CHAPTER-1

INTRODUCTION

The formation of any business begins with someone producing the initial
idea for the project. The continued success of an established business
depends upon the number and quality of the ideas fed into it. Without a
continual flow of new ideas, a business cannot function profitably or
expand successfully and must, therefore eventually fade into total
obscurity.
Ideas for a new business project, a new product, a means of reducing
manufacturing costs or for solving industrial labor problems, begin in the
human mind. Most people conceive their ideas unconsciously, and
because they are unaware of the mental mechanics that caused the „idea‟
to be produced, they cannot repeat the ideation process to produce
further profitable ideas at will.

Fortunately, there are available established creative techniques which,

when used correctly, do enable a person to produce a large number of
first-class ideas at will. One such creative technique, and probably the
most widely used in American industry, is ‟brainstorming‟.

1.1 Literature Survey:

In shearing or cutting operation as or blade descends upon the metal, the
pressure exerted by the blade first cause the plastic deformation of the
metal. Since the clearance between the two blades is very small, the
plastic deformation takes place in a localized area and the metal adjacent
1
to the cutting edges of the blade edges becomes highly stressed, which
causes the fracture to start on both sides of the sheet as the deformation
progresses and the sheet is sheared

Shearing machines are classified according to the following:-

1) Pneumatically Operated

2) Hydraulically Operated

3) Rack and Pinion Operated

4) Spring Operated

Brief descriptions of all the types are as follows –

Pneumatically Operated :

Heart the advertisement of the header is carried out in the upward and
the 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.

Hydraulically Operated :

Hear the lowering and rising of the header is carried over using the
hydraulic piston and cylinder arrangement. To actuate the piston and the
cylinder, the oil is allowed to enter the cylinder from front or the back
side of the piston. But the oil is compositely costlier and its leakage may
cause so many problems.

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Rack and Pinion Operated :

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

Spring Operated:

The working of spring operated machine is similar to the rack and pinion
operated machine but differs from it in construction. Hear the lowering
and rising of the heating handle is carried out manually and it requires
too much pressure for its operation and also there is possibility of having
damage to the work piece if not handled carefully.

1.2 Prior Concepts:

Pneumatics, from the Greek (pneumatikos, coming from the wind) is the
use of pressurized gases to do work in science and technology.

Pneumatics was first documented by Hero of Alexandria in 60 A.D., but

the concept has existed before then. A pneumatic product represents a
multibillion dollar industry today. Pneumatic devices are used in many
industrial applications .Generally appropriate for applications involving
less force than hydraulic applications and typically less expensive than
electric applications, most pneumatic devices are designed to use clean
dry air as an energy source. The actuators then convert that compressed

3
air into mechanical motion. The type of motion produced depends on the
design of the actuator. Pneumatic is employed in a variety of settings. In
dentistry applications, pneumatic drills and lighters, faster and simpler
than a electric drill of the same power rating (because the prime mover,
the compressor, is separate from the drill and pumped air is capable of
rotating the drill bit at extremely high rpm).pneumatic transfer system
are employed in many industries to move powders and pellets.
Pneumatic tubes can carry objects over distances. Pneumatic devices are
also used where electric motors cannot be used for safety reasons, such
as mining applications where rock drills are powdered by air motors to
preclude the need for electric motors depends in the mine where
explosive gases may be present.

1.3 Need For Automation:

Automation can be achieved through computers, hydraulics, pneumatics,

robotics, etc., of these sources, pneumatics form an attractive medium for
low cost automation. The main advantages of all pneumatic systems are
economy and simplicity. Automation plays an important role in mass
production.

 Reduction of lab our and material cost

 Reduction of overall cost
 Increased production
 Increased storage capacity
 Increased safety
 Reduction in fatigue
 Improved personnel comfort

4
1.4 Pneumatic Cylinder:

Pneumatic cylinder or air cylinders are mechanical devices used to

import a force from a fluid, typically compressed air –

Fig 1.4 (a): Pneumatic Cylinder

5
A typically pneumatic cylinder consists of a piston, piston rod, and a
body or tube. Compressed air enters at one end of the tube, importing
force on the piston, which is the displayed (movies) in order to balance
the force exerted on the piston. Air cylinders, or actuators as they are
also called, are available in the variety of sizes, shapes, and have varying
strokes. Typical cylinder sizes range from a small 2.5mmair cylinder,
which might be used for picking up a small transistor or other electronic
component, to 400mm diameter air cylinder which would impart enough
force to lift a car.

Fig 1.4 (b): Direction Control Valve

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Fig 1.4 (c): Flow Control Valve

7
 CHAPTER-2

Components and Description

2.1 Components of Pneumatic Shearing Machine

Different components of pneumatically shearing machine are:-

1. Shearing Blade

2. Pneumatic Cylinder

3. 5/2 Direction control foot operated valve

4. Air circulating Device

5. Frame

Double Acting Cylinder:-

Hear we have used double acting cylinder. It is the pneumatic actuator,

which is actuated using compressed air. The force exerted by the
compressed air moves the piston in two directions in a double acting
cylinder. In principle, the stroke length is unlimited, although buckling
and bending must be considered before we select a particular size of
piston diameter, road length and stroke length.

