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Pneumatic Shaper Machine - Project Report
Pneumatic Shaper Machine - Project Report
MACHINE
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PNEUMATIC SHAPER MACHINE
of
Bachelor of Technology
in
Mechanical Engineering
Submitted by
Head of Department
Of
Mechanical Engineering
2015-2016
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TABLE OF CONTENTS
S.NO. TOPIC PAGE NO.
1 CANDIDATE’S DECLARTION 4
2 CERTIFICATE 5
3 ACKNOWLEDGEMENT 6
4 ROLE AND RESPONSIBILITIES 7
5 PERSONAL ENGINEERING 8
ACTIVITY
6 ABSTRACT 9
7 INTRODUCTION 10
8 LITERATURE SURVEY 12
9 COMPONENTS AND 16
DESCRIPTION
10 EXPERIMENTAL MODELING 41
11 WORKING 42
12 MERITS AND DESMERITS 44
13 APPLICATIONS 55
14 CONCLUSION 46
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CANDIDATE’S DECLARTION
I hereby certify that the work which is being presented by Amit Jaiswal, Ajay
Singh Chauhan, Rajeev Kumar, Raman Kumar, Vijay Kumar in partial fulfillment
of requirement for the award of degree of B.Tech. in MECHANICAL ENGINEERING
submitted at KALPI INSTITUTE OF TECHNOLOGY under KURUKSHETRA
UNIVERSITY, KURUKSHETRA is an authentic record of my own work carried out
under the supervision of Er. Harish Kumar Sharma (HOD) and Er. Vikas Kunnar.
Project Member:
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CERTIFICATE
Mr.........................
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ACKNOWLEDGEMENT
First of all we would like to thank our project guide Mr. ......................
Assistant Professor, Mechanical engineering Department, Kurukshetra
University who has given valuable support during the course of our
project by clarifying our doubts and guiding us with her novel ideas.
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Role and Responsibilities
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PERSONAL ENGINEERING ACTIVITY
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ABSTRACT
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INTRODUCTION
They have been investigated to use pneumatic shaper for high production of
automatic gear cutting with auto indexing work piece. A small ratchet gear
structure has been thus devised to demonstrate the gear cutting attachment in
shaping machines.
The pneumatic source of power with control accessories is used to drive the ram
or the cylinder piston to obtain the forward and return strokes. By this
arrangement the forward/reverse stroke of the pneumatic cylinder is adjustable
type when compared with the conventional machines. We desired a shaping
machine which will automatically index the job and gives automatic tool feed to
the pneumatic cylinder.
Full automation.
Semi automation.
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Needs for pneumatic power :
Pneumatic system use pressurized gases to transmit and control power, as the
name implies, pneumatic systems typically use air as fluid medium, because air is
a safe, low cost and readily available fluid. It is particularly safe environments
where an electrical spark could ignite leaks from the system components.
There are several reasons for considering the use of pneumatic system instead of
hydraulic system Liquid exhibit greater inertia than gases. Therefore, in hydraulic
system the weight of the oil is a potential problem. To design and development a
material handling system for automation /semi automation of industries by using
pneumatic control system, which is used for low cost automation.
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LITERATURE SURVEY:
Pneumatics:
The word ‘pneuma’ comes from Greek and means breather wind. The word
pneumatics is the study of air movement and its phenomena is derived from the
word pneuma. Today pneumatics is mainly understood to means the application
of air as a working medium in industry especially the driving and controlling of
machines and equipment.
Pneumatics has for some considerable time between used for carrying out the
simplest mechanical tasks in more recent times has played a more important role
in the development of pneumatic technology for automation.
The key part of any facility for supply of compressed air is by means using
reciprocating compressor. A compressor is a machine that takes in air, gas at a
certain pressure and delivered the air at a high pressure.
Compressor capacity is the actual quantity of air compressed and delivered and
the volume expressed is that of the air at intake conditions namely at atmosphere
pressure and normal ambient temperature.
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The compressibility of the air was first investigated by Robert Boyle in 1962 and
that found that the product of pressure and volume of a particular quantity of
gas.
In this equation the pressure is the absolute pressured which for free is about
14.7 Psi and is of courage capable of maintaining a column of mercury, nearly 30
inches high in an ordinary barometer. Any gas can be used in pneumatic system
but air is the mostly used system now a days.
