MORNING STAR POLYTECHNIC

COLLEGE
CHUNKANKADAI

HYDRAULIC SHEET CUTTING MACHINE

A Project Report
In partial fulfillment of the requirement for the
award of diploma
In

MECHANICAL ENGINEERING
Project guided by
Mr.
Submitted By

DIRECTORATE OF TECHNICAL EDUCATION,

TAMILNADU
2013-2014

MORNING STAR POLYTECHNIC

COLLEGE
CHUNKANKADAI

Department Of Mechanical
Engineering
CERTIFICATE
This is to certificate that the project entitled
HYDRAULIC SHEET CUTTING MACHINE is a
bonafide
work
done
by..
reg.no........ of final year diploma in
mechanical engineering, during the year 2013-2014.

Guide
Of

Head
The

Department

Mr.T.KAMILLAS FRANKLIN,M.E

Mr.

Submitted For The Board Examination Held At

Morning Star Polytechnic College On ..

Internal Examiner
External Examiner
Place : Chunkankadai
Date :

ACKNOWLEDGEMENT

ACKNOWLEDGEMENT
I thank my God almighty who is the
SOURCE OF KNOWLEDGE and the one who guided
me in all aspects to bring out this project a successful
one.
My special thanks to my loving parents and
my beloved friends for their help in bringing out this
project successfully.
I wish to express my sincere thanks to the
correspondent Rev.Fr.P.PAUL RICHARD
JOSEPH,M.A.,M.Phil who provide me an opportunity
to do this project work in this esteemed institution.
I would like to express my sincere thanks to our
principal Mr.V.VINCENT
JAYASEELAN,B.E.,M.Tech .,M.A.,M.Ed.,M.Phil for
his encouragement while doing this project.
I also express my heart full thanks to my head
of the department Mr.T.KAMILLAS FRANKLIN,M.E.,
and my project guide -------------------------- for his keen

involvement in successful completion of my project

work.
I also thank for our all staff members for their
guidance while preparing my project work.
Also I thank the entire member who helped
directly and indirectly to complete my project work.

CONTENTS

CONTENTS

1
2

SYNOPSIS
INTRODUCTION

CONSTRUCTIONAL DETAILS AND

DRAWING
FABRICATION OF PARTS

WORKING PRINCIPLE

6
7

ADVANTAGES
APPLICATIONS

8
9
10

COST DETAILS
CONCLUSION
BIBLIOGRAPHY

SYNOPSIS

SYNOPSIS
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. The sheet
metal cutting machine works with the help of hydraulic double acting
cylinder. The piston is connected to the moving cutting tool. It is used
to cut the small size of the sheet metal. The machine is portable in
size, so easy transportable
The oil from the pump is used as the force medium for this
operation. There are solenoid valves, flow control valve unit is used.
The 5/2 solenoid valve is used. In one position oil enters to the
cylinder and pushes the piston so that the cutting stroke is obtained.

The next position oil enters to the other side of cylinder and pusses
the piston return back, so that the releasing stroke is obtained. The
speed of the cutting and releasing stroke is varied by the area inside
the cylinder.
.

INTRODUCTION

INTRODUCTION
In the mechanical field sheet metal cutting process is
one of the most important processes. All the small to
big products need sheet metal work.
In that sheet process now a days we use large size of
to sheet cutting machine .and also the machine
occupy large amount of space in the work shop.
In that project our aim is to make simple and easy
operate with less space machine. Simple in
mechanism

DRAWING

DRAWING

FABRICATION OF PARTS

COMPONENTS
MAJOR PARTS

 Oil pump
Direction Control Valve
Cylinder
Connecting hoses

OIL PUMP
Hydraulic pumps are sources of power for many
dynamic machines. Hydraulic pumps are capable of pushing
large amounts of oil through hydraulic cylinders or hydraulic
motors. In this fashion, the pump converts the mechanical
energy of the drive (i.e. torque, speed) into hydrostatic energy
(i.e. flow, pressure).
Hydraulic pumps operate according to the displacement
principle. This involves the existence of mechanically sealed
chambers in the pump. Through these chambers, fluid is
transported from the inlet (suction port) of the pump to the
outlet (pressure port). The sealed chambers ensure that there is
no direct connection between the two ports of the pump. As a
result, these pumps are very suitable to operate at high system
pressures and are ideal for hydraulics.