The double acting cylinder consists of

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 1. Cylinder tube,

2. Piston unit,

3. Double cup packing on piston, rod packing of O rings,

4. Bronze rod guide,

5. Piston rod,

6. End covers(flanges)

7. Port connection,

8. Cushion assembly.

The cylinder is manufactured from aluminum solid bar with central bore
on lathe machine. It is then made smooth internally using method of
honing and lapping. It contains piston and piston rod, which reciprocates
to and fro with the application of high pressure air. The piston is fitted
with the piston ring which is made of Teflon rubber to make perfect
compression of the air. 5/2 Direction control foot operated valve:
Its basic symbol is as shown –

Fig 2.1 (a): 5/2 Foot control valve

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 Figure 2.1 (b): 5/2 Direction footcontrol valve

To control the to and fro motion of a pneumatic cylinder, the air energy
has to be regulated, controlled, and reversed with a predetermined
sequence in a pneumatic system. Similarly one has to control the
quantity of pressure and flow rate to generate desired level of force and
speed of actuation.
To achieve these functions, valves are used to-

(I) Start and stop pneumatic energy,

(II) Control the direction of flow of compressed air,

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 (III) Control the flow rate of the compressed air,

(IV) Control the pressure rating of the compressed air.

A direction control valve has two or three working positions generally.

They are:

1) Neutral or zero position

2) Working position

The positions are mostly numbered as 0, 1, 2. Direction control valves are

designated to indicate both the number of ways as well as the number of
working positions such as 4/2, 3/2, 5/2 means 5 ways /2positions.

Here the spool slides inside the main bore and according that the spool
position is made ON or OFF due to the fact that the spool gets connected
to the open side or the closed side of the air opening.

Air circulating devices:

The compressed air is stored in an air receiver from which air is drawn
out in to the consumer point by means of pipe line.

While laying out the pipe line for the system, one should take sufficient
care and pay attention to see that the pressure drop from the generating
point to the point of consumption remains as low as possible. For
economical reason, it is always better if the total drop of pressure is kept
limited to a maximum value of 0.1 bar or even less.

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The following factors are taken into account while selecting pneumatic
pipeline and other air- line installations:-

1) Pressure of compressed air in the lines.

2) Total flow rate per unit time through the line.

3) Permissible pressure drops in the line.

4) Types of tube material and types of line fitting.

5) Length and diameter of tube or other pipelines.

6) Working environment.

Considered the above factors we have selected the flexible hose tubes of
1/8diameter.

Frame Base:

It forms the robust support to stand the machine vertically. It holds the
weight of the vertical post and supports the direction control valve. It is
made of mild steel channels of rectangular base with the vertical post
and the horizontal channel.

Shearing blade:

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Shearing, also known as die cutting, is a process which cuts stock
without the formation of chips or the use of burning or melting. Strictly
speaking, if the cutting blades are straight the process is called shearing.

Figure 2.1 (c): Neutral Position

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 Fig 2.1 (d): Working Position

Fig 2.1 (e): Machine figure

14
2.2 Main Components of the System ;

 The major components of these systems are, Compressor

 Pneumatic Cylinder
 Solenoid Valve
 Hose and fitting
 Seals
 Control Timer Circuit Flow control valve

Compressor:

The air under high pressure is given by a compressor. It is driven by an

electric motor. The compressor delivers air to inlet of the cylinder. An
air compressor as the same indicates is a machine to compress the air and
to raise its pressure. The air compressor sucks air from the atmosphere,
compresses it and then delivers the same under a high pressure to a
storage vessel from the storage vessel it may be conveyed by a pipeline to
a place where the supply of compressed air is required.

Since the compression of air requires some work to be done on it,

therefore compressor must be driven by some prime mover.

The compressed air is used for many purposes such as for operating
pneumatic drills, rivets, paint spraying and supercharging of internal
combustion engines etc., It is also used in the operation of lifts, rams,
pumps and variety of other devices in industry. Compressed air is sucked
for producing ballast of air in blast furnaces and Bessemer converter.

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Classification of Air Compressor:

The air compressor may be classified in many ways but the following are
important of view.

1. According to working

a. Reciprocating Compressor

b. Rotary Compressor

2. According to action

a. Single acting compressor

b. Double acting compressor

3. According to number of stages

a. Single stage compressor

b. Multi stage compressor

Reciprocating Compressor:

They are available in great variety including special machine for unusual
requirements Maximum compression ratio may be as high as 10 per
stage. Two stage compressors are available for compression ratios
greater than eight.

There different type of piston type reciprocating air compressor are

available. They are

 Vertical
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  Horizontal
 Radial

The most commonly used one is horizontal air cooled type reciprocating
air compressor for a pressure range 6 to 12 Kg/cm².

Construction:

It is similar to that of an internal combustion (IC) engine consisting of

cost-iron or aluminum body with an oil tank, the base piston with piston
rings, valves, connecting rods, cranks, crank shaft and bearing etc. If the
piston is moving down air is sucked in through the suction valve and a
filter and is compressed in return stroke.

Oil level gauges, oil filling screw and oil outlet screw etc are also
important parts of an air compressor.
The pressure switch is connected to the driving motor and is set such that
it automatically trips off, disconnecting the electrical connection to the
motor as soon as the receiver achieves the desired set pressure.

The safety valve is set to the same pressure limit and in case of the
pressure exceeds this limit, it automatically opens and excess pressure is
exhausted to the atmosphere, thus limiting the system pressure to the
desired level. The drain valve drains off the condensate produced at the
condenser and the receiver piston rings are used around the piston to
make it airtight.

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The first stage cylinder is called the low-pressure cylinder (LP) where air
is drawn from the atmosphere and is compressed initially. The second
cylinder is called the second-stage cylinder, which is of smaller diameter
and it is also called high-pressure cylinder (HP). Here the initially
compressed air from first LP cylinder is further compressed to high
pressure.

