CHAPTER 1 INTRODUCTION

1.1 INTRODUCTION

Aluminum sheet is a commonly used material, in various industries and factories,

like interior and exterior design, construction of ceilings, and architecture, among
many others. During its production aluminum sheet metals must undergo the
shearing operation to achieve the perfect dimension, necessary for the final product.
Various machines can be incorporated to carry out this shearing operation. They
include manual, hydraulic, pneumatic, spring and rack and pinion operated
machines. Small and medium scale industries use aluminum sheets extensively in
production as it is cheap and easily available. But when it comes to shearing
operation, manual methods of cutting are incorporated to save cost. Commonly
available sheet metal cutting machines are usually costly and sophisticated to use,
apart from the maintenance costs, it requires periodically. This project is aimed at
developing a cheap, safe, and effective system to shear aluminum sheets, using a
pneumatic system for actuation. The cutting mechanism comprises of an upper
blade, constrained to rotate about an axis perpendicular to the length of the blade
and a fixed lower blade. The sheet metal is placed between the blades. In shearing
cutting action takes place perpendicular to the direction towards the sheet metal.
Upon shearing, plastic deformation occurs at the sheet, which ultimately shears the
metal. The blades are actuated using a pneumatic system. In this type of machine
high pressure air is used as the working fluid for the transfer of power and the
motion. A small clearance is present between the edges of the upper and lower
tools, which facilitates the fracture of the material. Solenoid Valve is used to adjust
the air pressure from the source port to the desired port . A compressor regulates
the flow of air to the pneumatic cylinder, using a manually controlled circuit,
through the solenoid valve, to carry out the cutting operation. The advantage of
using a pneumatic system is that it can generate a considerable amount of force
while being cost effective . In this paper, the design aspects of the proposed system,
have been discussed and analyzed. The proposed system is designed to cut
Aluminum sheets up to a thickness of 2.5mm, using a pneumatic system.

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In some industries, hand sheet cutter is used which is operated manually, (i.e.) using
scissors for simple sheet metal cutting. Some of the sheet metals are to be wasted
sometimes by this manual method, because of mistakes happened such as wrong
dimensions etc., and also even a simple cutting may take long time. Hydraulic based
cutting machines are also available for sheet metal cutting. But this method is used
for only heavy metal cutting and it is expensive to afford. In this machine, we are
using pneumatic cylinder for metal sheet cutting. These machines can be easy to
operate and maintain also. Hence, we introduced here, a Pneumatic sheet metal
cutting machine which will reduce manufacturing cost and minimize industrial
labour problems which is the biggest headache for human. The main objective of
our project is to perform the job holding operation effectively with less human
efforts by using a machine with the pneumatic power. This will also help to reduce
the time required for metal cutting. By using these machines production rate can be
increase and automatically the industry will be in profit. Automation plays an
important role in mass production. Automation can be achieved through pneumatic
form. The main advantage of Pneumatic system is economically cheap and easy to
handle in small scale industries.
The production of iron and steel is of great importance for any country’s economy.
This is because the iron and steel industry directly influence the development of a
sustainable society and also it the basis for all other industries. Thus, the trend in
production and consumption in steel is also viewed as an indicator of the condition
of the country’s economy. This the reason why steel is called the “backbone” of a
country’s economy. Hence by increasing the production of steel, we can help in the
growth of our country’s economy. But this where the problem arises. A sheet metal
cutting or a punching machine is very important to the sheet metal industry and
since large scale industries are well established, they can afford to equip
themselves with hydraulically operated cutting and punching machines that
generate a large amount of force and also are easily automated. Thus, the production
output of large-scale industries is enormous. Same is not the case with medium to
small scale industries. Since hydraulic machines are too costly most of these
industries restrict themselves to only using hand-operated cutting or punching

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machines. The production output of handoperated machines is low. Because of this
problem, we are developing a pneumatically operated cutting and punching
machine. Pneumatics is the branch of engineering which uses pre-compressed air
or inert gas as a means to drive machinery. Certain properties of air make it
extremely suitable for its usage in modern machinery. The advantage of using a
pneumatic system is that it can generate a considerable amount of force while being
cost effective.

1.2 OBJECTIVES OF AUTOMATIC SHEET METAL CUTTING

MACHINE

One of the major objectives is to design and development of automatic sheet metal
cutting machine to reduce the manpower and cost. The machine can be portable
and transported anywhere easily and used to cut the small size sheet metal

i. The objective of the project is to develop the sheet metal cutting machine
which operates based on pneumatic force.
ii. To reduce the man power requirement for the sheet metal cutting process.
iii. To increase the accuracy and efficiency of the cutting operation .
iv. To automate the process with the help of solenoid valve, control timing unit
and proximity sensor.

