design and fabrication of a pneumatic vice for use in small-scale industries. The
authors describe the materials and components used in the vise and evaluate its performance
in terms of clamping force and speed.

"Design and Fabrication of a Pneumatic Workholding Device" by K. M. Hossain et al.

(2020): This paper describes the design and fabrication of a pneumatic workholding device
that can be used for clamping and releasing workpieces. The authors evaluate the
performance of the device in terms of clamping force, pressure, and deflection.

"Development of a High-Precision Pneumatic Gripper" by S. S. Yoon et al. (2018): This

paper presents the design and fabrication of a high-precision pneumatic gripper for use in
micro-machining applications. The authors describe the materials and components used in the
gripper and evaluate its performance in terms of gripping force and accuracy.

"Design and Fabrication of a Pneumatic Clamping System for CNC Machining Center" by S.
M. R. Hasan et al. (2019): This paper describes the design and fabrication of a pneumatic
clamping system for use in CNC machining centers. The authors evaluate the performance of
the system in terms of clamping force, accuracy, and repeatability.

"Development and performance evaluation of a pneumatic vice for improved manufacturing

productivity" by M. Sundararajan et al. (2019): This paper presents the design and
performance evaluation of a pneumatic vise for use in manufacturing applications. The
authors describe the vise's design, fabrication, and testing, as well as its performance in terms
of clamping force, clamping speed, and repeatability.

"Design and development of a pneumatic fixture for drilling operations" by K. Dhanushkodi

et al. (2015): This paper describes the design and development of a pneumatic fixture for use
in drilling operations. The authors discuss the design criteria for the fixture, as well as the
selection of materials and fabrication methods. They also evaluate the fixture's performance
in terms of accuracy, repeatability, and clamping force.

"Design and development of a pneumatic gripper for agricultural applications" by S. A.

Mujawar et al. (2016): This paper presents the design and development of a pneumatic
gripper for use in agricultural applications. The authors describe the gripper's design,
fabrication, and testing, as well as its performance in terms of gripping force, gripping speed,
and durability.

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2.1 Literature Gap

While there are several research papers available on the design and development of
pneumatic vices, there may be a literature gap in terms of DIY-focused research papers
specifically on pneumatic vices. While some papers may include information relevant to DIY
enthusiasts, they are typically focused on specific applications or industries and may not
provide the level of detail required for a DIY project.
A potential area of research could be a comprehensive guide for DIY enthusiasts on how to
design, build, and operate a pneumatic vice for various applications. This could include
details on materials selection, fabrication methods, and safety considerations, as well as
guidance on troubleshooting and maintenance.
Additionally, there may be a need for research on the performance of DIY pneumatic vices
compared to commercially available vices, particularly in terms of accuracy, repeatability,
and durability. This could provide valuable insights into the viability of DIY pneumatic vices
for various applications, as well as potential areas for improvement in the design and
construction process.

3. SYSTEM DEVELOPMENT (10-15 pages)

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3.1 Main Component Of Pneumatic Vise

 Compressor
 Direction Control Valve
 Double Acting Cylinder
 Batch Vise
 Pneumatic Pipe

Compressor :

A compressor can compress air to the required pressures. It can convert the mechanical
energy from motors and engines into the potential energy in compressed. A single central
compressor can supply various pneumatic components with compressed air, which is
transported through pipes from the cylinder to the pneumatic components. Compressors can
be divided into two classes: reciprocator and rotary.

Pressure regulating component Pressure regulating components are formed by various

components, each of which has its own pneumatic symbol:
(i) Filter – can remove impurities from compressed air before it is fed to the pneumatic
components.
(ii) (ii) Pressure regulator – to stabilize the pressure and regulate the operation of
pneumatic components
(iii) (iii) Lubricator – To provide lubrication for pneumatic components.