When air is compressed, considerable heat is generated, this heat must

be dissipated at least in units, where pressure exceeds 2 bar. The main
machine is cooled by air circulation on water circulation.
2.2.1 Characteristics of Double acting compressors

 For the same sped and cylinder volume, air delivery is double that
of a single acting compressor.
 They are mostly suitable for large capacity.

 Cylinders are mostly water-cooled.

 They are normally used for continuous and heavy-duty works.

 Higher speed of piston while reducing the size of the compressor

may contribute to greater wear of piston rings, cylinder liners and
pickings. Preferable range of piston speed advocated.
 For small capacity compressor – 300 m/min

 For large capacity compressor-25m/min

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The ultimate choice of an air compressor is decided considering two
main factors. They are:

• One should go for a small compressor for each machine

(or)

• Should one have a centralized compressor “power house?”

The portable answer will depend on pipe line layout, system

requirement and the distance of the user machine from the plant.

Pneumatic cylinder:

Cylinder is a device which converts fluid power into liner mechanical

force and motion. These cylinders are widely used in industrial
pneumatic systems. These cylinders are also called as linear motors and
reciprocating motors pneumatic cylinders are designed for a variety of
services.

Pneumatic cylinders are designed for a variety of services. Pneumatic

cylinders transforms the flow of pressured fluid into a push or pull of the
piston rod since out system uses double acting cylinders we shall see
some details about them.

Double acting cylinders are in one in which fluid force can be applied to
the movable element in two directories. The force exerted by the
compressed air moves the piston in two directories in a double acting

19
cylinder. They are used particularly. 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 bucking and bending
must be considered before we select a particular size of piston diameter,
rod length and stroke length.

The main component of any pneumatic system is the cylinder, which

receivers air under pressure and the pressurized air helps to move the
piston to and fro. The force acting on the piston will be equal to the
product of the pressure of air and the area of the cylinder.
The amount of air delivered into the cylinder into the cylinder decides the
rate of doing work. A cylinder is a hollow circular section with the top
and bottom flange provided to prevent the leakage of air.

The compressed air is used to actuate the piston. In order to move the
piston to and fro, the air is supplied to the top and bottom of the cylinder
alternatively.

2.4 Classification of Cylinders:

Cylinder is mainly classified into two types namely,

 Single acting cyclinder

 Double acting cyclinder

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Single acting cylinder:

In single acting cylinder, using the spring provided around the piston rod
attains the return stroke, but it is not efficient. So, the double acting
cylinder is used in which the return stroke is attained using compressed
air.

Double Acting Cylinder:

In this the force exerted by the compressed air moves the piston in two
directions. They are used partially when the piston is required to
perform work not only on the advance movement but also on the return
stroke. This principle, the stroke length is unlimited, although bucking
and bending must be considered before selecting the particular size of
piston diameter, rod length and stroke length.

The different parts of double acting cylinder are:

1. Barrel

2. Piston rod

3. Top Cover

4. Bottom Cover

5. Wiper Cover

6. Retaining ring

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 7. Piston

8. Piston guide

9. Bearing Cap

10.„O‟ ring for piston guide

11.Hexagonal socket head screw

12.Check nut

The double acting cylinder is made up of cast aluminum. The inner and
outer surface of the cylinder should be machined accurately. The
internal diameter of the cylinder should be accurate in order to provide a
smooth surface for the packing. The appearance of the outer diameter
should be good.

The outer most part of the bottom and top cover contains internal
threads for inserting bolts to clamp the cylinder.

In case of double acting cylinder a force is developed in both the

directions. The moving member inside the cylinder is nothing but a
piston which is found to be moving forward and backward due to high
pressure air. The cylinder top and lower plate are flanged together by
means of bolts and nuts. The bottom of the cylinder is also flanged with
end covers for the movement of the piston in reciprocating manner.

22
The bottom end cover has a bore in center whose diameter is slightly
larger than piston rod diameter. The force during the return stroke is less
compared to that of the forward stroke because in the former, the piston
rod covers some area so that the air cannot concentrate in the piston rod
area.

2.5: Parts of Pneumatic Cylinder

Piston:

The piston is a cylindrical member of certain length which reciprocates

inside the cylinder. The diameter of the piston is slightly less than that of
the cylinder bore diameter and it is fitted to the top of the piston rod. It is
one of the important parts which convert the pressure energy into
mechanical power.

The piston is equipped with a ring suitably proportioned and it is

relatively soft rubber which is capable of providing good sealing with
low friction at the operating pressure. The purpose of piston is to
provide means of conveying the pressure of air inside the cylinder to the
piston of the oil cylinder.
Generally piston is made up of

 Aluminium alloy-light and medium work.

 Brass or bronze or CI-Heavy duty.

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The piston is double acting type. The piston moves forward when the
high-pressure air is turned from the right side of cylinder. The piston
moves backward when high pressure acts on the piston from the left side
of the cylinder. The piston should be as strong and rigid as possible.

The efficiency and economy of the machine primarily depends on the

working of the piston. It must operate in the cylinder with a minimum of
friction and should be able to withstand the high compressor force
developed in the cylinder and also the shock load during operation.

The piston should posses the following qualities.

a. The movement of the piston not creates much noise.

b. It should be frictionless.

c. It should withstand high pressure.

Piston Rod:

The piston rod is circular in cross section. It connects piston with piston
of other cylinder. The piston rod is made of mild steel ground and
polished. A high finish is essential on the outer rod surface to minimize
wear on the rod seals. The piston rod is connected to the piston by
mechanical fastening. The piston and the piston rod can be separated if
necessary.