Different

Types

of

Hydraulic

Pumps
Hydraulic pumps are manufactured depending on different
functional and hydraulic system requirements, such as operating
medium, required range of pressure, type of drive, etc. A large
range of design principles and configurations exists behind
hydraulic pumps. Consequently, not every pump can fully meet all
sets of requirements to an optimum degree. Three different types
of hydraulic pumps exist:

Hydraulic Gear Pumps

External gear pump
Internal gear pump
Gear ring pump
Screw spindle pump

Hydraulic Vane Pumps

Single chamber vane pump
Double chamber vane pump

Hydraulic Piston Pumps

Axial piston pump

 Radial piston pump

Directional Control Valves

Hydraulic valves:

The pneumatic cylinder is regulated and controlled by

pneumatic

valves.

mechanically,

These

electrically,

valves

are

actuated

pneumatically,

and

manually,
by

various

combined mode of actuation.

Need of Valves

DIRECTIONAL CONTROL VALVES To control the to and fro

motion of cylinder, the fluid energy has to be regulated,
controlled and reversed with a predetermined sequence in a
pneumatic system.

Similarly one may have to control the quantity of pressure

and flow rate to generate the desired level of force and speed
of actuators.

To achieve these functions, valves are used.

Valves are fluid power elements used for controlling and

regulating the working medium.
The main functions of the valves are,

Start and stop the fluid energy

Control the direction of flow of compressed air
Control the flow rate of the fluid
Control the pressure rating of the fluid

Although various types of valves are available, they are mainly

classified as below,

Direction control valves

Direction control check valves
Flow control valves
Pressure control valves

The main purpose of a valve in a pneumatic circuit is to

control outputs. Valves can be divided into a number of groups
according to what they control.

Directional control valves

Directional control valve on the receipt of some external

signal, which might be mechanical, electrical or a fluid pressure
pilot signal, charges the direction of or stops, or starts the flow
of fluid in some part of the pneumatic/hydraulic circuit.

SOLENOID VALVE

A solenoid is an electrical mechanical device that can

convert electrical power to mechanical force and motion. It
consists mainly of plunger, mostly a T type plunger, wire or coil
and a C-frame. The working principle is such that when an
electric current is passed through a coiled wire, a magnetic field
sets up around the wire. Because of coiled wire, the magnetic
field would be several times stronger around and through its
center.
The solenoid force is directly fed to the spool of the
direction control valve to shift it. This force is applied through
the T-plunger that is surrounded by the coil, also called the
armature. To select a proper electromagnet, the forces resisting
the actuation of the magnet, i.e. the force of friction and spring
force have to be kept at their minimum so that the

electromagnet can develop a force greater than the resultant of

the resisting force.
Mostly in the case of dc magnets, the body and the
armature may be made of one piece whereas the ac magnets
require both the parts to be made from thin laminated sheets to
obstruct flow of eddy current and to avoid increase of the
solenoid body-temperature.
Whether one has to go for a dc or ac magnet, depends
fully on the requirement of the control system. However in
majority of pneumatic direction control valves, only dc magnets
are used as the overall requirement of force and response time
is quite suitable for such application.

OPERATION OF SOLENOID VALVE

With solenoid valves, a current through a solenoid is used

to implement switching between positions. When a current
flows through the solenoid, a magnetic field is produced which
pulls the laminated steel core into the coil, the force depending
on the current through the solenoid? The larger the current the
greater the force exerted.

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 in 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.
The name of the parts of the solenoid should be learned
so that they can be recognized when called upon to make
repairs, to do service work or to install them.

Parts of a Solenoid Valve

1 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 an 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.

2 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 attract 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.

3 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.

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.

Working of Solenoid Valve

The solenoid valve has 5 openings.

This ensure 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 closed.

SOLENOID VALVE (OR) CUT OFF VALVE:

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.

1.Pressure control valves

These are used to control the pressure in part of the
pneumatic/hydraulic circuit.

2.Flow control valves

These are used to control the rate of flow of a fluid
through the valve.
A directional control valve on the receipt of some, external
signal, which might be mechanical, electrical or a fluid pilot
signal, changes the direction of stops, or starts the flow of fluid

in some part of the pneumatic/hydraulic circuit. They can be

used to carry out such functions as:

1 Controlling the direction of motion of an actuator

2 Selecting alternative flow paths for a fluid.
3 Stopping and starting the flow of fluid.

Actuators
An actuator is a device that is used to apply a force to an
object Fluid power actuators can be classified into two groups:

Linear actuators are used to move an object or apply a

force in a straight line.
Linear actuators can be divided into two types.
They are
1. Single acting cylinders
2. Double acting cylinders
A single acting cylinder is powered by fluid for the
movement of the piston in one direction with it being returned

in the other direction by an internal spring or an external force,

a double acting cylinder is powered by fluid in both directions.