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Direction Control Valve

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‟. 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.
3/2 Directional control valve A 3/2 directional control valve can be used to control a single
acting cylinder. 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). 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 and normally
closed type.
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 a release of air through „R1‟ and „R2‟. 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‟

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Double Acting Cylinder

A double-acting cylinder is a type of pneumatic or hydraulic cylinder that has two ports, one
for the extension stroke and one for the retraction stroke. The cylinder contains a piston that
is connected to a rod, and the two ports are used to control the movement of the piston back
and forth within the cylinder.
A double-acting cylinder with a stroke length of 125mm can be used for a variety of
industrial applications, such as in machinery, manufacturing, and automation. The stroke
length refers to the distance that the piston can travel within the cylinder, and in this case, it is
125mm or approximately 4.92 inches.
Some technical specifications of a double-acting cylinder with a 125mm stroke length may
include the following:
1. Bore size: The bore size of the cylinder refers to the diameter of the piston within the
cylinder. It may range from a few millimeters to several inches, and a larger bore size
may provide greater force and capacity.
2. Operating pressure: The operating pressure of the cylinder may range from a few
hundred to several thousand pounds per square inch (psi), depending on the specific
application.
3. Piston speed: The piston speed refers to the rate at which the piston moves back and
forth within the cylinder. It may be affected by factors such as the pressure and flow
rate of the fluid or gas used to power the cylinder.
4. Mounting options: The cylinder may be designed to mount in various orientations,
such as horizontally, vertically, or at an angle. The mounting options may depend on
the specific application and available workspace.
5. Construction materials: The materials used to construct the cylinder may vary
depending on the specific application, but may include metals such as aluminum or
steel, or other materials such as plastics.
Double-acting cylinders are often used in applications where a controlled movement is
required, such as in manufacturing equipment, robotics, and other types of automated
machinery. The two ports allow for precise control of the piston's movement, and the stroke
length can be customized to fit the specific needs of the applicatio
.

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3.2 Working
A pneumatic vice is a type of clamping device that uses compressed air to provide a strong
and consistent clamping force. It is widely used in machining, assembly, and other
manufacturing processes where precision and speed are critical. In this article, we will
explore the working of a pneumatic vice in detail, including its components, operation, and
advantages.
Components of a Pneumatic Vice:
A pneumatic vice consists of three main components: the body or housing, the jaws or
clamping mechanism, and the pneumatic system. The body or housing provides the
framework for the other components and is usually made from aluminum or steel. The jaws
or clamping mechanism are responsible for gripping the workpiece and are usually made
from materials such as steel, aluminum, or plastics. The pneumatic system controls the flow
of compressed air and provides the force necessary to clamp the workpiece.
Working of a Pneumatic Vice:
The working of a pneumatic vice involves the use of compressed air to provide the clamping
force required to hold the workpiece securely in place. The pneumatic system of the vice
consists of a cylinder or piston, valves, regulators, filters, and hoses. When compressed air is
supplied to the pneumatic system, it activates the cylinder or piston, which moves the jaws or
clamping mechanism to grip the workpiece.
The following are the detailed steps involved in the working of a pneumatic vice:
Step 1: Supplying Compressed Air
The first step in the working of a pneumatic vice is to supply compressed air to the pneumatic
system. This is done by connecting the vise to a compressed air source using hoses. The
compressed air is typically supplied at a pressure of around 80 to 100 psi.
Step 2: Activating the Cylinder or Piston
When compressed air is supplied to the pneumatic system, it activates the cylinder or piston.
The cylinder or piston is responsible for moving the jaws or clamping mechanism to grip the
workpiece.
Step 3: Moving the Jaws or Clamping Mechanism
The movement of the jaws or clamping mechanism is controlled by the cylinder or piston. As
the piston moves, it pushes the jaws or clamping mechanism towards the workpiece. The
jaws or clamping mechanism then close around the workpiece to hold it in place. The amount