PNEUMATIC ACTUATOR:
Physical processes proceeding in drives are submitted to the gas laws. The gas
laws are a set of laws that describe the relationship between thermodynamic
temperature (T), pressure (P) and volume (V) of gases. Three of these laws,
Boyle’s law, Charles’s law, and Gay-Lussac’s law, may be combined to form the
combined gas law
Which with the addition of Avogadro’s law later gave way to the ideal gas law.
Other important gas laws include Dalton’s law of partial pressures. The kinetic
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theory of gases, Graham’s law of effusion and root mean square velocity explains
how individual molecules act in a gas and their relation to pressure, volume, and
temperature. A gas that obeys these gas laws is known exactly as an ideal gas (or
perfect gas). An ideal gas does not exist; however, some gases follow the laws
more closely than the others in given standard conditions.
The most important gas law is the ideal gas law, which states that: PV = nRT
Other gas laws, such as vander Waals equation, seek to correct the ideal gas laws
to reflect the behaviour of actual gases. Van der Waals equation alters the ideal
gas law to reflect how actual gases function using a series of calculated values
called van der Waals constant
Any gas can be used in pneumatic system but air is the mostly used system now a
days.
SELECTION OF PNEUMATICS
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The main advantage of an all pneumatic system are usually economic and
simplicity the latter reducing maintenance to a low level. It can also have out
standing advantages in terms of safety.
PNEUMATIC POWER
Pneumatic systems use pressurised gas to transmit and control power. Pneumatic
systems typically use air as the fluid medium because air is safe, free and readily
available.
Advantages of Pneumatics:
Disadvantages of Pneumatics:
2. Pneumatic pressures are quite low due to compressor design limitations (less
that 250 psi).
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COMPONENTS AND DESCRIPTION :
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DESCRIPTION OF EQUIPMENT
The key part of any pneumatic system for supply of compressed air is by means
using reciprocating compressor. A compressor is a machine that takes in air, gas
at a certain pressure and delivers it at a higher pressure. Compressor capacity is
the actual quantity of air compressed and delivered. And the volume expressed is
that of the air at intake conditions namely at atmosphere pressure and normal
ambient temperature.
Clean condition of the suction air is one of the factors, which decides the life of a
compressor. Warm and moist suction air will result in increased precipitation of
condense from the compressed air.
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Turbo compressors are employed where large capacity of air required at low
discharge pressures. They cannot attain pressure necessary for pneumatic control
application unless built in multistage designs and are seldom encountered in
pneumatic service.
RECIPROCATING COMPRESSORS:
Built for either stationary (or) portable service the reciprocating compressor is by
far the most common type. Reciprocating compressors deliver more than 500
m³/min. In single stage compressor, even if the air pressure is of 6 bar, the
machines can discharge pressure of 15 bars. Discharge pressure in the range of
250 bars can be obtained with high pressure reciprocating compressors that of
three & four stages. Single stage and 1200 stage models are particularly suitable
for pneumatic applications , with preferences going to the two stage design as
soon as the discharge pressure exceeds 6 bar, because it in capable of matching
the performance of single stage machine at lower costs per driving powers in the
range.
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Air Compressor
2. Turbo compressor
Positive displacement:-
• Piston-type air compressors use this principle by pumping air into an air
chamber through the use of the constant motion of pistons. They use one-way
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valves to guide air into a cylinder chamber, where the air is compressed. Rotary
screw compressors use positive-displacement compression by matching two
helical screws that, when turned, guide air into a chamber, whose volume is
decreased as the screws turn.
• Vane compressors use a slotted rotor with varied blade placement to guide
air into a chamber and compress the volume. A type of compressor that delivers a
fixed volume of air at high pressures.
Negative displacement:-
Cooling:-
Applications:-
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• To supply moderate-pressure clean air for driving some office and school
building pneumatic HVAC control system valves.
Most air compressors either are reciprocating piston type, rotary vane or rotary
screw. Centrifugal compressors are common in very large applications. There are
two main types of air compressor's pumps: oil-lubed and oil-less. The oil-less
system has more technical development, but is more expensive, louder and lasts
for less time than oil-lubed pumps. The oil-less system also delivers air of better
quality.
Repair leaks
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PNEUMATIC CONTROL COMPONENT:
PNEUMATIC CYLINDER
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Key points:-
• Custom designs can perform better and save money when standard
cylinders don’t fit the job.