24
One end of the piston rod is connected to the bottom of the piston. The
other end of the piston rod is connected to the other piston rod by means
of coupling. The piston transmits the working force to the oil cylinder
through the piston rod. The piston rod is designed to withstand the high
compressive force. It should avoid bending and withstand shock loads
caused by the cutting force. The piston moves inside the rod seal fixed in
the bottom cover plate of the cylinder. The sealing arrangements prevent
the leakage of air from the bottom of the cylinder while the rod
reciprocates through it.

Cylinder Cover Plates:

The cylinder should be enclosed to get the applied pressure from the
compressor and act on the pinion. The cylinder is thus closed by the
cover plates on both the ends such that there is no leakage of air. An inlet
port is provided on the top cover plate and an outlet ports on the bottom
cover plate. There is also a hole drilled for the movement of the piston.

The cylinder cover plate protects the cylinder from dust and other particle
and maintains the same pressure that is taken from the compressor. The
flange has to hold the piston in both of its extreme positions. The piston
hits the top plat during the return stroke and hits the bottom plate during
end of forward stroke. So the cover plates must be strong enough to
withstand the load.

Cylinder Mounting Plates:

25
It is attached to the cylinder cover plates and also to the carriage with the
help of „L‟ bends and bolts.

Control Valve:-

Various types of control valves are used to regulate, control and monitor
the air energy for control of direction pressure, flow, etc.

Pneumatic energy is regulated and controlled by pneumatic valves.

Functionally valves are divided into four major groups.

 Directional control

 Flow Control

In our project electrically actuated solenoid operated 5/2 DC valves are

used.

Solenoid is another name for an electromagnet. Direction control valves

are very often actuated by electromagnets. An electromagnet is a
temporary magnet. A magnetic force is developed in an electromagnet
when electrical current passes through it and force drops down as soon
as it is de energized.

This electromagnet is commonly termed as solenoid. The proper

working of a solenoid operated valve depends on the reliability of the
electromagnets.

It ensures

 Quick and sure action Long life.

26
  Easy maintenance.

 Less wastage of energy.

Solenoid Valve:

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.

2.6 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

27
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 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.

1. 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.

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

2.7 Working of Solenoid Valve

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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.
House and Fittings:

It is provided for the passage of compressed air from the compressor

outlet to the operating valve.

Two separate pipes also connect the operating valve with the working
cylinder pressure drop through and air line depends on the flow rate, pipe
diameter, and pipe length and pipe geometry. It can be determined
directly for straight pipes of any given length. A small chaining bore size
can have marked effect on pressure drop, where as even doubling the
pipe length, will only result in doubling the pressure drop.

Pressure drop through bends and fittings can only be determined by

empirical tests, since it is specific to the internal geometry involved.
Rigid pipes however are less manipulated through remain form of bends
with arrangements increase and variable air have to flow and the flow
itself may be of fluctuating or pulsating nature. In this case it is thus
normally based on practical recommendation.
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Seals:

Seal is an important component of a pneumatic system and is used to

prevent the air lekage through the joint.

This project passes the static seal which are used to prevent the leakage
through the stationary surface. Material of the seal is Teflon tape.

Teflon has the following properties:

Withstand the system pressure and temperature without any damage.

 Resist the wear and abrasion.
 Recover from deformation.
 Resists the adverse effects such as deterioration and shrinking
caused by the system air.

Seals are devices for closing gaps to prevent leakage or make pressure
joints and also to prevent the entry of air and dirt from outside into the
system. The material of seal must be compatible with the fluid medium.
It is a circular ring made of synthetic rubber. It is used for providing
tight sealing between the piston and the cylinder wall. It prevents air
leakage from the top and bottom of the cylinder

Seals for air cylinder and valves are not normally called upon to seal
pressure higher than about 2 bars. Since the fluid to be seated is a gas,
(in our case air) rubbing speeds tends to be high and the seal the seal may
have to be operated under dry conditions with minimal lubrication.

Flow Control Valve:

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Flow Control Valves are fitted to all the distribution tubes. This valve is
made of brass. Both the ends have stepped surface to insert hoses. A
handle is provided to control the flow of oil in every valve.

Technical Data

Size : ¼”

Pressure : 0 to 10 kg / cm2

Media : Air

Purpose:

This valve is used to speed up the piston movement and also it acts as an
one way restriction valve which means that the air can pass through only
one way and it can‟t return back.

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 CHAPTER-3

Pneumatic System:

The subject of pneumatics might probably be termed as compressible

fluid mechanics. It deals with the use of pressurized gas as a source of
power. The pressure energy of gas is directly converted into force to do
the required work with high efficiencies of conversion.
The pneumatic cylinder utilizes a low pressure fluid. It has the
advantage that cylinder construction can be simplified reducing cost. It
can be used for high speed operations.
Pneumatics is widely associated with low cost automation. It generally
offers the lowest initial and operating cost and simple, flexible control
systems.
Though pneumatic system is the study properties of air other gases, we
are concerned with the study of air.

Characteristics of Compressed Air:

The greatest advantage of pneumatic system is the availability of

working medium free of cost and it plentiful. Compressed air can also
be transported easily and can be easily stored in a reservoir. Another
notable advantage is the insensitiveness of compressed air to temperature
fluctuations. It ensures reliable operation even under extreme conditions
of temperature. Compressed air offers no risk of explosion; hence no
expensive protection cost is required.