1.3 DESIGN OF THE SYSTEM

The pneumatic sheet metal cutting machine system is based on structure and its
automated. The automated pneumatic sheet metal cutting machine system is created
in Creo as per the measurement parameters. The automated pneumatic sheet metal
cutting machine consists of pneumatic double cutting cylinder, solenoid valve,
control timing unit, compressor, proximity sensor, sheet cutter, and timing circuits.

1.4 Structure of the system

The automated pneumatic sheet metal cutting machine consists of pneumatic

double cutting cylinder, solenoid valve, control timing unit, compressor, proximity
sensor, sheet cutter, and timing circuits. Double-acting cylinders make use of the

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 force of air to extend and retract strokes. The piston is connected to the cylinder.
They consist of two ports to allow the movement of air inside and another for out
stroke and one more of in stroke. A high-speed carbon cutting material has
incorporated with the double acting cylinder will perform the cutting operation by
the use of force of air

1.5 Merits

1. Hydraulics has certain advantages than pneumatics, but in a given

application ,pneumatic powered

2. equipment is more suitable ,particularly in industries where the factory units

are plumbed for compressed air

3. Moreover, to avoid corrosive actions, oil or lubricants are added so that

friction effects can be reduced.

4. Compressed air is used in most of the machines and in some cases

compressed carbon dioxide, whereas make easier of cutting process.

5. Fast cutting action is carried out.

6. Cutting without bending is achieved.

1.6 Demerits

1. Sheet more than 2 mm thickness cannot cut easily.

2. Compressed air is must.

3. Foundation is required also safety major must be taken.

1.7 APPLICATIONS

Sheet metals are used in

1. Car bodies

2. Airplane wings

3. Medical tables

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4. Roofs for buildings and many other things.

5. Sheet metal of iron and other materials with high magnetic permeability,
also known as laminated steel cores, has applications in transformers and
electric machines.

6. Historically, an important use of sheet metal was in plate arm or worn by

cavalry, and sheet metal continues to have many decorative uses, including
in horse track.

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CHAPTER 2 LITERATURE REVIEW

2.1.Introduction

In cutting operation as or blade descends upon the metal, the pressure exerted by the
blade first caused the plastic deformation of the metal, since the clearance between to
blade is very small. The plastic deformation takes place in localize area and the metal
adjacent to the cutting edges of the blade edges become highly stress, with courses the
facture to start on both side of the sheet as the deformation progresses and sheet is
shear. Types of cutting machine:

1. Pneumatically operated
2. Hydraulically operated
3. Rack and pinion operated
4. Spring operated

2.2.Different type of Cutting Machine

2.2.1. Pneumatically operated

Here is the advancement of the header which is carried out in the upward and
downward direction using the pneumatic double acting piston and cylinder unit
arrangement along with the foot operated direction control valve. In this type of
machine high pressure air is used as the working fluid for the transfer of power and
the motion.

Fig 2.1 Pneumatically operated sheet metal cutter

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2.2.2. Hydraulically operated

Here the lowering and raising of the header which is carried over using the hydraulic
piston and cylinder arrangement. To actuate the piston and cylinder, the oil is allowed
to enter the cylinder for front or back side of the piston. But the oil is comparatively
cost layer and it is leakage may cause so many problems.

Fig 2.2 Hydraulically operated sheet metal cutter

2.2.3. Rack and pinion operate

Here the lowering and raising of the header carried out manually using the rack and
pinion arrangement. In this case the required pressure is applied manually using direct
hand pressure on the rack using pinion and leaver arrangement. Since the machine
robust and required large pressure, hence it is not suitable.

Fig. 2.3 Rack and pinion operated sheet metal cutter

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2.2.4. Spring operated

The working of spring-operated machine is similar to rack and pinion operated

machine but differs for it in construction. Here the lowering and the raising of the
heating handle are carried out manually and it required too much pressure for its
operation also their possibility to having damage to the work piece if not handled
carefully.