Resources:-
Pneumatic cylinders are widely used to generate force and motion on a vast range
of OEM equipment. They can move products directly or indirectly by pushing,
pulling, lifting, lowering, or rotating, and can keep them from moving by clamping
them in place.
Wide acceptance comes in large part because cylinders are simple, economical,
durable, and easy to install. They can produce thousands of pounds of force over
a broad range of velocities; cycle at high speeds without overheating; and stall
without internal damage. And they readily tolerate tough conditions such as high
humidity, dusty environments, and repetitive high-pressure wash downs.
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Cylinder design:-
The basic, rod-style industrial cylinder consists of a tube sealed by end caps. A rod
attached to an internal piston extends through a sealed opening in one of the
ends. The cylinder mounts to a machine and the piston rod acts upon the load.
A port at one end of the cylinder supplies compressed air to one side of the
piston, causing it (and the piston rod) to move. The port at the other end lets air
on the opposite side of the piston escape — usually to atmosphere. Reversing the
roles of the two ports makes the piston and rod stroke in the opposite direction.
Rod-style cylinders function in two ways:
Double-acting cylinders use compressed air to power both the extend and retract
strokes, moving the rod back and forth. This arrangement makes them ideal for
pushing and pulling loads. Controlling the rate at which air exhausts determines
rod speed.
Single-acting cylinders have compressed air supplied to only one side of the
piston; the other side vents to atmosphere. Depending on whether air is routed
to the cap or rod end determines whether the rod extends or retracts.
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Rod-style cylinders come in various designs:-
Compact:-
Cylinders fit into smaller spaces where only a short stroke is required. They are
used in lighter-duty applications due to the small bearing surface on which the
rod slides. They mainly come in single-acting versions, but double-acting styles
also are available.
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Guided :-
Cylinders have guide rods and guide blocks mounted parallel to the piston rod, or
dual piston rods. They prevent the piston from rotating and provide precise,
controlled linear motion — especially when the unit is subject to high side loads.
In such cases, the guides reduce rod and piston bending and uneven seal wear.
They are recommended in applications with sizeable offset loads or require that
the load be guided, for example, down a conveyor.
A double acting cylinder is employed in control systems with the full pneumatic
cushioning and it is essential when the cylinder itself is required to retard heavy
loads. This can only be done at the end positions of the piston stock. In all
intermediate positions a separate externally mounted cushioning device must be
provided with the damping feature.
The normal escape of air is out off by a cushioning piston before the end of the
stock is required. As a result the sit in the cushioning chamber is again
compressed since it cannot escape but slowly according to the setting made on
reverses.
The air freely enters the cylinder and the piston stokes in the other direction at
full force and velocity.
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Double Acting Cylinder
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SINGLE ACTING CYLINDER:
VALVES:
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SOLENOID VALVE: (Direction Control Valve:-)
Directional control valves are one of the most fundamental parts in hydraulic
machinery as well and pneumatic machinery. They allow fluid flow into different
paths from one or more sources. They usually consist of a spool inside a cylinder
which is mechanically or electrically controlled. The movement of the spool
restricts or permits the flow, thus it controls the fluid flow.
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The directional valve is one of the important parts of a pneumatic system.
Commonly known as DCV, this valve is used to control the direction of air flow in
the pneumatic system. The directional valve does this by changing the position of
its internal movable parts.
This valve was selected for speedy operation and to reduce the manual effort and
also for the modification of the machine into automatic machine by means of
using a solenoid valve.
A solenoid is an electrical device that converts electrical energy into straight line
motion and force. These are also used to operate a mechanical operation which in
turn operates the valve mechanism. Solenoids may be push type or pull type.
The push type solenoid is one which the plunger is pushed when the solenoid is
energized electrically. The pull type solenoid is one is which the plunger is pulled
when the solenoid is energized.
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PARTS OF A SOLENOID VALVE:
A. COIL:
The solenoid coil is made of copper wire. The layers of wire are separated by
insulating layer. The entire solenoid coil is covered with a varnish that is not
affected by solvents, moisture, cutting oil or often fluids. Coils are rated in various
voltages such as 115 volts AC, 230 volts AC, 460 volts AC, 575 Volts AC, 6 Volts DC,
12 Volts DC, 24 Volts DC, 115 Volts DC & 230 Volts DC. They are designed for such
frequencies as 50 Hz to 60 Hz.