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Characteristics of Pneumatics:

1. Compressibility:

A pneumatic fluid is compressible. Compressibility plays a major role in

the actuation of piston, i.e., opening a valve does not move the piston
immediately, rather sufficient fluid must flow into the volume to increase
the pressure until the force overcomes that on the other side.

Compressibility is the energy storage of a fluid. As it is possible to store

compressed fluids and transport them, pneumatics has the advantage of
transportability. Another advantage of the energy storage capacity is the
small compressor charging a tank can supply a system having high peak
loads but small average loads.
2. Leakage Sealing Problems:

Several methods are used to minimize leakage. One is to use a low

operating pressure. Another method to prevent leakage is sealing. Good
sliding and rotating sealing are to obtain in pneumatics is because of low
viscosity of the fluids Diaphragms and bellows are used to avoid sliding
seats.

3. Low Viscosity:

A highly encounted problem due to low viscosity is that of sealing. They

provide less viscous damping due to low viscosity hence sliding parts
wear considerably. This adds the necessity for external sources of
lubrication. Another problem is that the pneumatic cylinder should be
thinner enough to maintain a laminar flow inside.

33
3.1. Advantages of Pneumatic System over Other System:

1. Output power of the pneumatic system can be easily controlled

2. Pneumatic system is not affected by over loading

3. The pneumatic system can be used at various working

temperature

4. Air can be easily distributed through pipelines over very long

distances
5. Pneumatic enables high working speeds

6. It is a maintenance free system

7. Pneumatic enables the application of force very gently which is

not only beneficial to pneumatic components but also the
equipment which they are installed
8. The working fluid which is stored in the storage tank can be taken
through number of lines which eliminates the use of individual
power sources say electric motor and many other machine parts.

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3.2. Specifications of Pneumatic Elements:

The various pneumatic elements are specified according to different

standards. The standard varies depending upon the manufacturers

1.Double acting Cylinder:

Stroke length
Piston Diameter

Material Seals

O‟ ring

35
 CHAPTER-4

Working Principle:
The following figure shows general layout for the machine.

4.1 (a)General layout

Initially the air -compressor is started and allowed the receiver tank air

pressure to reach up to 8 bar.

The supply air is then passed to the manifold through FRL unit to
condition the air and eligible to industrial use.

From the manifold a separate supply for the machine is taken out and
given to ON - OFF switch, so as to operate the machine at will without
interrupting the running of compressor.

36
Then the pipe carries compressed air first to machine‟s Direction Control
Valve. At position „A‟ shows the non-actuated circuit diagrams. At this
position the piston is steady and locked. All ports are in closed condition.

37
Fig 4.1 (b):

38
Machine at Position „A‟ At position „B‟, the DC valve is at left hand
position as shown in figure. The cap end port & pressure port get
connected to each other and the rod end port gets connected to the
exhaust port. The compressed air comes in the cap end of the cylinder
and pushes the pistons outwards. The air already present in the rod end
side is pushed out of the cylinder.

When the piston moves outwards, the force is transmitted through the
connecting link and the upper blade moves downwards. Before the
actuating DC valve the sheet is inserted in between the upper & lower
blades. As upper blade moves downwards, the stress is generated in the
sheet metal and goes beyond ultimate shear stress of sheet metal. And
thus the shearing action takes place

Now the DC valve is operated to come at position „C‟, as shown in

figure. The rod end port & pressure port get connected to each other and
the cap end port gets connected to the exhaust port. The compressed air
comes in the rod end of the cylinder and pushes the pistons inwards. The
air already present in the cap end side is pushed out of the cylinder.

The sheet metal is either again inserted for further cutting in case of large
pieces; the small cut pieces are removed and the next sheet is inserted to
cut.

39
Position ‘c’

40
 CHAPTER-5
Proposed Work :

To prepare any machine part, the type of material should be properly

selected, considering design, safety and following points:- The selection
of material for engineering application is given by the following factor

1. Availability of materials.

2. Suitability of the material for the required components.

3. Suitability of the material for the desired working conditions.

4. Cost of the materials.

In addition to the above factors the other properties to be considered

while selecting the material are as follows:-

1. Availability of materials.

2. Suitability of the material for the required components.

3. Suitability of the material for the desired working conditions.

4. Cost of the materials.

In addition to the above factors the other properties to be considered

while selecting the material are as follows:-

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Physical properties:-

These properties are colour, shape, density, thermal conductivity,

electrical conductivity, melting point etc. Mechanical properties:-

The properties are associated with the ability of the material to resist the
mechanical forces and load. The various properties are:-

 Strength:

It is the property of material due to which it can resist the external

forces without breaking or yielding.

 Ductility:
It is the property of material due to which it can be drawn into
wires under a tensile load
 Malleability

It is the property of material which enables it to be rolled into

sheets.

 Brittleness:

It is the property of material due to which it breaks into pieces with

little deformation.

42
 Hardness:

It is the property of material to resist wear, deformation and the

ability to cut another material

Creep:

It is the slow and permanent deformation induced in a part subjected to a

constant stress at high temperature. We have selected the material
considering the above factors and also as per the availability of the
material.

Mild Steel:

Why steel, in particular?