Fig 2.4 Spring operated sheet metal cutter

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CHAPTER 3 MATERIAL AND METHODS

3.1 METHODOLOGY

The sheet metal cutting machine works with the help of pneumatic double acting
cylinder. The piston is connected to the moving cutting tool. It is used to cut the small
size of the sheet metal. Auto Feed Pneumatic Sheet Metal Cutting Machine. The
machine is portable in size, so easily transportable. The compressed air from the
compressor is used as the force medium for this operation. There are pneumatic double
acting cylinders solenoid valves, flow control valve and the timer unit are used. The
sheet metal cutting process is a main part of the all industries. Normally the sheet metal
cutting machine is manually hand operated one for medium and small-scale industries.
Automation in the modern world is inevitable. Any automatic machine aimed at the
economical use of man, machine, and material worth the most. In our project is
solenoid valve and control timing unit are used for automation The sheet metal cutting
machine works with the help of pneumatic double acting cylinder. The manually
operated machine is converted into pneumatically operated machine by applying
proper design procedure. At the end of task, the conclusion is made and several
recommendations are suggesting to make an improvement about the result and the
project for future study.

3.2 Operation of the Pneumatic Sheet metal cutting machine

The most common cutting processes are performed by applying a shear force, and are
therefore sometimes referred to as shearing processes. Cutting processes are those in
which a piece of sheet metal is separated by applying a great enough force to cause the
material to fail .When a great enough shearing force is applied, the shear stress in the
material will exceed the ultimate shear strength and the material will fail and separate
at the cut location. This shearing force is applied by two tools, one above and one
below the sheet. Whether these tools are a punch and die or upper and lower blades,
the tool above the sheet delivers a quick downward blow to the sheet metal that rests
over the lower tool. A small clearance is present between the edges of the upper and

9
lower tools, which facilitates the fracture of the material. The effects of shearing on
the material change as the cut progresses and are visible on the edge of the sheared
material. When the punch or blade impacts the sheet, the clearance between the tools
allows the sheet to plastically deform and “rollover” the edge. As the tool penetrates
the sheet further, the shearing results in a vertical burnished zone of material, finally,
the shear stress is too great and the material fractures at an angle with a small burr
formed at the edge. The height of these portions of the cut depends on several factors,
including the sharpness of the tools and the clearance between the tools. The pneumatic
machine includes a table with support arms to hold the sheet, stops or guides to secure
the sheet, upper and lower straight - edge blades, a gauging device to precisely position
the sheet. The table also includes the two-way directional valve. The two-way
directional valve is connected to the compressor. The compressor has a piston for a
movable member. The piston is connected to a crankshaft, which is in turn connected
to a prime mover (electric motor, internal combustion engine).

Fig.3.1 Working procedure of the Pneumatic Sheet metal cutting machine

At inlet and outlet ports, valves allow air to enter and exit the chamber. When the
compressor is switched ON, the compressed air is flow to inlet of the pneumatic
cylinder. The sheet is placed between the upper and the lower blade. The lower blade

10
remains stationary while the upper blade is forced downward. The upper blade is
slightly offset from the lower blade, approximately 5 – 10% of the sheet thickness.
Also, the upper blade is usually angled so that the cut progresses from one end to the
other, thus reducing the required force. When the pneumatic hand operated lever is
moved forward, the piston starts moving in the forward direction. The upper blade
which are then forced against the sheet, cutting the material. When the pneumatic hand
operated lever is moved backward, the upper blade will come to the original position
(i.e., the upper blade will move upwards). After the material is cut, adjust the
pneumatic hand lever to the mid position (i.e., normal position) and then the
compressor is switched OFF.

3.2.1 Working Flow Chart

fig.3.2 Flowchart for fabrication of sheet metal cutting machine.

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3.2.2. Pneumatic Transmission of Energy

The reason for using pneumatics, or any other type of energy transmission on a
machine, is to perform work. The accomplishment of work requires the application of
kinetic energy to a resisting object resulting in the object moving through a distance.
In a pneumatic system, energy is stored in a potential state under the form of
compressed air. Working energy (kinetic energy and pressure) results in a pneumatic
system when the compressed air is allowed to expand. For example, a tank is charged
to 100 psi with compressed air. When the valve at the tank outlet is opened, the air
inside the tank expands until the pressure inside the tank equals the atmospheric
pressure. Air expansion takes the form of airflow. A positive displacement compressor
basically consists of a movable member inside a housing. The compressor has a piston
for a movable member. The piston is connected to a crankshaft, which is in turn
connected to a prime mover (electric motor, internal combustion engine). At inlet and
outlet ports, valves allow air to enter and exit the chamber.

3.2.3. Control Of Pneumatic Energy

Working energy transmitted pneumatically must be directed and under complete

control at all times. If not under control, useful work will not be done and machinery
or machine operators might be harmed. One of the advantages of transmitting energy
pneumatically is that energy can be controlled relatively easily by using valves.