B. FRAME:
The solenoid frame serves several purposes. Since it is made of laminated sheets,
it is magnetized when the current passes through the coil. The magnetized coil
attracts the metal plunger to move. The frame has provisions for attaching the
mounting. They are usually bolted or welded to the frame. The frame has
provisions for receivers, the plunger. The wear strips are mounted to the solenoid
frame, and are made of materials such as metal or impregnated less fiber cloth.
C. SOLENOID PLUNGER
The Solenoid plunger is the mover mechanism of the solenoid. The plunger is
made of steel laminations which are riveted together under high pressure, so that
there will be no movement of the lamination with respect to one another. At the
top of the plunger a pin hole is placed for making a connection to some device.
The solenoid plunger is moved by a magnetic force in one direction and is usually
returned by spring action.
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Solenoid operated valves are usually provided with cover over either the solenoid
or the entire valve. This protects the solenoid from dirt and other foreign matter,
and protects the actuator. In many applications it is necessary to use explosion
proof solenoids.
The solenoid valve has 5 openings. This ensures easy exhausting of 5/2 valve. The
spool of the 5/2 valve slide inside the main bore according to spool position; the
ports get connected and disconnected. The working principle is as follows
POSITION-1
When the spool is actuated towards outer direction port ‘P’ gets connected to ‘B’
and ‘S’ remains closed while ‘A’ gets connected to ‘R’
POISITION-2
When the spool is pushed in the inner direction port ‘P’ and ‘A’ gets connected to
each other and ‘B’ to ‘S’ while port ‘R’ remains close
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5/2 Way Solenoid Valve Sectional View
The control valve is used to control the flow direction is called cut off valve or
solenoid valve. This solenoid cut off valve is controlled by the electronic control
unit.
In our project separate solenoid valve is used for flow direction of vice cylinder. It
is used to flow the air from compressor to the single acting cylinder.
In any fluid power circuit, flow control valve is used to control the speed of the
actuator. The flow control can be achieved by varying the area of flow through
which the air in passing.
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When area is increased, more quantity of air will be sent to actuator as a result its
speed will increase. If the quantity of air entering into the actuator is reduced, the
speed of the actuator is reduced.
Flow control valves facilitate high precision adjustment of flow volumes and are
used to precisely control the piston speed of a drive.
For adjustable speed via exhaust air flow control. The piston moves between air
cushions created through freely flowing supply air and restricted exhaust air. The
benefit is improved operating behaviour, even in the event of load changes
For adjustable speed via supply air flow control. The piston is moved via an air
cushion at one end, created by freely flowing exhaust air and restricted supply air.
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In contrast with exhaust air restriction, there is a tendency towards a stick-slip
effect.
HOSES
Hoses used in this pneumatic system are made up of polyurethane. These hose
can with stand at a maximum pressure level of 10 N/m². Polyurethane combines
the best properties of both plastic and rubber. It offers abrasion and tear
resistance, high tensile and elongation values, and low compression set.
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Polyurethane is naturally flexible and exhibits virtually unlimited flexural abilities.
Combining good chemical resistance with excellent weathering characteristics
sets polyurethane apart from most other thermoplastics. It has exceptional
resistance to most gasolines, oils, kerosene, and other petroleum based
chemicals, making it an ideal choice for fuel lines (although additives in today’s
gasoline and petroleum products warrant field testing).
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APPLICATIONS OF PU TUBE:
• Any time condensation can occur with small actuators, air grippers and air
operated valves. Condensation in a pneumatic system will cause operating failure
and affect the life of pneumatic equipment.
• When you need to eliminate water condensation but you cannot use a
membrane or desiccant dryer (as you cannot use a fast exhaust).
BENEFITS OF PU TUBE:
• Prevents operational failure of small actuators, air grippers and pilot operated
valves due to condensation.
• Easy mounting.
CONNECTORS:
In our system hose connectors are used . Hose connectors normally comprise an
adoptee hose nipple. These types of connectors are made up of brass (or)
Aluminum (or) hardened pneumatic steel. For these type hose connectors no
need of hose clamp these are self-locking hose connectors. a Multi way four way
hose connecter.