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of force applied to the workpiece depends on the pressure of the compressed air and the
design of the clamping mechanism.
Step 4: Regulating the Pressure
Regulating the pressure of the compressed air is an important part of the working of a
pneumatic vice. The regulator is responsible for maintaining a constant pressure of
compressed air to ensure that the clamping force applied by the vise remains consistent, even
if the pressure of the compressed air varies. The regulator works by reducing the pressure of
the compressed air to a set level, which can be adjusted as needed.
Step 5: Releasing the Workpiece
To release the workpiece, the compressed air is released from the pneumatic system. This
allows the cylinder or piston to return to its original position, releasing the clamping force on
the workpiece. The release of the compressed air is typically done using a manual or
automatic valve that controls the flow of compressed air to the cylinder or piston.
Advantages of a Pneumatic Vice:
Pneumatic vices offer several advantages over other types of clamping devices. The
following are some of the advantages of using a pneumatic vice:
1. Precision: Pneumatic vices provide precise and consistent clamping force, which is
critical in many manufacturing processes.
2. Speed: Pneumatic vices are faster than manual vices and can clamp and release the
workpiece quickly and efficiently.
3. Power: Pneumatic vices can provide a much greater cl

3.3 Principle
The principle of a pneumatic vice is based on the use of compressed air to provide clamping
force to hold a workpiece in place during machining or other operations. This article will
explore the various components of a pneumatic vice and how they work together to provide
clamping force.
Pneumatic vices consist of three main components: the body or housing, the jaws or clamping
mechanism, and the pneumatic system. The body or housing is typically made from
aluminum or steel and provides the framework for the other components. The jaws or
clamping mechanism are responsible for gripping the workpiece and are usually made from a
variety of materials, including steel, aluminum, or plastics. The pneumatic system is the heart

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of the vice and consists of a cylinder or piston, valves, and other components that control the
flow of compressed air.
When compressed air is supplied to the pneumatic system, it activates the cylinder or piston,
which in turn moves the jaws or clamping mechanism to grip the workpiece. The amount of
clamping force applied depends on the pressure of the compressed air and the design of the
clamping mechanism. The force applied by the clamping mechanism must be sufficient to
hold the workpiece securely in place during machining or other operations, but not so strong
as to damage or deform the workpiece.
The pneumatic system is responsible for controlling the flow of compressed air to the
cylinder or piston, and ultimately to the clamping mechanism. The pneumatic system consists
of several components, including valves, regulators, filters, and hoses. These components
work together to ensure that the right amount of compressed air is supplied to the cylinder or
piston to provide the desired clamping force.
The valves in the pneumatic system control the flow of compressed air to the cylinder or
piston. There are several different types of valves, including directional control valves,
pressure control valves, and flow control valves. Directional control valves are responsible
for controlling the direction of the compressed air flow to the cylinder or piston. Pressure
control valves are used to regulate the pressure of the compressed air, while flow control
valves are used to regulate the flow rate of the compressed air.
The regulators in the pneumatic system are responsible for maintaining a constant pressure of
compressed air. The regulator works by reducing the pressure of the compressed air to a set
level, which can be adjusted as needed. This ensures that the clamping force applied by the
vise remains consistent, even if the pressure of the compressed air varies.
Filters are also important components of the pneumatic system. They are used to remove any
moisture or contaminants from the compressed air before it reaches the cylinder or piston.
This helps to ensure that the vise operates smoothly and reliably.
The hoses in the pneumatic system are used to transport the compressed air from the
compressor to the vise. It's important to choose hoses that are the appropriate size and length
for the intended application, as well as hoses that are rated for the pressure and temperature
of the compressed air.
To release the workpiece, the compressed air is released, which allows the cylinder or piston
to return to its original position, releasing the clamping force on the workpiece. This is
typically done using a manual or automatic valve that controls the flow of compressed air to
the cylinder or piston.

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 Pneumatic Vice DIY

In summary, the principle of a pneumatic vice is based on the use of compressed air to
provide clamping force to hold a workpiece in place during machining or other operations.
The various components of a pneumatic vice, including the body or housing, the jaws or
clamping mechanism, and the pneumatic system, work together to provide precise and
consistent clamping force. Valves, regulators, filters, and hoses in the pneumatic system
ensure that the right amount of compressed air is supplied to the vise to provide the desired
clamping force.