3.2.4. Control Of Pressure

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

3.2.5. Control Of Pressure After a Compressor

In a pneumatic system, energy delivered by a compressor is not generally used

immediately, but is stored as potential energy in air receiver tank in the form of
compressed air. In most instances, a compressor is designed into a system so that it

12
operates intermittently. A compressor is a device that usually delivers compressed air
to a receiver tank until high pressure is reached, then it is shut down. When air pressure
in the tank decreases, the compressor cuts in and recharges the tank. Intermittent
compressor operation in this manner is a power saving benefit for the system. A
common way of sensing tank pressure and controlling actuation and deactuation of
relatively small compressors, is with a pressure switch.

3.2.6. Construction

The pneumatic sheet metal cutting is supported by a table includes with support arms
to hold the sheet. The table also includes the two-way directional control valve. The
two-way directional control valve is also known as solenoid control valve. We used
two-way directional control valve that is connected with the compressor by air pipe.
The compressor has a piston for a movable member. The piston is connected to a
crankshaft, which is in turn connected to a prime mover. At inlet and outlet ports,
valves allow air to enter and exit the chamber. When the compressor is switched ON,
the compressed air is flow to inlet of the pneumatic cylinder. The sheet is placed
between the upper and the lower blade. The lower blade remains stationary while the
upper blade is forced downward. The upper blade is slightly offset from the lower
blade, approximately 5 – 10% of the sheet thickness. Also, the upper blade is usually
angled so that the cut progresses from one end to the other, thus reducing the required
force. When the pneumatic hand operated solenoid valve is moved forward, the piston
starts moving in the forward direction. The upper blade which are then forced against
the sheet, cutting the material. When the pneumatic hand operated lever is moved
backward, the upper blade will come to the original position (i.e., the upper blade will
move upwards).After the material is cut, adjust the pneumatic hand operated solenoid
valve to the mid position (i.e., normal position) and then the compressor is switched
off

3.3 SHEET METAL CUTTING MACHINE

The main objective of our project is to perform job holding operation effectively with
less human effort by incorporating a machine with the pneumatic power. This also
takes less time due to its quick action. For a developing industry the operation

13
performed and the parts (or) components produced should have it minimum possible
production cost, and then only industry runs profitably

3.4 DESCRIPTION OF EQUIPMENT PNEUMATIC CYLINDER

1 PNUMATIC CYLINDER

A Double-acting cylinder is a cylinder in which the working fluid acts alternately on

both sides of the piston. In order to connect the piston in a double-acting cylinder to
an external mechanism, such as a crank shaft a hole must be provided in one end of
the cylinder for the piston rod, and this is fitted with a gland or "stuffing box" to prevent
escape of the working fluid. Double-acting cylinders are common in steam engines but
unusual in other engine types.

Fig. 3.3 Pneumatic cylinder

2 Cutting Blades

A blade is used to cut the sheet metal in a desired dimension. Here we are using high
speed steel blades to cut the sheet metal. Cutting blades are made of WPS metal
welding process steel.

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 Fig. 3.4 Cutting Blades

3 Compressor
Pneumatic systems operate on a supply of compressed air, which must be made
available in sufficient quantity and at a pressure to suit the capacity of the system.
When pneumatic system is being adopted for the first time, however it wills indeed
the necessary to deal with the question of compressed air supply. 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 may be classified in two general types.
1. Positive displacement compressor.
2. Turbo compressor.
Positive displacement compressors are most frequently employed for compressed
air plant and have proved highly successful and supply air for pneumatic control
application.
The types of positive compressor are
1. Reciprocating type compressor
2. Rotary type compressor.
4 Flexible Hose
The flexible hoses connect the solenoid valve and the cylinder block. Hoses are
made of in layer of elastomer (or) synthetic rubber and braided fabric which takes
up the higher pressure. If the hose is subjected to rubbing, it should be enclosed in
a protective sleeve.

15
Fig.3.5 Flexible Hose

16
Fig.3.6 Pneumatic Sheet Metal Cutter

17
CHAPTER 4 RESULT AND DISCUSSION

4.1 RESULT

The compressed air from the compressor is used as the force medium for this
operation. There are pneumatic double acting cylinders, solenoid valve; flow control
valve and timer unit used .The arm from the compressor enters to the flow control
Valve. The controlled air from the flow control valve enters to the solenoid valve. The
function of solenoid valve is to supply air of correct time interval. The 5/2 solenoid
valve is used. In one position air enter to the cylinder and pushes the piston, so that the
cutting stroke is obtained.  The next position air enters to the other side of cylinder
and pushes the piston return back, so that the releasing stroke is obtained. The speed
of the cutting and releasing stroke is varied by the timer control unit circuit.