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The universal combination at an attractive price. Can be widely used thanks to
resistant materials. Easy to install thanks to optimised bending radii. Limited reset
effect. Attractively priced: the universal solution for metal fittings. Perfect for
standard pneumatic applications – in many different fields. Wide range of variants
Over 1000 types for maximum flexibility in standard applications. Hydrolysis
resistant For applications in damp environments or in contact with water at up to
60 °C. Resistant to pressure Secure connection when used with pressure ranges of
up to 14 bar. Economical for pneumatic installations in the high pressure ranges.
Hose Connector
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fitting Approved for the food Industry Food and Drug Administration certification
for use in the food industry:
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applications in direct proximity to welding splatter Double-sheathed tube and
special fitting.
CONTROL UNIT
The nozzles welded to the fan can be rotated in either direction. The rpm and
torque of the shaft depends upon the pressure of the air admitted so by varying
the pressure, the RPM and torque can be varied. Thick tubes interconnect the
parts. The Clamps are used at the connecting parts to prevent leakage. In thread
parts seals are used to prevent leakage.
The compressed air from the compressor first enters the control unit. In the
control unit the pressure of the air is controlled and sent to the barrel to rotate
the fan in the required direction. The gate valve controls the pressure and volume
of air. Then the pressure is read by a pressure gauge. Later the air is admitted to
the barrel, a shaft is placed and it carries the fan.
The shaft is supported by bearing. The bearings are placed in the couplings, which
covers the end of barrel.
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EXPERIMENTAL MODELING
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WORKING
Initially starting with air compresses, its function is to compress air from a low
inlet pressure (usually atmospheric) to a higher pressure level. This is an
accomplished by reducing the volume of the air. Air compressors are generally
positive displacement units and are either of the reciprocating piston type or the
rotary screw or rotary vane types. The air compressor used here is a typically
small sized, two-stage compressor unit. It also consists of a compressed air tank,
electric rotor and pulley drive, pressure controls and instruments for quick hook
up and use. The pressure exceeds the designed pressure of the receiver a release
value provided releases the excesses air and thus stays a head of any hazards to
take place.
The compressed air goes to the solenoid valve through flow control valve. The
flow control valve is used to control the amount air flow to the cylinder. This flow
is adjusted by manually by the nap is fixed above the flow control valve. Then this
air goes to the 5/2 solenoid valve. The 5/2 solenoid valve is having one input port,
two output port and two exhaust port. The 5/2 solenoid valve is controlled by the
electronic timing control unit. The speed of the on/off the solenoid valve is
controlled by this timing control unit. The 2 outlet ports are connected to an
actuator (Cylinder). The pneumatic activates is a double acting, single rod
cylinder. The cylinder output is coupled to further purpose. The piston end has an
air horning effect to prevent sudden thrust at extreme ends.
The compressed air from the compressor reaches the solenoid valve. The solenoid
valve changes the direction of flow according to the signals from the timing
device. The compressed air pass through the 5/2 solenoid valve and it is admitted
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into the front end of the cylinder block. The air pushes the piston for the cutting
stroke. At the end of the cutting stroke air from the solenoid valve reaches the
rear end of the cylinder block. The pressure remains the same but the area is less
due to the presence of piston rod. This exerts greater pressure on the piston,
pushing it at a faster rate thus enabling faster return stroke.
The compressed air pass through the 3/2 solenoid valve and it is admitted into the
front end of the cylinder block. The air pushes the piston for the gear changer. At
the end of the cutting stroke air from the solenoid valve reaches the rear end of
the cylinder block. The pressure remains the same but the area is less due to the
presence of piston rod. This exerts greater pressure on the piston, pushing it at a
faster rate thus enabling faster return stroke. The screw attached is fixed to the
clapper box frame gives constant loads which lower the sapper to enable
continuous cutting of the work. The stroke length of the piston can be changed by
making suitable adjustment in the timer.
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MERITS AND DEMERTIES
MERITS
DEMERITS
noise in operation .
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APPLICATIONS
Applications :
Used in small scale industries.
It can be used as machine with fixed mounting and as a portable machine
because it is flexible to move.
For performing the operations in huge numbers which cannot be done in
ordinary machines, Since it’s portable.
In such places where frequent change in operation is required.
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CONCLUSION
In the gear cutting attachment for sapping machine variable speeds can be
obtained by adjusting the timer device and pressure of the compressed air. Since
the mechanism is so simple and versatile it can be handled by any operator,
constriction of the unit is very simple. Handling the machine is easy and smooth
operation is achieved.
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