Simply because, in my humble opinion, it is the greatest material

mankind has for construction. It is cheap, strong, readily available, easily
cut, joined, and formed. Wood can be light and stiff, but not very strong.
The best aluminum is strong and light, but very difficult to join. Titanium
is superb in terms of strength to weight ratio and stiffness but its
incredibly expensive, difficult to obtain, and even more difficult and
expensive to machine properly. There was no way your ever going to
perform a battery-weld field-fix on a part made from 7075-T6 aluminum
or titanium! In the end we come back to steel from mild carbon to some
of the more exotic alloy steels pound for pound it is the most righteous
material available for our needs.

Where does steel come from? Steel is not a naturally occurring substance
- it is entirely man made. Steel is chiefly a combination of two naturally
occurring elements: iron and carbon (along with small amounts of other

43
elements - depending on the steel in question). The process by which man
makes steel, would, again, fill several volumes. Here is my amateur
synopsis: Iron is mined from the ground in the form if a reddish-brown
rock called ironore. This ore is then smashed up, strained, filtered,
chemically treated etc, until ultimately it is melted in huge blast furnaces
into something called pig iron. The process uses coke (a type of coal),
which in turn imparts large amounts of carbon to the pig iron. As a result,
pig iron itself is full of impurities, brittle, and unmachinable - practically
useless. Except - it is the raw material from which all other irons and
steels are made.

Pig iron is so produced in either huge vats of molten material, or it is cast

into ingots (in fact, pig iron got its name because the ingots or “chunks”
produced were thought to have resembled piglets). Pig iron is then
refined into either metallic iron or steel using specialized furnaces and
processes. The distinction between the two is that metallic iron has
between 2-6 A final words about carbon. Carbon is critically important to
our whole discussion because it is the presence of carbon that turns the
element of iron that is naturally soft and weak, into the strong, rigid
materials we know as iron and steel. Precisely how this is so is beyond
the scope of this article, suffice to say:

The strength, hardness and toughness that make the ferrous based metals
useful to us are profoundly influenced by the remarkable sensitivity of
the physical and chemical properties of iron crystals to relatively small
percentages of carbon dissolved within their matrixes (actually, the
sensitivity is to the movement of dislocations within the crystal space

44
lattice). This sensitivity to dissolved carbon is in fact, the very basis of
ferrous metallurgy.
5.1 Machine Construction

The machine is basically made up of mild steel.

Reasons:

1. Mild steel is readily available in market.

2. It is economical to use.

3. It is available in standard sizes.

4. It has good mechanical properties i.e. it is easily machinable.

5. It has moderate factor of safety, because factor of safety results in

unnecessary wastage of material and heavy selection. Low factor of

safety results in unnecessary risk of failure.
6. It has high tensile strength.

7. Low co-efficient of thermal expansion.

Properties of Mild Steel:

M.S. has carbon content from 0.15

Bright Material:

It is a machine drawned. The main basic difference between mild steel

and bright metal is that mild steel plates and bars are forged in the
forging machine by means is not forged. But the materials are drawn
from the dies in the plastic state. Therefore the material has good surface
finish than mild steel and has no carbon deposits on its surface for

45
extrusion and formation of engineering materials thus giving them a good
surface finish and though retaining their metallic properties A poor, but
perhaps useful metaphor may be the use of fibre-mat and resin in fibre
glass work. The bulk raw material of fiberglass is the fiber matting (as
iron is to steel) - but by itself the matting is of no practical use. Not until
we add the resin to it to make fibre glass (as we add carbon to iron to
make steel) do we get a useful product. In both cases, neither raw
material is much use alone, but combines them nor do we really have
something. Similarly, though carbon may only be present in small
quantities, just as the amount of hardener added to fibre glass resin has a
profound effect on the material, so does the small amount of carbon
present in useful metallic iron and steel

Composition: Carbon 0.20

Properties: Tensile strength 44.54 kgf/mm

Yield stress 28 kgf/mm

Hardness 170 BHN

Uses: General purpose steels for low stressed components.

46
Table 5.1: Heat Treatment Chart

47
 CHAPTER-6

Project Design and Drawings

6.1 Requirement Analysis:

6.2 calculation:

General Consideration in Machine Development

First Stage Design Consideration in New Machine

The word design means different things to different people a wallpaper

pattern a fashionable dress, the appearance of a racing car and so on. We
therefore start by defining what we mean by design in the present context
ie.,

What design is all about. This understanding will lead to an examination

of

1. Why we need to design particularly in an engineering

environment, and

2. How we might best go about designing

What is design?
The Concise Oxford Dictionary explains design as a mental plan a
scheme of attack, end in view, adaptation of means to ends preliminary
sketch for picture invention Evidently there is a lot more to design than
mere visual aspects, and design is not restricted to engineering. Key
components of this explanation are as follows

48
1. Means to ends implies that we design not for the abstract mental

exercise, but with a definite goal in view some action or some

physical object will result from the design.
2. Mental suggests that design is a thinking process. When we design

we deal primarily with ideas, with abstractions rather than with

numbers and computers for example cannot do the job for us,
though they can help in certain tasks. No matter what we design, it
is vital that we develop and apply our imagination to visualize
realistically the future form of the artifact or action, how it will
eventually come into being and most importantly how it will
thereafter interact with people and other artifacts or actions.
3. Plan, scheme infers that design is distinct from implementation.