The sheet metal cutting and bending machine works with the help of pneumatic double
acting cylinder. The piston is connected to the moving cutting tool. It is used to cut
and bend the small size of the sheet metal. The machine is portable in size, so easily
transportable. The compressed air from the compressor is used as the force medium
for this operation. There are pneumatic double acting cylinders solenoid valves, flow
control valve and the timer unit are used. The controlled air from the flow control valve
enters to the solenoid valve. The function of solenoid valves all of air correct time
interval. The 5/2 solenoid valve is used. In one position air enters to the cylinder and
pushes the piston so that the cutting stroke is obtained. The next position air enters to
the other side of cylinder and pusses the piston returns back, so that the releasing stroke
is obtained. The speed of the cutting and releasing stroke is varied by the timer control
unit circuit. The pneumatic machine includes a table with support arms to hold the
sheet, stops or guides to secure the sheet, upper and lower straight – edge blades, a
gauging device to precisely position the sheet. The table also includes the two-way
directional valve. The two-way directional valve is connected to the compressor. The
compressor has a piston for a movable member. The piston is connected to a
crankshaft, which is in turn connected to a prime mover (electric motor, internal
combustion engine). At inlet and outlet ports, valves allow air to enter and exit the

18
chamber. When the compressor is switched ON, the compressed air is flow to inlet of
the pneumatic cylinder.

The sheet is placed between the upper and the lower blade. The lower blade remains
stationary while the upper blade is forced downward.

The upper blade is slightly offset from the lower blade, approximately 5 – 10% of the
sheet thickness. Also, the upper blade is usually angled so that the cut progresses from
one end to the other, thus reducing the required force.

When the pneumatic hand operated lever is moved forward, the piston starts moving
in the forward direction. The upper blade which are then forced against the sheet,
cutting the material. When the pneumatic hand operated lever is moved backward, the
upper blade will come to the original position (i.e., the upper blade will move
upwards).

After the material is cut, adjust the pneumatic hand lever to the mid position (i.e.,
normal position) and then the compressor is switched OFF.

4.2 FORCE CALCULATION

To calculate the force exerted by the pneumatic cylinder, we need to know the units of
the cylinder area. If the cylinder area is given in square centimeters (cm²), we can
proceed with the calculation.

Given:

Air Pressure (P) = 2 bar

Cylinder Area (A) = 200.00 cm²

First, let's convert the air pressure from bar to the corresponding pressure unit of
newtons per square centimeter (N/cm²). Since 1 bar is equal to 1 N/cm², the conversion
factor is 1.

Air Pressure (P) = 2 bar = 2 N/cm²

Now we can calculate the force (F) exerted by the cylinder using the formula:

19
F=P×A

F = (2 N/cm²) × (200.00 cm²)

Performing the calculation:

F = 400.00 N

Therefore, the force exerted by the pneumatic cylinder, with an air pressure of 2 bar
and a cylinder area of 200.00 cm², is 400.00 newtons (N).

4.3 Operation Flow chart

Fig.4.1 Flow Chart Operating Process

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CHAPTER 5 CONCLUSIONS AND FUTURE SCOPE

5.1 CONCLUSION

Now we know that pneumatic shearing machine is very cheap as compared to hydraulic
shearing machine. The range of the cutting thickness can be increased by arranging a high-
pressure compressor and installing more hardened blades. This machine is advantageous
to small sheet metal cutting industries as they cannot afford the expensive hydraulic
shearing machine.

The design and development of Automatic Sheet Metal Cutting machine is totally
economical in human effort and useful in improvement of cost factory. The pneumatic
cutting machine is very cheap as compared to Hydraulic cutting machine. The range of the
cutting thickness can be increased by arranging a high-pressure compressor and installing
hardened blades. This machine is advantageous to small sheet metal cutting industries as
they cannot afford the expensive hydraulic cutting machine.

This paper proposes an efficient and cost-effective way to shear aluminum metal sheets,
using a pneumatic actuation system which can be applicable in small and medium scale
industries. The machine was also found to be accurate in its operation and safe, as opposed
to manual cutting operations. Compared to its hydraulic counterparts, pneumatic systems
are cheap, due to its application of air, which is abundant, inexpensive, and easy to contain
and regulate. Pneumatic systems have a long operating life and require little maintenance,
as gases are compressible, which makes the system less vulnerable to shock damage.
Hydraulic systems on the other hand, require constant maintenance as fluids used need to
be replaced over a period, which increases the cost too. Thus, pneumatic system was found
to be more reliable than hydraulic system, as cost of maintenance is low apart from the
total cost incurred. Thus, this project, provides a safe and effective way to cut metal
aluminum sheets, with minimal cost incurred for maintenance.

21
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