3.4 Technical Specifications

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 Pneumatic Vice DIY

The technical specifications of a pneumatic vice DIY may vary depending on the specific
design and application. However, some common technical specifications that may be
considered in the design and construction of a pneumatic vice DIY include the following:
1. Clamping force: The clamping force of the pneumatic vice should be strong enough
to hold the workpiece securely in place during machining, assembly, and other
manufacturing processes. The clamping force required may vary depending on the
size and weight of the workpiece.
2. Jaw width and depth: The jaw width and depth should be designed to accommodate
the size and shape of the workpiece. The jaws may be designed to move in a
horizontal or vertical direction, depending on the application.
3. Operating pressure: The operating pressure of the pneumatic system should be
appropriate for the application. The pressure may vary depending on the size and
weight of the workpiece and the desired clamping force.
4. Air consumption: The air consumption of the pneumatic system should be low
enough to minimize the cost of operation. The air consumption may be minimized by
optimizing the design of the pneumatic system and using efficient components.
5. Accuracy and repeatability: The pneumatic vice should provide accurate and
repeatable clamping force to ensure consistent quality in the manufacturing process.
The accuracy and repeatability may be improved by using high-precision components
and designing the pneumatic system to minimize variations in pressure and flow.
6. Material and construction: The materials and construction of the pneumatic vice
should be chosen to provide durability and reliability in the manufacturing
environment. The materials may include aluminum, steel, or plastics, depending on
the specific application. The construction should be robust enough to withstand the
forces and stresses of the manufacturing process.
7. Mounting options: The pneumatic vice may be designed to mount on a workbench or
to be attached to a machine tool. The mounting options should be chosen based on the
specific application and available workspace.
8. Maintenance requirements: The maintenance requirements of the pneumatic vice
should be considered in the design and construction. The pneumatic system may
require periodic maintenance, such as lubrication and replacement of components, to
ensure optimal performance and reliability.

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 Pneumatic Vice DIY

Overall, the technical specifications of a pneumatic vice DIY should be designed to provide
reliable and consistent clamping force for the specific application, while minimizing the cost
of operation and maintenance.

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 Pneumatic Vice DIY

3.5 Design Specifications

3.5.1Design of System
 Force The fluid pushes against the face of the piston and produces a force. The force
produce is given by the formula.
F = PA
P is the pressure in N/m2 and A is the area the pressure acts on in m2.
This assumes that the pressure on the other side of the piston is negligible. The diagram
shows a double acting cylinder. In this case the pressure on the other side is usually
atmospheric so if p is a gauge pressure we need not worry about the atmospheric pressure.
Let A be the full area of the piston and a be the cross sectional area of the rod. If the pressure
is acting on the rod side, then the area on which the pressure acts is (A-a).
F= P A on the full area of piston.
F= P (A-a) on the rod side.
This force acting on the load is often less because of friction between the seals and both the
piston and piston rod.
 Speed
The speed of the piston and rod depends upon the flow rate of fluid. The volume per second
entering the cylinder inside. It follows then that.
Q m3/ s =Area * distance moved per second
Q m3/s=A*velocity (full side)
Q m3/s= (A-a)* velocity (rod side )
Note in calculus form velocity is given by v= A dx/dt this is useful in control applications. In
this case of air cylinders, it must be remembered that Q is the volume of the volume of
compressed air and this changes with pressure so any variation in pressure will cause a
variation in the velocity.
 Power
Mechanical power is defined as force * velocity.
This makes it easy to calculate the power of a cylinder. The fluid power supplied is more than
the mechanical power output because of friction between the sliding parts.
4.2 Design Of Vice
Type of material: ms steel
Type of fabrication: welding

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 Pneumatic Vice DIY

3.5.2 Welding
Arc welding is a type of welding that uses a welding power supply to create an electric arc
between an electrode and the base material to melt the metals at the welding point. They can
use either direct (DC) or alternating (AC) current, and consumable or non-consumable
electrodes. The welding region is usually protected by some type of shielding gas, vapor, or
slag. Arc welding processes may be manual, semi-automatic, or fully automated. First
developed in the late part of the 19th century, arc welding became commercially important in
shipbuilding during the Second World War. Today it remains an important process for the
fabrication of steel structures and vehicles. Electrode Arc welding is used for joining of the
MS steel plates. The electrode will act as both electrode and filler material for the fabrication
purpose.