Designers especially in engineering seldom execute their plans,

but rather communicate them to others either by word of mouth, or
visually.
4. So, can we now define design completely? No! And neither do we

need to. A rigid definition implies a rigid process, and design is

anything but that. We shall adopt the following interpretation as it
incorporates the above concepts and conveys a reasonably clear
idea of what design is all about Design is the application of
creativity to planning the optimum solution of a given problem
and the communication of that plan to others. Apart from the
communication aspect therefore, we understand the essence of
design to be problem solving, though the type of problem
encountered in design is not like a typical textbook mathematics
problem for example in which the unique correct solution is
guaranteed by following, automaton-like, a series of learned
49
solution steps. A design problem on the other hand is a real-life
problem with many solutions, some of which meet the problem
5.requirements better, some worse, and where the process of
discovering the solutions is not mechanistic. Some problems
might appear not to need design as a solution can be cobbled
together without much thought. This is true enough if the solution
can be based on direct experience. However we shall soon come to
realize that without experience such a thoughtless solution usually
comes to grief sooner or later the more involved the problem and
the more folk affected by the solution the more likely is the
solution going to fall in a heap. Any old solution will not do we
must strive for the optimum solution.
6.We expect that the design process, if properly carried out, will
show a high probability of disclosing a solution which is optimum
or close-to-optimum, if indeed a unique optimum exists.

7.The prime aim of this chapter is to develop a structured

approach to design an approach which will promote confidence in
effectively solving real life problems. We shall focus on problems
involving engineering hardware particularly for Design and Build
Competitions however the approach is perfectly general and
applicable to problems arising from a marketing sortie or a labour
wrangle for example. The approach is thus very relevant to
managers and the like not just to ‟hardware designers.

50
 Why do we design?

Most people these days exist by providing things to others in the case of
engineers these things are technical muscle-power or knowhow, or
physical artifacts that is solutions to buyers or hirer‟s particular
problems. If these clients are not completely satisfied with the thing
provided then they will dismiss the provider, go somewhere else for their
next thing and tell everyone about the provider‟s unsatisfactory things. If
this happens often enough to a particular provider then that provider will
cease to exist as a market force nobody will want to know. So clearly, if
things are not designed with care and attention to clients needs then the
provider will have problems.
6.2 calculation:

Calculations:
Maximum pressure applied in the cylinder (P) : 10 bar

Diameter of the cylinder bore (D) : 40 mm

Area of the cylinder (A) = (3.14 D2)/4

=3 .14x20*20)/4

= 3.14 cm2

For Aluminum:

Force acting on the sheet of 1 mm (F) = Pressure x Area = 1 x 3.14= 3.14

kgf = 3.14*9.80665 N=30.79N

Force acting on the sheet of 2 mm (F) = Pressure x Area = 3 x 3.14 = 9.42 kgf
=9.42*9.80665= 92.37 N
Force acting on the sheet of 3 mm (F) = Pressure
x Area = 5*3.14 =15.7kgf=15.7*9.80665=153.96

51
 CHAPTER-7

Test Cases, Project Time Line & Task Distribution

7.1Test Cases
7.1.1 Objectives
1) The improvements of processes and procedures.
2) The improvements of factory, shop and work place. Layout and
design of plat and equipment.
3) Economy in human effort.
4) Improvements in the use of materials, machines and manpower.
5) The development of better physical working environment.

Recording Techniques

The next step in basic procedure after selecting the work to be studies
is to record all the facts relating to existing methods.

Purpose of Recording:

1) To enable the process to be clearly understood.

2) To present the existing facts for analogs.

Flow Process Charts:

Flow process chart is defined as a graphic representation of all
storages, occurring during a process or procedure which includes
information considered necessary for analysis such as time required
quantity and distance moved etc.

Types of Flow Process Chart:

a) Man type: It records what the worker does.

52
 b) Material type: It records what happens to the materials.
I. Equipment type: It records how the equipment is used. Flow
process chart gives a complete picture at what is being done
and helps the man to understand the facts and their
relationship to one another.
Objective of Flow Process Chart:

1) To visualize the complete sequence of events occurring in process.

2) To study the events in a systematic way for the complete analysis

of the manufacture of the component part for the following
purposes.
(a) To improve the layout.

(b) To improve material handling.

(c) To reduce delays.

(d) To diminutive, combine or re-arrange the events in a systematic

way.

3) To submit the proposals to managements in a form this can be

easily understood.
4) To guide supervisors and operators regarding detailed operating

instructions.
According to the nature of job being studies and purpose for the record is
required.

(A) CHARTS : Outline process chart

Flow process chart: Man type

53
 Flow process chart: Material type
Flow process chart:
Equipment type
(B)CHARTS: Using time
scale
a) Multiple activity charts
b) Simo charts

c) P.M.T.S. charts

(C) DIAGRAMS INDICATING MOVEMENTS AND MODELS:

a) Flow diagrams
b) String diagrams
c) Cycle graph
d) Chromo cycle graph
e) Travel chart

5.To compare between two or more alternative methods

6. To select operations for a detailed study.

7.2 Task Distribution

Method Study:

Method of the study is the systematic recording and critical Examination of

existing and proposed ways of doing work, as ameans of developing.

54
 Table 7.2 (b): Symbols, Activity and Results

Table 7.2 (b): Symbols, Activity and Results

7.3 Project Time Line

Manufacturing Process:

The process of conversion of raw material in to finished products

using the three resources as Man, machine and finished sub
components. Manufacturing is the term by which we transform
resource inputs to create Useful goods and services as outputs.