CYLINDERS
Cylinders are the one, which offers the rectilinear motion
to mechanical elements. Cylinders are classified as light,
medium, and heavy duty with respect to their application. In
our project we use double acting cylinder.

Double acting cylinder

The force exerted by the compressed air moves the
piston in two directions in a double acting cylinder. They are
used particularly when the piston is required to perform work
not only on the advance movement but also on the return. In
principle, the stroke length is unlimited, although buckling and
bending must be considered before we select a particular size
of piston diameter, rod length and stroke length.

We use cylinders that are double acting type (i.e.) the

compressed air can be passed to either end of the cylinder.
These cylinders are made up of cast iron.

Oil Seal
Air seal is used to prevent the leakage of air pressure from
the cylinder. Normally it is made up of neoprene rubber. If there
are any air leakages in the system, it will reduce the efficiency.

Wiper Seal:
Wiper seal is provided at the entrance of the cylinder to
avoid dust materials from the environment. It is made up of
neoprene rubber.

Circlip
Circlip is used to protect the out coming of air seal and
wiper seal from the cylinder. It is made up of steel.

O Ring
The O rings are fitted into the grooves of piston to
maintain perfect seal between the piston and the cylinder wall.
They are mostly made up of neoprene rubber.

CYLINDER TECHNICAL DATA:

Barrel:

It is made of cold drawn aluminimum honed to 25mm.

Piston Rod:
M.S. hard Chrome plated

Seals:
Nitrile (Buna N) Elastomerhieced by the electronic
circuit.

End Covers:
Cast iron graded fine grained from 25mm to 300mm

Piston:
Aluminium.

Media:
Oil
Temperature Range:
0c to 85c

CUTTING EDGE

 The cutting edge used is of two metal plates are pivoted

at the one end like the scissor
The other end has a pivot point for the piston rod
The cutter cuts the sheet metal by using shear force

WORKING PRINCIPLE

WORKING PRINCIPLE

The oil pump is rotated by an electric motor. The pump

pressurizes the oil into the main gallery from where the oil is
supplied to the direction control valves for the operation of the
cylinder.
The sheet metal to be cut is placed between the
cutting edges. The upper cutting edge is in pivot to the end of
the piston rod. When pressure is applied to the cylinder the
piston forces the cutter to cut the metal.
Oil from the pump is used as the force medium for this
operation. There are direction control valves, flow control
valve unit is used. The 5/2 dc valve is used. In one position oil
enters to the cylinder and pushes the piston so that the
cutting stroke is obtained. The next position oil enters to the
other side of cylinder and pusses the piston return back, so
that the releasing stroke is obtained.
The speed of the cutting and releasing stroke is varied by
the area inside the cylinder.The sheet metal is placed between
the two cutting edges and the cutting is obtained.

ADVANTAGES

ADVANTAGES

Hydraulic power is more efficient in the technical field

Quick response is achieved
Simple in construction
Easy to maintain and repair
Cost of the unit is less when compared to other robotics
The operation is very easy
Manual effort is less
Operation time is less
Low investing cost
The machine is simple

APPLICATIONS

APPLICATIONS

It is used in sheet metal industries

It can be used labs in colleges
It can be used in sheet metal shops

COST DETAILS

COST DETAILS
MATERIAL COST

=1500

COST OF CYLINDER

=1500

COST OF DC VALVE

=1000

COST OF OIL PUMP

=1500

TOTAL COST

=5500

Total cost for this project = 5,500.00

CONCLUSION

CONCLUSION
Thus the sheet cutting machine provides an easy
way to cut the material and it can also be used in the
sheet metal shops and the industries for the easy
cutting of the sheet metal

BIBLIOGRAPHY

BIBLIOGRAPHY
Anthony Esposito (2012) Fluid Power Pearson, ISBN
978-81-775-8580-3
Dr.R.K.Bansal (2010) Fluid Mechanics and Hydraulic
Machines Laxmi Publications, ISBN 978-81-318-0815-3
Er.R.K.Rajput (2006) Strength of Materials S.Chand,
ISBN 81-219-2594-0
PSG College of Technology PSG Design Data Book(2012)
T.J.Prabhu (2011) Design of Transmission Element
V.B.Bhandari (2012) Design of Machine Elements Mc
Graw Hill, ISBN 978-0-07-068179-8

 Vanalkar.A.V., Mechanism Synthesis for Stirrup Making

Machine, Proceeding, 4th International Conference on
Mechanical

Engineering,

ICME-

2001,

BANGLADESH, pp. 271, December-2001

www.sciencedirect .com

BUET,

Dhaka,