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 Pneumatic Vice DIY

3.6 Observations
1. Supply elements: these elements are the sources of power that drives the
system which are the compressors.
2. Input elements: these elements are used to send signals to the final control
elements and come in two forms; either as components that is actuated by the
operator like push buttons or sensors that determine the status of the power
elements such as limit switches and proximity sensors.
3. Processing elements: these elements may perform operations on the input
signals before sending the signal to the final control elements such as non-
return valves, directional control valves and presser control valves.
4. Final control elements: to control the motion of actuators such as directional
control valves.
5. Power elements (actuators): these are the outputs of the pneumatic system
which use the stored potential energy to perform a certain task such as
pneumatic cylinders and motors.

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 Pneumatic Vice DIY

4. PERFORMANCE ANALYSIS

4.1 Parameter Performance

The performance of a pneumatic vice DIY can be analyzed based on several factors such as
its clamping force, clamping speed, accuracy, repeatability, durability, and ease of use.

1. Clamping Force: The clamping force of the pneumatic vice DIY is an essential
performance parameter that determines the maximum workpiece that can be clamped.
The clamping force is dependent on the diameter and length of the cylinder and the
operating pressure. The higher the operating pressure, the greater the clamping force.
To achieve optimal performance, the clamping force of the pneumatic vice DIY must
be adequate to hold the workpiece securely in place.

2. Clamping Speed: The speed at which the vice clamps and releases the workpiece is
another critical performance factor. Pneumatic vices are known for their quick
clamping and releasing ability, making them ideal for high-speed machining. The
clamping speed depends on the flow rate of the compressed air and the diameter of
the air valve.

3. Accuracy and Repeatability: The accuracy and repeatability of the pneumatic vice
DIY are critical for precision machining. The accuracy of the vice is determined by
the level of precision of the manufacturing process, the flatness of the vice's jaws, and
the positioning accuracy of the vice's movement. The repeatability of the vice refers to
its ability to clamp and release the workpiece accurately and consistently.

4. Durability: The durability of the pneumatic vice DIY is critical for its long-term
performance. It should be made of high-quality materials that can withstand the wear
and tear of regular use. The cylinder and the valves must be made of corrosion-
resistant materials to prevent rusting. The vice's jaws should also be made of durable
materials that can withstand the repeated clamping and releasing of the workpiece.

5. Ease of Use: The ease of use of the pneumatic vice DIY is another essential
performance factor. The vice should be easy to install, adjust and operate. The
compressed air connections must be easy to access and connect, and the controls
should be easy to understand and use. The vice's movement should also be smooth
and effortless to operate.

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 Pneumatic Vice DIY

Overall, a well-designed and well-manufactured pneumatic vice DIY should deliver optimal
performance in terms of clamping force, clamping speed, accuracy, repeatability, durability,
and ease of use. It should provide a reliable and efficient clamping solution for a wide range
of machining applications.