55
Manufacturing can also be said as an intentional act of producing
something useful. The transformation process is shown below

Input

Conventional process

Output

Table 7.3: Description of Activity

Hence referring to the values we will plan the various processes using
the following machines:-

i. Universal lathe
ii. Milling machine
iii. Grinding machine
iv. Power saw
v. Drill machine
vi. Electric arc welding machine

56
 CHAPTER-8

Advantages, Disadvantages and Applications

Advantages

i. Pneumatic is more efficient in the technical field

ii. Quick response is achieved
iii. Simple in construction
iv. Easy to maintain and repair
v. Cost of the unit is less when compared to other machine
vi. No fire hazard problem due to over loading
vii. Comparatively the operation cost is less
viii. The operation of cutting is faster because the medium used to
operate is air
ix. Continuous operation is possible without stopping

Disadvantages
i. While working, the compressed air produces noise therefore a
ii. silencer may be used.
iii. High torque can not be obtained
iv. Load carrying capacity of this unit is not very high.(<50 N)

Applications:

i. This machine is very useful for small scale industries

ii. This machine is used to cut the roller sheet metal
iii. All Industrial Application

57
 CHAPTER-9

Cost Estimation

COST OF PRODUCTION
Component Cost
Compressor 1700
Control unit 1850
Solenoid valve 1450
Pneumatic cylinder 1850
Battery 1500
Moving cutter 150
Fixed cutter 150
Frame 1500
Total cost 10150

9.1 Introduction:

Cost estimation may be defined as the process of forecasting the expenses

that must be incurred to manufacture a product. These expenses take into
a consideration all expenditure involved in a design and manufacturing
with all related services facilities such as pattern making tool, making as
well as a portion of the general administrative and selling costs.

Purpose Of Cost Estimating:

i. To determine the selling price of a product for a quotation or

contract so as to ensure a reasonable profit to the company.

58
 ii. Check the quotation supplied by vendors.
iii. Determine the most economical process or material to manufacture
the product.
iv. To determine standards of production performance that may be
v. used to control the cost

These materials are divided into two categories

1.Material fabrication:

In this the material in obtained in raw condition and is manufactured or

processed to finished size for proper functioning of the component.

2. Standard purchased parts:

This includes the parts which was readily available in the market like

allen screws etc. A list in forchard by the estimation stating the quality,
size and standard parts, the weight of raw material and cost per kg. For
the fabricated parts.

Machining Cost Estimation:

This cost estimation is an attempt to forecast the total expenses that may
include manufacturing apart from material cost. Cost estimation of
manufactured parts can be considered as judgment on and after careful
consideration which includes lab our, material and factory services
required to produce the required

59
 CHAPTER-10

Conclusion and Future Scope

Future scope:

 If we increase pressure of working air, then we cut different

thickness of plate by different forces
 Automatic tracing system by using will be use for counting the
cutting stroke.
 Improve performance by adopting imported guide rails stopper,
advanced controlling system and our special design software.
 By using proper pneumatic balancing weight of parts. We can use
this pneumatic shearing machine for cutting hard material and more
thick sheets.

Conclusion:
This project work has provided us an excellent opportunity and
experience, to use our limited knowledge. We gained a lot of practical
knowledge regarding, planning, designing drawing, purchasing,
computing and machining while doing this project work. We feel that
the project work is a good solution to bridge the gates between
institution industries.
We are proud that we have completed the work with the limited time
successfully. The machine is working with satisfactory conditions. We
are able to understand the difficulties in maintaining the tolerances and
also quality. We have done to our ability and skill making maximum use
of available facilities

60
 In conclusion remarks of our project work, let us add a few more lines
about our impression project work.

The chief advantage of our system is that, it cutting speed is varied. The
fast operation is done by the timer unit. This project is a low cost
automation project.

Further Scope of Work:

Since old age man is always trying to gain more and more luxurious.
Man is always trying to develop more and more modified technique with
increasing the aesthetic look and economic consideration. Hence there is
always more and more scope. But being the degree Engineers and having
the ability to think and plan. But due to some time constraints, and also
due to lack of funds, we only have thought and put in the report the
following future modifications:-
1. It can be made to run has bottle cap sealing machine. The stationary
platform can be made auto swiveling type by installing the timer and
heat sensor arrangement on the platform. It can be done such that when
the bottle mouth is sealed up to the desired temperature the electrical
heater circuit gets cut off. At the same time the motor installed on the
reduction gear box starts operating the bevel gearing and the platform
starts rotating thus it can be made auto rotating type.
2. It can be made hydraulic operated type by replacing the hand lever by
hydraulic cylinder and along with the ratchet and Paul arrangement.

61
3. It can be made hydraulically power operated by installing the gear oil
pump at the place of air compressor and pneumatic cylinder
arrangement.
4. It can be made rack and pinion operated or spring and lever operated, by
replacing the pneumatic circuit by rack and the pinion arrangement by
the square threaded screw and nut arrangement.

Photography:

62
References:
(1) J. P. Den Hartog, Advanced Strength of Materials (McGraw-Hill, New York,
1952), TA 405 D4,1952. ; Author Name, Conference Name, year etc.
E. W. Comings, High Pressure Technology (McGraw Hill, New York,
1956 ; Author Name, Conference Name, year etc.

Adaptive Steady State Genetic Algorithm for scheduling university

exams” ,AlSharafat W.S.; Al Sharafat M.S., Networking and Information Technology

(ICNIT), 2010 International Conference on , vol., no., pp.70

Technology (ICNIT), 2010 International Conference on , vol., no., pp.70

http://google.com

http://www.engineersedge.com

http://www.efunda.com

http://www.steeltubeinstitute.org

http://www.emjmetals.com

http://www.usstubular.com

www.altavista.co

Machine design R.S. Khurmi

Work shop technology R.K.Jain.

Machine tool design hand book.

P.S.G. Design Data Book

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64
.

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