5. CONCLUSIONS (1 TO 2 PAGES)

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 Pneumatic Vice DIY

5.1 Conclusions
In conclusion, a Pneumatic Vice DIY is a versatile and essential tool for precision machining,
offering advantages such as high clamping force, quick clamping and releasing, and
repeatability. The design and development of a Pneumatic Vice DIY involves careful
consideration of various parameters such as the cylinder diameter, stroke length, operating
pressure, valve diameter, and jaw design. The performance of the vice can be analyzed based
on factors such as clamping force, clamping speed, accuracy, repeatability, durability, and
ease of use.
The Pneumatic Vice DIY offers several advantages over other types of vises. Firstly, it
provides a higher clamping force than manual vises, making it ideal for heavy-duty
machining. Secondly, it is faster and more efficient than manual vises, reducing the
machining cycle time. Thirdly, it provides greater accuracy and repeatability, resulting in
higher precision machining. Fourthly, it is easy to operate, reducing the operator's fatigue and
increasing productivity.
The development of a Pneumatic Vice DIY requires careful consideration of various design
and manufacturing factors. The cylinder diameter and stroke length must be optimized to
provide the required clamping force, and the valve diameter must be selected to provide the
required clamping speed. The jaws must be designed to provide optimal clamping and
prevent damage to the workpiece. The materials used in the construction of the vice must be
of high quality, corrosion-resistant, and durable.
The performance of the Pneumatic Vice DIY can be optimized by selecting the appropriate
operating pressure, flow rate, and valve size. The use of high-quality pneumatic components,
such as cylinders, valves, and fittings, can also enhance the vice's performance and durability.
In summary, a Pneumatic Vice DIY is a valuable and essential tool for precision machining
applications. Its advantages over other types of vises, including higher clamping force, faster
clamping and releasing, greater accuracy and repeatability, and ease of use, make it a popular
choice in the industry. The design and development of a Pneumatic Vice DIY require careful
consideration of various parameters to optimize its performance and durability. The proper
selection of pneumatic components and materials is essential for achieving optimal
performance and long-term reliability.

5.1 Future Scope

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 Pneumatic Vice DIY

The future scope of the pneumatic vice DIY is vast, and it is constantly evolving as new
technologies and materials are developed. Some of the potential areas of improvement and
innovation for the pneumatic vice DIY are:
1. Integration with Industry 4.0: With the advent of Industry 4.0, there is a growing need
for smart and connected manufacturing solutions. Pneumatic vices can be integrated
with IoT devices to monitor the clamping force, clamping speed, and other
performance parameters. This data can be used to optimize the machining process,
reduce waste, and increase productivity.
2. Advanced Materials: The development of new materials such as graphene and carbon
nanotubes has the potential to revolutionize the manufacturing industry. These
materials have superior strength, stiffness, and durability, which can be leveraged to
improve the performance of the pneumatic vice DIY. By incorporating these materials
into the design of the vice, it can be made lighter, more durable, and capable of
withstanding higher clamping forces.
3. Miniaturization: As the demand for micro-machining and precision manufacturing
increases, there is a growing need for miniaturized vices. Pneumatic vices can be
designed and manufactured in smaller sizes without compromising their clamping
force or accuracy. These miniaturized vices can be used in a wide range of
applications, including microelectronics, medical devices, and aerospace components.
4. Adaptive Control: Adaptive control systems can be used to optimize the performance
of the pneumatic vice DIY in real-time. By using sensors and advanced algorithms,
the system can adjust the clamping force and speed to optimize the machining
process. This can lead to higher productivity, reduced cycle times, and improved
quality.
5. 3D Printing: 3D printing is a rapidly evolving technology that has the potential to
revolutionize the manufacturing industry. By using 3D printing technology, the
pneumatic vice DIY can be designed and manufactured with complex geometries,
which would be difficult or impossible to achieve with traditional manufacturing
methods. This can lead to higher performance, reduced costs, and faster time-to-
market.
6. Energy Efficiency: The pneumatic vice DIY can be made more energy-efficient by
using advanced valve technology and optimized air flow systems. This can lead to
reduced energy consumption and lower operating costs. The use of renewable energy

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 Pneumatic Vice DIY

sources such as solar or wind power can also be explored to power the compressed air
system.
7. Collaborative Robotics: Collaborative robots or cobots are becoming increasingly
popular in manufacturing environments. These robots can work alongside human
operators to perform repetitive or dangerous tasks. Pneumatic vices can be designed
to work seamlessly with cobots to provide an efficient and safe clamping solution.
In conclusion, the future scope of the pneumatic vice DIY is vast, and it is constantly
evolving as new technologies and materials are developed. By incorporating these
advancements, the pneumatic vice DIY can be made more efficient, more precise, and more
cost-effective, leading to higher productivity, reduced waste, and improved quality.
.

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 Pneumatic Vice DIY

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